Don t lose your bearings

Transcription

1 Don t lose your bearings Klüber special lubricants for plain bearings The right choice made easy Lubrication is our World

2 Contents Plain bearings and lubricants 3 The selection of operating lubricants 4 1. Lubricating oils 4 2. Lubricating greases Dry lubricants 14 Selection of lubricants for running-in and repair lubrication 17 Cleaning bearings and determination of oil ageing 20 Product survey 22 Technical Questionnaire Plain Bearings 30 2

3 Plain bearings and lubricants High loads call for high performance Plain bearing bearing consisting of stationary bearing shells in which a rotating journal slides (supported by an oil film) What the dictionary does not mention is the loads a plain bearing can be exposed to: breathtakingly high speeds, extreme temperatures from 180 to degrees centigrade and the effects of aggressive media operating conditions like these take their toll. Proper lubrication of the bearing helps to improve wear resistance, corrosion protection, performance and, consequently, the bearing s service life. For all plain bearings whether dry sliding bearings, sintered bearings, hydrodynamic or hydrostatic bearings the lubricant must be accurately tuned to the individual requirements of the application and the bearing design in order to become effective before the bearing s vital functions are put at risk. Klüber Lubrication has developed a wide range of high-quality special lubrication products to cover all aspects of up-to-date plain bearing lubrication. This range encompasses high-performance greases for extreme loads as well as food-grade lubricants for the food-processing and pharmaceutical industries and rapidly bio - degradable lubricants for applications in agriculture, forestry and the water resources industry. Lubricants as design elements For plain bearings to offer maximum performance throughout their nominal service life, it makes sense to regard the selection and specification of the lubricant as an integral part of the design process. Only if lubricants are conceded the full worth of design elements can the potential of the manufactured component be fully utilised. With appropriate lubrication, plain bearings allow lowwear operation over a long time, in the mixed friction regime at high loads and/or low sliding speeds, as well as with fluid friction at high speeds. Is the old lubricant still fit for its job? However, selecting the right lubricant is of importance not only when designing new plain bearings. Higher transmitted power, higher speeds or changing ambient temperatures in existing machines, plants or vehicles may make a modification or even replacement of the lubricant necessary. Changing ecological requirements, or situations where the lubricant may come into contact with foodstuffs, are further factors that require the lubricant to be adjusted to the individual application. As a supplier of special lubricants, Klüber offers tailor-made up-todate solutions for any task on hand. Klüber the right choice Depending on the design and the type of application, plain bearings are lubricated by oils, greases, bonded coatings, solid lubricants or their combinations (see diagram). The Klüber product range can be divided into two categories: Operating lubricants Running-in lubricants This classification makes for easy orientation in lubricant selection. 3

4 The selection of operating lubricants 1. Lubricating oils For oil-lubricated plain bearings to offer full performance and attain their specified service life, a lubricant must be chosen that ensures low-wear continuous operation and minimum friction during starting and slowing down. However, wear can be reduced to a minimum only if journal and bushings are completely separated by a lubricant film under operating conditions (operating load, temperature, speed, etc.) such that the surfaces of the friction bodies are not in contact, i.e. the bearing must operate in the hydrodynamic range. The formation of a load-bearing lubricant film separating the friction bodies depends largely on the oil s viscosity. This is why the determination of the appropriate viscosity is a central aspect in the selection of the plain bearing oil. Tables 1 to 3, pages 6 to 8, are to help in quickly and reliably selecting the right lubricating oil. Proceed as follows: a) Determination of requirements 1. Determining values for: Mean bearing load Sliding speed Operating temperature of bearing p F (N/mm 2 m = ) D B v = d π n (m/s) ϑ ( C) 2. Determination of additional requirements: Lubricating oils for standard applications, table I, page 6. Lubricating oils especially designed for longterm use, table II, page 7 for applications where long oil change intervals bring about major savings in oil quantities and oil disposal quantities as well as in costs for maintenance and repair, production loss and organisation of disposal. Lubricating oils with USDA-H1 approval for the food-processing and pharmaceutical industries (food-grade lubricants), table III, page 8 for applications where there may be an incidental, technically unavoidable contact between the lubricant and the food product. Rapidly biodegradable lubricating oils / lubricating oils of water hazard class 1, table IV, page 8 for applications where lubricating oils may be released into the environment, e.g. the water or the soil, under normal operating conditions. 4

5 b) Oil selection 1. Selection based on additional requirements. 2. Selection of lubricating oil suitable for the operating conditions (p m, v, ϑ). 3. Accurate calculation of required oil viscosity. (Calculations could be made for one bearing type only to give a rough idea of the viscosity range. Accurate calculations of the plain bearing functions have to be made prior to series application.) Based on the values found for The viscosity grade, which is indicated by the product name e.g. ISO VG 150 in the case of Klübersynth GH was obtained by means of a generally recognised plain bearings computing program (see box on page 6). Not every individual bearing application could be taken into account for these tables, so the viscosities given are to be regarded as orientation values only. Most of the products listed are available in a wide range of viscosities. To ensure reliable operation in all bearing applications, users are advised to carry out their own calculations based on recognised methods. Of course, our application engineers will be glad to assist you. surface pressure, sliding speed and bearing operating temperature, as well as the other criteria listed above, a suitable lubricating oil can be selected. Lubricant selection depending on sliding speed Lubricating paste Grease lubrication Bonded coating Solid-film lubrication Oil lubrication for circulation lubrication (ISO VG > 460) Oil lubrication Sliding speed v (m/s) 5

6 Lubricating oils for standard applications Operating Operational Product recommendation temperatures bearing temperature [ C] I Sliding speed v = 2 up to 4 m/s / mean bearing load p m < 3 N/mm 2 up to 50 LAMORA HLP 32 Almost constant up to 70 LAMORA HLP 68 up to 90 Klüberoil GEM N 0 Sliding speed v = 2 up to 4 m/s / mean bearing load p m = 3 up to 7 N/mm 2 up to 50 LAMORA HLP 68 Almost constant up to 70 Klüberoil GEM N up to 90 Klüberoil GEM N Sliding speed v > 4 m/s / mean bearing load p m < 3 N/mm 2 up to 50 LAMORA HLP 32 Almost constant up to 70 LAMORA HLP 46 up to 90 Klüberoil GEM N Sliding speed v > 4 m/s / mean bearing load p m = 3 up to 7 N/mm 2 up to 50 LAMORA HLP 68 Almost constant up to 70 Klüberoil GEM N up to 90 Klüberoil GEM N The viscosity data in the tables for lubricating oil selection were determined by means of the ASSIG PC system (assistance system for the design of hydrodynamic plain bearings). This program was developed by the Department of Mechanical Engineering, Machine Elements and Design of the Engineering and Business Polytechnic in Zwickau, in cooperation with the Research Association for Power Transmission Engineering FVA in the years 1991 to The calculations are based on the following data: plain bearing acc. to DIN , size 9 shaft diameter D = 90 mm bearing width B 1 = 60 mm proj. of load-bearing surface: B 1 x D = mm 2 housing surface: m bearing 6

7 providing excellent long-term resistance Operating Operational Product recommendation temperatures bearing temperature [ C] II Sliding speed v = 2 up to 4 m/s / mean bearing load p m < 3 N/mm 2 up to 50 Klüber Summit SH 32 Almost constant up to 70 Klüber Summit SH 68 up to 90 Klübersynth GH 6-80 up to 120 Klübersynth GH Varying 20 up to 60 Klüber Summit SH up to 90 Klüber Summit SH 100 Low start-up and 45 up to 50 Klüber Summit SH 32 service temperatures 60 up to 30 ISOFLEX PDP 38 Sliding speed v = 2 up to 4 m/s / mean bearing load p m = 3 up to 7 N/mm 2 up to 50 Klüber Summit SH 68 Almost constant up to 70 Klübersynth GH up to 90 Klübersynth GH up to 120 Klübersynth GH Varying 20 up to 60 Klübersynth GH up to 90 Klübersynth GH Low start-up and 40 up to 40 Klüber Summit SH 46 service temperatures 55 up to 60 ISOFLEX PDP 65 Sliding speed v > 4 m/s / mean bearing load p m < 3 N/mm 2 up to 50 Klüber Summit SH 32 Almost constant up to 70 Klüber Summit SH 46 up to 90 Klüber Summit SH 100 up to 120 Klübersynth GH Varying 20 up to 60 ISOFLEX PDP up to 90 Klüber Summit SH 100 Low start-up and 55 up to 50 ISOFLEX PDP 40 service temperatures 65 up to 40 ISOFLEX PDP 38 Sliding speed v > 4 m/s / mean bearing load p m = 3 up to 7 N/mm 2 up to 50 Klüber Summit SH 68 Almost constant up to 70 Klübersynth GH up to 90 Klübersynth GH up to 120 Klübersynth GH Varying 20 up to 60 Klüber Summit SH up to 90 Klübersynth GH Low start-up and 40 up to 40 Klüber Summit SH 46 service temperatures 50 up to 60 ISOFLEX PDP 65 7

8 Lubricating oils for the food-processing and pharmaceutical industries Operating Operational Product recommendation temperatures bearing temperature [ C] III Sliding speed v = 2 up to 4 m/s / mean bearing load p m < 3 N/mm 2 up to 50 Klüber Summit HySyn FG-32 Almost constant up to 70 Klüber Summit HySyn FG-68 up to 90 Klüber Summit HySyn FG-100 Low start-up and 45 up to 50 Klüber Summit HySyn FG-32 service temperatures Sliding speed v = 2 up to 4 m/s / mean bearing load p m = 3 up to 7 N/mm 2 up to 50 Klüber Summit HySyn FG-68 Almost constant up to 70 Klüberoil 4 UH1-150 N up to 90 Klüberoil 4 UH1-220 N Low start-up and 40 up to 40 Klüber Summit HySyn FG-46 service temperatures Sliding speed v > 4 m/s / mean bearing load p m < 3 N/mm 2 up to 50 Klüber Summit HySyn FG-32 Almost constant up to 70 Klüber Summit HySyn FG-46 up to 90 Klüber Summit HySyn FG-100 Low start-up and 45 up to 50 Klüber Summit HySyn FG-32 service temperatures Sliding speed v > 4 m/s / mean bearing load p m = 3 up to 7 N/mm 2 up to 50 Klüber Summit HySyn FG-68 Almost constant up to 70 Klüber Summit HySyn FG-100 up to 90 Klüberoil 4 UH1-220 N Low start-up and 40 up to 45 Klüber Summit HySyn FG-46 service temperatures Rapidly biodegradable lubricating oils falling under water pollution category 1 Sliding speed v = 2 up to 10 m/s / mean bearing load p m = 0.1 up to 7 N/mm 2 IV up to 60 Klüberbio CA Almost constant up to 90 Klübersynth GEM up to 110 Klüberbio CA Low start-up and 25 up to 40 Klüberbio C 2-46 service temperatures 8

9 Selection example for lubricating oils In a tabletting machine producing fondant sweets, the screw conveying the heated sugar mass runs in two oil-lubricated plain bearings. Since it is technically unavoidable that small lubricant quantities may occasionally leak through the seals and into the sugar mass, a food-grade lubricant certified in line with NSF-H1 requirements is indispensable for lubricating these bearings. Bearing data / operating conditions: Inner Ø of bearing Width of bearing: Bearing material: D = 40 mm B 1 = 38 mm B 2 = 50 mm red bronze Speed of conveyor screw: n = 4000 min 1 = 66.6 s 1 Load force: Measured bearing operating temperature F = 500 N ϑ = approx. 70 C, constant Selection of required lubricating oil 1a. Calculation of mean bearing load p m pm = pm = F (N/mm 2 ) D B b. Calculation of sliding speed v v = d π n (m/s) v = v = 8.4 m/s = 0.33 N/mm 2 2. Determination of additional requirements (see under 2, page 4) For this application, a food-grade lubricant with NSF-H1 certification is required. 3. Selection according to additional requirements Selection table to be used: Table III (page 8) 4. Selection of required lubricating oil Table III is divided up into four sections. The section in which to look is determined by the calculated sliding speed v and the mean bearing load p m. Sliding speed v: 8.4 m/s; this value belongs to section v > 4 m/s Bearing load p: p m = 0.33 N/mm 2 this value belongs to section p < 3 N/mm 2 Result: For a constant operating temperature of approx. 70 C, the appropriate lubricating oil would be Klüber Summit HySyn FG-46. The recommended oil has a kinematic viscosity of 50 mm 2 /s at 40 C. When making an accurate calculation for this bearing application, one will find that the viscosity of Klüber Summit HySyn FG-32 is also sufficient. This is due in particular to the sliding speed above 8 m/s. This calculation is based on the viscosity data given in the product survey (page 22/23). The lubricant selection can be checked against the product data given on page 22/23. 9

10 The selection of operating lubricants 2. Lubricating greases Klüber offers a comprehensive range of products for grease-lubricated metal and plastic plain bearings. The products suitability for the lubrication of plain bearings has been tested in practice-oriented tests (bench tests on bearings with different surface designs: smooth, perforated or with holes). The task of deciding which lubricant to use for a plain bearing is made easy by the selection tables V, VI and VII, page 12/13. Please observe the following criteria to ensure maximum performance of the bearings throughout their service lives: Operating motion: rotating or oscillating Sliding speed range for grease lubrication: v = 0.01 to 2.5 m/s (see diagram on page 5) Permissible bearing load: Depends on bearing material and bearing geometry (note: high surface pressures at low speeds e.g. during starting and slowing down lead to mixed friction. Under conditions like these, the special lubricants shown in table V enable low wear and a long lubricant and bearing life.) Resistance to and sealing against media: To compare the different lubricating greases, they are tested for water resistance acc. to DIN pt. 1, 3 h/90 C (page 25). The lower the test result, the better the grease s water resistance (i.e. 0 = best). Service temperature range: The service temperatures given in the tables are orientative values assuming the grease is used in a plain bearing; they depend on the individual operating conditions. In the following you will find the areas of application that are of interest for you: General machinery, plants, equipment and vehicles: lubricating grease selection in table V (page 12/13) Machinery, plants and equipment in food-processing and pharmaceutical industries: lubricating grease selection in table VI (page 12/13) Machinery, plants, equipment and vehicles where contact between lubricant and the environment is possible (e.g. agricultural and forestry machines, hydroelectric power plants): lubricant selection in table VII (page12/13) 10

11 Selection example for lubricating greases The grease required is to lubricate the plain bearings of calender rollers used in a rubber production plant. What is difficult about this application is that the rollers rotate at very slow speeds while loads acting on the bearings and bearing temperatures are very high. Bearing specifications / operating conditions: Bore diameter: Bearing width: Running surface: Bearing material: D = 295 mm B = 320 mm smooth bronze Operating speed: n = 4 min 1 Radial bearing load: F = kn Bearing temperature: ϑ = 145 C Resistance to media: Lubrication method: sodium hydroxide solution continuous lubrication by means of automatic lubricant dispenser Selection of lubricating grease: The calender rollers are pieces of general machinery. Selection table to be used: table V (page 12/13), section: sliding speed < 1 m/s, maximum surface pressure approx. 100 N/mm 2, operating temperature range 1) 20 to 160 C Result: Suitable lubricating grease: Klüberlub BVH Please note: All plain bearing greases listed in tables V and VI are high-performance lubricants. Friction measurements made on test bearings at room temperature (25 C) have shown that a low friction coefficient and low temperatures can be obtained even under difficult operating conditions, e.g. v = 0.01 m/s, p = 50 N/mm 2. Sliding speed v v = d π n (m/s) v = x 3.14 x = m/s Permissible sliding speed range for grease lubrication = 0.01 bis 2.5 m/s, i.e. in this range grease lubrication is possible. Mean pressure p m p m = F D B (N/mm 2 ) p m = = 7.27 N/mm 2 This is clearly below the permissible maximum of 100 N/mm 2. 1) see page 30 11

12 Lubricating greases General machinery, plants, equipment and Mode of operation Sliding Max. surface Service speed pressure temperature 1) [m/s] [N/mm 2 ] [ C] 20 up to up to 140 oscillating / rotating < 1 approx up to up to up to up to 140 mainly rotating 1 approx up to 150 mainly rotating 2 approx up to 130 Food-processing and pharmaceutical industries oscillating / rotating < 1 approx up to up to 150 mainly rotating 1 approx up to 120 Machinery, plants, equipment and vehicles where the oscillating / rotating < 1 approx up to 120 mainly rotating 1 approx up to 120 Dry lubricants Tribo-system materials rotating / oscillating < 1 approx up to 180 Bonded coatings 40 up to 230 rotating / oscillating depending on coated part 180 up to up to ) see page 30

13 vehicles Product proposal Notes V Klüberlub BVH Plain bearing lubricant for long service life and long relubrication intervals, NLGI 1 Klüberlub BE Alternative product, NLGI 2 PETAMO GHY 441 Alternative product for higher ambient temperatures Klüberalfa BHR High-temperature and long-term lubricant which is almost neutral to many materials (metals, plastics) POLYLUB GLY 501 Especially for plastic plain bearings Klüberlub BEM For pivoting bearings (steel steel) POLYLUB GLY 151 Klübersynth LR Klüberlub BVH Klübersynth UH Klübersynth UH VI NSF H2 lubricant for the food-processing and pharmaceutical industries NSF H1 lubricant for the food-processing and pharmaceutical industries NSF H1 lubricant for the food-processing and pharmaceutical industries lubricant may get into the environment Klüberbio BM Rapidly biodegradable if lubricant gets into contact with environment VII Klüberbio M Rapidly biodegradable if lubricant gets into contact with environment Klüberdur KM For bronze plain bearings with lubricating holes VIII FLUOROPAN 340 N A/B UNIMOLY C 220 Klübertop TG Thermosetting Hygrosetting Suitable for ultra-high-vacuum applications Thermosetting IX 13

14 The selection of operating lubricants 3. Dry lubricants Dry lubrication is of advantage in applications where, due to low sliding speeds, no load-bearing lubricant film can form, so the friction bodies are not sufficiently separated. A layer separating the two sliding surfaces can therefore only be obtained by interposing a bonded coating or a self-lubricating layer in these cases, there is a lubricating film right from the start of the motion. Dry lubricants, i.e. bonded coatings or tribo-system materials, offer maintenancefree permanent lubrication especially for plain bearings running under high loads at low speeds. This includes oscillating motions. Even under extreme operating conditions, e.g. at very high temperatures, in a vacuum or when exposed to chemicals, these dry lubricants help to reduce wear significantly. Dry lubricants are particularly useful in applications where the use of lubricating oils or greases is problematic, where lubricant dripping off the friction point may contaminate the product or where bearings cannot be maintained. And what s more: dry lubrication by means of bonded coatings or tribo-system materials makes sense not only economically but ecologically as well! a) Bonded coatings (see table IX, page 12/13) Bonded coatings consist of three different components: solid lubricant, binder and solvent. The lubricity of a bonded coating depends on the type and quantity of solid lubricant it contains, while its service life and abrasion resistance are influenced by the binder. The solvent serves for applying and spreading the bonded coating on the friction bodies sliding surfaces. Upon application, the solvent evaporates and has no further effect on the friction and wear behaviour of the bonded coating. Bonded coatings are frequently used for lifetime lubrication which requires special testing but also for running-in or correction purposes. A variety of bonded coatings are available for use in plain bearings. They contain solid lubricants that are particularly suitable for dry lubrication and wear-resistant organic binders. Which bonded coating contains the best suitable dry lubricant component for a particular application is determined by the operating conditions, i.e. temperature, sliding speed, load and the surrounding atmosphere. Other criteria are the special requirements to be met by the bonded coating, for instance use in a vacuum or a very low friction coefficient. For further information, please refer to the following brief product descriptions and tables VIII and IX, page 12/13. Adhesion and service life of bonded coatings depend primarily on the pretreatment of the parts to be coated, the application method used for the coatings, the care dedicated to hardening and the subsequent use of the parts. Before using a bonded coating, please observe the information in the product information leaflet, which we will be pleased to send you on request. 14

15 FLUOROPAN 340 N A/B Solid lubricant: Characteristics: polytetrafluoroethylene (PTFE) good wear resistance long service life low friction coefficient good corrosion protection good resistance to chemicals and oils 2) Suitable for metal/metal or metal/plastics material pairings. Recommended especially for very low sliding speeds: v < 0.05 m/s UNIMOLY C 220 Solid lubricant: molybdenum disulphide (MoS 2 ) Characteristics: good pressure resistance low friction coefficient good wear resistance good resistance to chemicals and oils 2) Suitable for metal/metal friction pairings (especially where high pressures forbid the use of PTFE bonded coatings). Also well suitable for use in a vacuum. Not suitable for applications in a moist atmosphere. Klübertop TG Solid lubricant: Characteristics: graphite wide operating temperature range long service life and good wear resistance low friction coefficient good resistance to chemicals and oils 2) good lubricity also when exposed to moisture Suitable for metal/metal or metal/plastics friction pairings. Especially suitable also for plain bearings that are normally lubricated by oil (e.g. for supporting lubrication when starting motors until the operating lubricant reaches the friction point). 2) see page 30 15

16 b) Tribo-system materials (see table VIII, page 12/13) Klüberdur KM This product is a two-component system and contains a solid lubricant component consisting primarily of graphite with incorporated lubricating oil. The two components i.e. the resin and the hardening agent are mixed to form a paste-like mass, which is then filled into the bore holes of plain bearing bushings. Once Klüberdur KM has hardened and, thanks to its good adhesion, is firmly fixed inside the lubricating holes, the plain bearings can be subjected to high loads without requiring wet lubrication or maintenance. The friction bodies are lubricated by a permanent transfer of dry lubricant from the lubricating holes in the bushings. However, there is also constant minor wear to the inside metal surfaces. The service life of plain bearings containing Klüberdur in lubricating holes does not, therefore, depend on the supply of solid lubricant but on the maximum permissible internal clearance of the bearing. Klüberdur KM is oil- and grease-resistant, which allows combined lubri cation (dry lubricant together with oil or grease) if required. New bearings can additionally be filled with grease for running-in or to facilitate assembly. This additional one-time lubrication helps to prevent boundary and mixed friction until the solid lubricant is distributed throughout the bearing. However, this kind of priming lubrication is not obligatory. 16 3) see page 30

17 Selection of lubricants for running-in and repair lubrication 1. Running-in lubrication The surfaces of new plain bearing elements always show a certain degree of surface roughness, which can be more or less pronounced depending on the finishing method used. By applying a bonded coating or a lubricating paste, the roughness peaks can be smooth - ened during the running-in process without scoring or scuffing the surfaces. If two friction components have very smooth surfaces, mixed friction (partial contact of the surfaces) only occurs under very adverse conditions, even with very thin lubricating films. Bonded coatings or pastes used for running-in also protect the friction points in the case of starved lubrication during normal operation, e.g. during the start-up and slow-down of a machine, when low sliding speeds prevent the formation of a load-bearing and coherent grease or oil film. Hint: to ensure a perfect surface finish, we recommend running in bearings at reduced load (approx. one third of the rated load and one third of the rated speed). 2. Repair lubrication In many cases, scoring and scuffing marks on functional surfaces of plain bearings can be eliminated by means of a so-called repair lubrication : by the application of a bonded coating or a lubricating paste on the damaged bearing surfaces followed by a running-in process (at reduced sliding speed and load), scores and scratches can be smoothed considerably thus restoring the surface characteristics. Additional advantage: the emergency lubricating properties of dry lubricants used in subsequent operation for repair purposes protect the bearings from the effects of starved lubrication and reduce the risk of new surface damage. 17

18 Selection example: Running-in of truck engine bearing with bonded coating and operational lubricant For the camshaft bearing in a truck diesel engine, a bonded coating is needed which together with the operational lubricant (engine oil) improves the bearing run-in and prevents the formation of initial damage to the sliding surfaces during the run-in phase, Selection example: Running-in of a conveyor screw bearing with lubricating paste A lubricating paste is required to run in and smooth the functional plain bearing surfaces of a screw conveyor of a soft candy making machine. The paste has to be physiologically safe and comply with relevant regulations, as a contact between the food product and the lubricant cannot be completely excluded. The criteria of an NSF H1 approval have to be met as well. supports lubrication during the start-up phase until engine oil has reached the fric tion points to form a hydrodynamic lubricating film. For the operational lubrication of the bearings, a lubricating oil is used (see selection example for lubricating oils, page 9). Bearing data / operating conditions: Bearing shell, ID Ø 50 mm Width: Material pairing: 32 mm St/St Operating temperature: 40 to 120 C Load p: oscillating or impact load, N/mm 2 Selecting the suitable bonded coating: Running-in of bearings by means of bonded coating in combination with the operational lubricant. For product selection, please refer to table XII, page 19. Selecting the suitable lubricating paste The bearings are to be run in with a lubricating paste. For product selection, please refer to table XI, page 19. Result: the suitable lubricating paste for this application is Klüberpaste UH Bearings should be run in at reduced speed in order to ensure proper smoothing of the surfaces. After the running-in process, and provided the lubricants are compatible, it is possible to immediately switch to operational oil lubrication without prior cleaning of the bearings. Please consult our application engineers as far as the compatibility of lubricants is concerned. Result: an excellent bonded coating for bearing shells made of steel is Klübertop TG , offering long service life, wear protection and resistance to lubricating oils. It contains graphite as solid lubricant. Hint: in normal operation, the solid lubricant particles on the functional bearing surfaces protect the friction points in case of starved lubrication, e.g. during the start-up and slow-down of a machine. 18

19 Lubricants for running-in and repair Lubricating pastes General machinery, plants, equipment and vehicles Material of Service Product proposal Consistency the bearing temperature 1) NLGI grade bushing [ C] X Aluminium- 15 up to 150 Klüberpaste ME / 2 alloy 40 up to 140 DUOTEMPI PMY 45 2 / 3 Copper alloy, 15 up to 150 Klüberpaste ME / 2 steel 40 up to 150 Klüberpaste 46 MR / 2 40 up to 230 UNIMOLY RAP 3 / 2 40 up to 200 (1000 4) ) Klüberpaste HEL Lubricating pastes Food-processing and pharmaceutical industries Material of Approval Service Product proposal Consistency the bearing temperature 1) NLGI grade bushing [ C] XI Aluminium- NSF H1 45 up to 120 Klüberpaste UH alloy Copper alloy, NSF H1 40 up to 200 (1200 4) ) Klüberpaste UH steel NSF H2 40 up to 140 DUOTEMPI PMY 45 2 / 3 Bonded coatings for the running-in lubrication in conjunction with the operational lubricant Material of Solid Service Product proposal Notes the bearing lubricant temperature 1) bushing [ C] XII Aluminium, copper Graphite 40 up to 300 Klübertop TG thermosetting alloy, steel Steel MoS up to 450 UNIMOLY C 220 Hygrosetting, suitable for ultra-high-vacuum applications, avail - able as aerosols 1) and 4) see page 30 19

20 Cleaning bearings and determination of oil ageing 1. Concentrated conditioner: Klüber-Summit Varnasolv The use of mineral-based lubricating oils in plain bearings may lead to varnish and carbon buildup in the entire lubrication system, especially at high bearing temperatures. Such residues can damage bearing components or clog oil lines and filters. Starved lubrication, or even bearing failure, may occur, resulting in high maintenance and repair costs. Klüber-Summit Varnasolv puts an end to expensive maintenance and repair works. Hint: Klüber-Summit Varnasolv is a concentrated conditioner fluid which dissolves varnish and carbon residues during operation. When using this product prior to an oil change, it is no longer necessary to dismantle bearings and lubrication systems for cleaning purposes. Application notes: As the cleaning agent dissolves buildups and residues, the system does not have to undergo expensive flushing processes before switching to the new product. Klüber-Summit Varnasolv is added to the existing plain bearing oil at a ratio of 10% (i.e. add 1 litre of Klüber-Summit Varnasolv to 9 litres of lubricating oil). For this purpose, enough lubricating oil has to be drained. After filling the conditioner into the bearings, let them run for an additional 40 to 60 hours at service temperature to dissolve all varnish and carbon residues. Drain the unit while the oil is still hot in order to prevent the dissolved residues from settling. Then exchange the oil filters and refill with the synthetic oil. Material compatibility: According to our knowledge, a 10% concentration of Klüber-Summit Varnasolv in mineral oil is compatible with all materials resistant to mineral oil. 20

21 2. Test kit, also for plain bearing oils: Klüber Summit T.A.N. Kit The Klüber Summit T.A.N. Kit is a simple and rapid way of checking the ageing condition of lubricating oils. This Kit can be used to test all conventional mineral and synthetic lubricating oils that have an initial T.A.N. of less than 2. This applies to all oils mentioned in this brochure. Application notes: Draw a small sample of the used oil to be tested to the 1 ml mark of the graduated pipette. Wipe off the excess oil on the outside of the tube with the provided cloth, and add the contents of the pipette to the glass vial. Draw the solution in the vial into the pipette and squeeze it back several times in order to completely transfer all of the oil into the vial. Replace the vial cap and shake the contents for a few seconds. Observe the solution colour. a blue colour means: a green colour means: a brown/orange colour means: the lubricant condition has not changed significantly the lubricant has suffered slight ageing, but can still be used; repeat oil ageing test at short intervals the oil has to be changed. When using the test kit, please observe the material safety data sheet. Avoid contact with clothing and skin. Do not get in eyes. The Kit consists of: Plastic bag containing glass vial with test solution Pipette Cloth 21

22 Product survey Lubricating oils Klüber product ISO VG Service Density Kinematic temperature viscosity DIN range 1) DIN DIN , part [ C] [mm 2 /s] approx. [g/cm 3 ] at at 20 C 40 C 100 C approx. approx. approx. Mineral oils Klüberoil GEM N up to Klüberoil GEM N up to Klüberoil GEM N up to Klüberoil GEM N up to Klüberoil GEM N up to LAMORA HLP up to LAMORA HLP up to LAMORA HLP up to Synthetic hydrocarbon oils Klüber Summit SH up to Klüber Summit SH up to Klüber Summit SH up to Klüber Summit SH up to Food-grade lubricants Klüberoil 4 UH1-150N up to Klüberoil 4 UH1-220N up to Klüber Summit HySyn FG up to Klüber Summit HySyn FG up to Klüber Summit HySyn FG up to Klüber Summit HySyn FG up to Polyglycol oils Klübersynth GH up to Klübersynth GH up to Klübersynth GH up to Klübersynth GH up to Klübersynth GH up to Ester oils ISOFLEX PDP up to ISOFLEX PDP up to ISOFLEX PDP up to Rapidly biodegradable lubricating oils Klüberbio C up to Klüberbio CA up to Klüberbio CA up to Klübersynth GEM up to

23 Dynamic Viscosity Flash Pour viscosity index point point mpa s DIN DIN DIN at ISO 2909 ISO 2592 ISO 3016 (VI) [ C] [ C] 40 C 100 C approx. approx approx approx approx approx approx approx approx approx approx approx approx. 100 > 200 approx approx. 100 > 210 approx approx. 100 > 220 approx approx. 140 > 230 approx approx. 140 > 240 approx approx. 145 > 240 approx approx. 140 > 240 approx > 150 > 220 approx > 150 > 220 approx approx. 130 > 230 approx approx. 130 > 240 approx approx. 125 > 240 approx approx. 130 > 240 approx > 190 > 280 < > 190 > 280 < > 200 > 280 < > 220 approx. 250 approx > 220 > 280 < approx. 150 approx. 200 approx approx. 230 approx. 200 approx > 245 approx. 200 approx > 200 < > 140 > 200 < > 160 > 220 < approx. 150 approx. 270 < 30 For details as to the application and compatibility of lubricants please refer to the product information leaflets 1) see page 30 23

24 Product survey Lubricating greases Klüber product Base oil / Consis- Worked Service thickener tency 5) pene- temperature tration range DIN DIN [ C] ISO 2137 approx. [0.1 mm] approx. Klüberalfa BHR Perfluorinated up to 260 polyether oil/ Na complex soap Klüberbio GM Ester oil/ 0 / up to 120 Rapidly biodegradable calcium soap Klüberbio M Ester oil/ up to 140 Rapidly biodegradable polyurea Klüberlub BE Mineral oil/special up to 140 lithium soap Klüberlub BEM Mineral oil/special upp to 140 lithium soap Klüberlub BVH Mineral oil/synth. 0 / up to 160 Special lubricating grease hydrocarbon oil/ with NSF H2 approval polyurea Klübersynth LR Mineral oil/synth up to 130 hydrocarbon oil/ spec. lithium soap Klübersynth UH Synth up to 150 Food-grade lubricant hydrocarbon oil/ with NSF H1 approval silicate Klübersynth UH Synth. hydrocar up to 120 Food-grade lubricant bon oil/aluminium with NSF H1 approval complex soap PETAMO GHY 441 Ester oil/ up to 180 polyurea POLYLUB GLY 151 Mineral oil, synth up to 150 hydrocarbon oil/ spec. lithium soap POLYLUB GLY 501 Mineral oil, synth up to 150 hydrocarbon oil/ spec. lithium soap 24

25 Density Base oil Drop Water Apparent Colour viscosity point resistance viscosity DIN DIN DIN Klüber [g/cm 3 ] part 1 ISO 2176 DIN viscosity at [mm 2 /s] part 1 grades 20 C at [ C] 3h/90 C see approx. 40 C 100 C approx. below 6) approx. approx not S white measurable > up to 40 E/L lightbrown > L/M reddish brownbeige > / 1 S brown > 190 yellow > / 1 S lightbrown > EL beige without 0 / 1 S beige > 250 L/M beige > L/M beige > L beige > / 1 L / M beige 1), 5) and 6) see page 30 25

26 Product survey Lubricating pastes Klüber product Base oil/ Service Density Base oil thickener temperature at 20 C viscosity range 1) DIN [ C] [g/cm 3 ] part 1 approx. approx. [mm 2 /s] at 40 C approx. DUOTEMPI PMY 45 Mineral oil/synth. 40 up to NSF H2 approval hydrocarbon oil/ spec. Li soap/ solid lubricants Klüberpaste HEL Ester oil/ 40 up to polyglycol oil/ > 200 C solid lubricant dry lubrication Klüberpaste ME Mineral oil/ 15 up to calcium complex soap/ solid lubricant Klüberpaste 46 MR 401 Polyglycol oil/ 40 up to lithium soap/ solid lubricant mixture Klüberpaste UH Synth. hydro- 45 up to NSF H1 approval carbon oil/ptfe, solid lubricant Klüberpaste UH Polyglycol oil/ 30 up to NSF H1 approval silicate, > 200 C solid lubricant dry lubrication UNIMOLY RAP Paraff. mineral oil/ 10 up to silicate/ > 150 C solid lubricant dry lubrication MoS 2 26

27 Drop Four ball Flow Consistency Colour point tester, pressure DIN welding load DIN ISO 2176 DIN DIN part 4 at C [ C] [N] [mbar] > 190 > 3200 at 35 C < / 3 beige > 250 > 5000 at 35 C / 0 black > 170 > / 2 beige > 185 > 4400 at 40 C < / 2 whitish > 240 > 3000 at 45 C < white > 250 > 2400 at 40 C < white > / 2 black 1) see page 30 27

28 Product survey Bonded coatings Klüber product Service Colour Solid Drying temperature lubricant or range 1) baking [ C] conditions approx. FLUOROPAN 340 N A/B 40 up to 230 black Polytetra- dry: fluoroethylene 5 min/100 C (PTFE) burning-in: 15 min/250 C Klübertop TG up to 300 greyish- Graphite dry: black (C) 5 min/100 C burning-in: 15 min/220 C UNIMOLY C up to 450 grey Molybdenum dry: disulphide 5 min/20 C (MoS2) hardening: 30 min/20 C Tribo-system materials Klüber product Service Colour Chemical temperature composition range 1) [ C] approx. Klüberdur KM up to 200 dark grey Component A: epoxy resin, solid lubricant Two-component mixture, ester oil; Component B: special tribo-system material hardening agent, graphite, ester oil 28

29 Yield Friction [m 2 /l] coefficient with a layer (Tannert 20 C) thickness of approx., 10 µm V max = mm/s, F = 300 N Friction coefficient acc. to Tannert linear contact against steel V max = mm/s, 30 N/mm approx. 20 C 120 C no stick-slip no stick-slip 1) see page 30 29

30 Notes 1) Service temperatures are guide values which depend on the lubricant s composition, the intended use and the application method. Lubricants change their consistency, apparent dynamic viscosity or viscosity depending on the mechano-dynamical loads, time, pressure and temperature. These changes in product characteristics may affect the function of a component. 2) Especially if series application is planned, we recommend checking the compatibility of the materials to be coated (our results were obtained in tests made on random samples and do not release the user from the obligation to perform his own tests). 3) Especially if series application is planned, we recommend checking the compatibility of the chemicals to be in contact with the material (our results were obtained in tests made on random samples and do not release the user from the obligation to perform his own tests). 4) Dry lubricants 5) Consistency Worked penetration Texture DIN DIN ISO 2137 (NLGI) [0.1 mm] up to 475 fluid up to 430 almost fluid up to 385 extremely soft up to 340 very soft up to 295 soft up to 250 moderate up to 205 stiff up to 160 very stiff 6 85 up to 115 extremely stiff 6) Klüber viscosity grade EL L M S ES Definition Extra light lubricating grease for extremely low torques, e.g. smooth running grease Light lubricating grease for low torques or high speeds in rolling bearings, e.g. high-speed grease Medium lubricating grease for standard requirements in the whole range of grease lubrication Heavy lubricating grease for applications subject to high loads or fluids, e.g. high-pressure/sealing greases Extra heavy lubricating grease for applications requiring high torques or securing effect, e.g. ocular grease or grease for valves and fittings 30

31 Publisher and Copyright: Klüber Lubrication München KG Reprints, total or in part, are permitted if source is indicated and voucher copy is forwarded e Edition 04.08, replaces edition The data in this technical brochure is based on our general experience and knowledge at the time of printing and is intended to give information of possible applications to a reader with technical experience. It constitutes neither an assurance of product properties nor does it release the user from the obligation of performing preliminary tests with the selected product. We recommend contacting our Technical Consulting Staff to discuss your specific application. If required and possible we will be pleased to provide a sample for testing. Klüber products are continually improved. Therefore, Klüber Lubrication reserves the right to change all the technical data in this technical brochure at any time without notice. 31

32 We are where you are. Klüber Lubrication the world market leader in speciality lubricants subsidiaries in over 30 countries more than 1,700 staff products available worldwide Klüber Lubrication offers expert tribological solutions. Through our worldwide presence, we meet customers needs reliably and on time. We supply tailor-made speciality lubricants to customers from nearly all branches of industry and around the world oils, greases, bonded coatings, pastes and many more. Over 75 years of experience, industry-specific know-how, and exceptional test facilities all help to optimise our solutions. Klüber Lubrication München KG A company of the Freudenberg Group