Don`t lose your bearings

Transcription

Don’t lose your bearings
Klüber special lubricants for plain bearings
The right choice made easy
Lubrication is our World
Contents
2
Plain bearings and lubricants
3
The selection of operating lubricants
4
1. Lubricating oils
2. Lubricating greases
3. Dry lubricants
4
10
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
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 + 450 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 biodegradable lubricants for applications
in agriculture, forestry and the water
resources industry.
Lubricants as design elements
Klüber – the right choice
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.
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:
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.
J Operating lubricants
J Running-in lubricants
This classification makes for easy
orientation in lubricant selection.
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.
3
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:
K
K
K
4
Mean bearing load
Sliding speed
Operating temperature
of bearing
pm =
F
(N/mm2)
D·B
2. Determination of additional
requirements:
K
Lubricating oils for standard applications,
table I, page 6.
K
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.
K
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.
K
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.
v = d · π · n (m/s)
ϑ (°C)
b) Oil selection
1. Selection based on additional
requirements.
2. Selection of lubricating oil suitable
for the operating conditions
(pm, 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.)
The viscosity grade, which is indicated by the
product name – e.g. ISO VG 150 in the case of
Klübersynth GH 6-150 – 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.
Based on the values found for
K
K
K
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
Grease lubrication
Lubricating paste
Bonded coating
Oil lubrication
Solid-film
lubrication
0
0.01
0.5
Oil lubrication
for circulation lubrication (ISO VG > 460)
1.0
1.5
2.0
2.5
Sliding speed v (m/s)
5
Lubricating oils
for standard applications
Operating
temperatures
Operational
bearing
temperature
[°C]
Sliding speed v = 2 up to 4 m/s
Almost constant
0
LAMORA HLP 32
up to 70
LAMORA HLP 68
up to 90
Klüberoil GEM 1-150 N
mean bearing load pm = 3 up to 7 N/mm2
LAMORA HLP 68
up to 70
up to 90
/
mean bearing load pm < 3 N/mm2
up to 50
LAMORA HLP 32
up to 70
LAMORA HLP 46
up to 90
Sliding speed v > 4 m/s
Almost constant
/
up to 50
Almost constant
up to 50
Almost constant
/
Product recommendation
/
up to 50
LAMORA HLP 68
up to 70
up to 90
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 1994.
The calculations are based on the following data:
K plain bearing acc. to DIN 31 690, size 9
K shaft diameter D = 90 mm
K bearing width B1 = 60 mm
K proj. of load-bearing surface: B1 x D = 5 400 mm2
K housing surface: 0.416 m2
K 360° bearing
6
I
providing excellent long-term resistance
Operating
temperatures
Operational
bearing
temperature
[°C]
Almost constant
Varying
/
mean bearing load p m < 3 N/mm2
up to 50
Klüber Summit SH 32
up to 70
up to 90
Klübersynth GH 6-80
up to 120
20 up to 60
20 up to 90
Low start-up and
– 45 up to 50
service temperatures
– 60 up to 30
ISOFLEX PDP 38
Almost constant
Varying
/
up to 50
up to 70
up to 90
up to 120
20 up to 60
20 up to 90
Low start-up and
– 40 up to 40
– 55 up to 60
ISOFLEX PDP 65
Almost constant
Varying
/
up to 50
up to 70
up to 90
up to 120
20 up to 60
ISOFLEX PDP 48
20 up to 90
Low start-up and
– 55 up to 50
ISOFLEX PDP 40
– 65 up to 40
ISOFLEX PDP 38
Almost constant
Varying
/
II
up to 50
up to 70
up to 90
up to 120
20 up to 60
20 up to 90
Low start-up and
– 40 up to 40
– 50 up to 60
ISOFLEX PDP 65
7
Lubricating oils
for the food-processing and pharmaceutical industries
Operating
temperatures
Operational
bearing
temperature
[°C]
Almost constant
Low start-up and
III
/
up to 50
Klüber Summit HySyn FG-32
up to 70
up to 90
– 45 up to 50
Almost constant
Low start-up and
/
up to 50
up to 70
Klüberoil 4 UH1-150 N
up to 90
– 40 up to 40
Almost constant
Low start-up and
/
up to 50
up to 70
up to 90
– 45 up to 50
Almost constant
Low start-up and
/
up to 50
up to 70
up to 90
– 40 up to 45
Rapidly biodegradable lubricating oils falling
under water pollution category 1
Almost constant
Low start-up and
8
/
mean bearing load pm = 0.1 up to 7 N/mm2
up to 60
Klüberbio CA 2-100
up to 90
Klübersynth GEM 2-220
up to 110
Klüberbio CA 2-460
– 25 up to 40
Klüberbio C 2-46
IV
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
D = 40 mm
Width of bearing:
B1 = 38 mm
B2 = 50 mm
Bearing material:
red bronze
3. Selection according to additional requirements
Selection table to be used: Table III (page 8)
4. Selection of required lubricating oil
–1
–1
Speed of conveyor screw: n = 4000 min = 66.6 s
Load force:
F = 500 N
Measured bearing
operating temperature
ϑ = approx. 70 °C,
constant
Selection of required lubricating oil
1a. Calculation of mean bearing load pm
p =
m
p =
m
F
(N/mm2)
D·B
500
40 · 38
= 0.33 N/mm2
1b. Calculation of sliding speed v
v = d · π · n (m/s)
v = 0.04 · 3.14 · 66.6
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 pm.
Sliding speed v:
8.4 m/s; this value
belongs to section
v > 4 m/s
Bearing load p:
pm = 0.33 N/mm2
this value belongs
to section
p < 3 N/mm2
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 mm2/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).
v = 8.4 m/s
2. Determination of additional requirements
The lubricant selection can be checked
against the product data given on page
22/23.
(see under 2, page 4)
For this application, a food-grade lubricant with
NSF-H1 certification is required.
9
The selection of
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:
K
Operating motion: rotating or oscillating
K
Sliding speed range for grease lubrication:
v = 0.01 to 2.5 m/s (see diagram on page 5)
K
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.)
K
Resistance to and sealing against media: To compare
the different lubricating greases, they are tested for
water resistance acc. to DIN 51 807 pt. 1, 3 h/90 °C
(page 25). The lower the test result, the better the
grease’s water resistance (i.e. 0 = best).
K
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:
K
K
K
10
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)
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:
D = 295 mm
Bearing width:
B = 320 mm
Running surface:
smooth
Bearing material:
bronze
Operating speed:
n = 4 min–1
Radial bearing load:
F = 685.7 kN
Bearing temperature:
ϑ = 145 °C
Resistance to media:
sodium
hydroxide solution
Lubrication method:
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/mm2,
operating temperature range1) – 20 to 160 °C
Result:
Suitable lubricating grease: Klüberlub BVH 71-461
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/mm2.
Sliding speed v
v = d · π · n (m/s)
v = 0.295 x 3.14 x 0.066 = 0.061 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 pm
pm =
F
(N/mm2)
D·B
pm =
686 700
295 · 320
= 7.27 N/mm2
This is clearly below the permissible maximum
of 100 N/mm2.
1)
see page 30
11
Lubricating greases
General machinery, plants, equipment and
Mode of operation
Sliding
speed
[m/s]
Max. surface
pressure
[N/mm2]
Service
temperature1)
[°C]
– 20 up to 160
– 20 up to 140
oscillating / rotating
<1
approx. 100
– 30 up to 180
– 40 up to 260
– 40 up to 150
– 30 up to 140
mainly rotating
≥1
approx. 10
– 50 up to 150
mainly rotating
≥2
approx. 1
– 50 up to 130
Food-processing and pharmaceutical industries
<1
approx. 100
– 20 up to 160
– 5 up to 150
≥1
mainly rotating
approx. 10
– 40 up to 120
Machinery, plants, equipment and vehicles where the
<1
approx. 100
– 40 up to 120
mainly rotating
≥1
approx. 10
– 40 up to 120
approx. 50
– 40 up to 180
Dry lubricants
Tribo-system materials
rotating / oscillating
<1
Bonded coatings
– 40 up to 230
rotating / oscillating
depending on coated part
– 180 up to 450
– 40 up to 300
1)
12
see page 30
V
vehicles
Product proposal
Notes
Klüberlub BVH 71-461
Plain bearing lubricant for long service life and
long relubrication intervals, NLGI 1
Klüberlub BE 41-542
Alternative product, NLGI 2
PETAMO GHY 441
Alternative product for higher ambient temperatures
Klüberalfa BHR 53-402
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 41-122
For pivoting bearings (steel–steel)
POLYLUB GLY 151
Klübersynth LR 44-21
VI
NSF H2 lubricant for the food-processing and pharmaceutical industries
Klübersynth UH1 64-1302
lubricant may get into the environment
VII
Klüberbio BM 72-501
Rapidly biodegradable if lubricant gets into contact with environment
Klüberbio M 72-82
Rapidly biodegradable if lubricant gets into contact with environment
VIII
Klüberdur KM 02-854
For bronze plain bearings with lubricating holes
IX
FLUOROPAN 340 N A/B
Thermosetting
UNIMOLY C 220
Hygrosetting
Suitable for ultra-high-vacuum applications
Klübertop TG 05-371
Thermosetting
13
The selection of
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
14
(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.
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.
Bonded coatings are frequently used
for lifetime lubrication – which requires
special testing – but also for running-in
or correction purposes.
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.
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.
FLUOROPAN 340 N A/B
Solid lubricant:
polytetrafluoroethylene (PTFE)
Characteristics:
good wear resistance
long service life
low friction coefficient
good corrosion protection
good resistance to chemicals and oils2)
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 (MoS2)
Characteristics:
good pressure resistance
good wear resistance
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.
Solid lubricant:
graphite
Characteristics:
wide operating temperature range
long service life and good wear resistance
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
b) Tribo-system materials
(see table VIII, page 12/13)
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 02-854 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 02-854 is oil- and
grease-resistant, which allows combined
lubrication (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.
3)
16
see page 30
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 smoothened 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
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
K
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,
K
supports lubrication during the start-up
phase until engine oil has reached the friction
points to form a hydrodynamic lubricating
film.
Bearing data / operating conditions:
Bearing shell, ID Ø
50 mm
Width:
32 mm
Material pairing:
St/St
Operating temperature: – 40 to 120 °C
Load p:
oscillating or impact
load, 6 ... 8 N/mm2
Selecting the suitable bonded coating:
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.
For the operational lubrication of the bearings, a
lubricating oil is used (see selection example for
lubricating oils, page 9).
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 UH1 84-201.
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.
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.
Result: an excellent bonded coating for bearing
shells made of steel is Klübertop TG 05-371,
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
Lubricants for
running-in and repair
Lubricating pastes
General machinery, plants, equipment and vehicles
Material of
the bearing
bushing
X
Service
temperature1)
[°C]
Product proposal
Consistency
NLGI grade
Aluminium-
– 15 up to 150
Klüberpaste ME 31-52
3/2
alloy
– 40 up to 140
DUOTEMPI PMY 45
2/3
Copper alloy,
– 15 up to 150
3/2
steel
– 40 up to 150
Klüberpaste 46 MR 401
1/2
– 40 up to 230
UNIMOLY RAP
3/2
– 40 up to 200 (10004) )
Klüberpaste HEL 46-450
1
Lubricating pastes
Food-processing and pharmaceutical industries
XI
Material of Approval
the bearing
bushing
Service
temperature1)
[°C]
Product proposal
Aluminium-
– 45 up to 120
Klüberpaste UH1 84-201
NSF H1
Consistency
NLGI grade
1
alloy
Copper alloy, NSF H1
steel
– 40 up to 200 (12004) )
NSF H2
– 40 up to 140
DUOTEMPI PMY 45
2
2/3
Bonded coatings for the
running-in lubrication in conjunction with the operational lubricant
Material of
the bearing
bushing
Solid
Service
lubricant temperature1)
[°C]
Product proposal
Notes
Aluminium, copper
Graphite
thermosetting
UNIMOLY C 220
Hygrosetting, suitable
– 40 up to 300
XII
alloy, steel
Steel
MoS2
– 180 up to 450
for ultra-high-vacuum
applications, available as aerosols
1)
and 4) see page 30
19
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
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:
K
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.
K
Replace the vial cap and shake the contents for a few seconds.
K
Observe the solution colour.
a blue colour means:
– the lubricant condition has not changed
significantly
a green colour means:
– the lubricant has suffered slight ageing,
but can still be used; repeat oil ageing
test at short intervals
a brown/orange colour means:
– 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:
K
Plastic bag containing glass vial with test solution
K
Pipette
K
Cloth
21
Product survey
Lubricating oils
Klüber product
ISO VG
DIN
51 519
Service
temperature
range1)
[°C]
approx.
Density
DIN
51 757
[g/cm3]
at 20 °C
approx.
Kinematic
viscosity
DIN 51 562, part 1
[mm2/s]
at
40 °C
100 °C
approx. approx.
Mineral oils
100
– 5 up to 100
0.85
100
11.0
150
– 5 up to 100
0.88
150
15.0
220
– 5 up to 100
0.85
220
19.0
320
– 0 up to 100
0.85
320
25.0
460
– 0 up to 100
0.85
460
25.0
LAMORA HLP 32
32
– 25 up to 120
0.87
32
5.4
LAMORA HLP 46
46
– 20 up to 120
0.88
46
7.0
LAMORA HLP 68
68
– 15 up to 120
0.88
68
8.8
32
– 45 up to 145
0.85
32
6.0
46
– 40 up to 145
0.86
46
7.8
68
– 40 up to 145
0.88
62
10.0
100
– 30 up to 145
0.87
100
12.0
Klüberoil 4 UH1-150N
150
– 25 up to 120
0.85
150
19.0
Klüberoil 4 UH1-220N
Synthetic hydrocarbon oils
Food-grade lubricants
220
– 25 up to 120
0.85
220
26.0
Klüber Summit HySyn FG- 32
32
– 45 up to 135
0.83
33
6.1
46
– 40 up to 135
0.84
46
7.9
68
– 40 up to 135
0.83
70
9.9
100
– 35 up to 135
0.84
95
12.7
Klübersynth GH 6- 80
–
– 35 up to 160
1.05
80
16
100
– 35 up to 160
1.05
100
20
150
– 35 up to 160
1.05
150
28
220
– 30 up to 160
1.06
220
42
320
– 30 up to 160
1.05
320
58
ISOFLEX PDP 38
–
– 65 up to 100
0.92
12
3.2
ISOFLEX PDP 40
–
– 50 up to 100
0.92
19
5.0
ISOFLEX PDP 65
–
– 50 up to 100
0.92
68
17.0
Polyglycol oils
Ester oils
Rapidly biodegradable lubricating oils
Klüberbio C 2- 46
22
46
– 40 up to 80
0.93
46
10
Klüberbio CA 2-100
100
– 30 up to 110
0.94
100
15
Klüberbio CA 2-460
460
– 15 up to 110
0.95
460
50
Klübersynth GEM 2-220
220
– 30 up to 130
0.95
220
27
Dynamic
viscosity
mPa · s
at
40 °C
approx.
Viscosity
index
DIN
ISO 2909
(VI)
Flash
point
DIN
ISO 2592
[°C]
Pour
point
DIN
ISO 3016
[°C]
100 °C
approx.
85.0
9.4
approx. 90
≥ 200
approx. – 15
132.0
13.2
approx. 90
≥ 200
approx. – 10
187.0
16.1
approx. 90
≥ 200
approx. – 10
272.0
21.3
approx. 90
≥ 200
approx. – 10
391.0
21.3
approx. 90
≥ 200
approx. – 10
27.5
4.4
approx. 100
> 200
approx. – 30
39.9
5.8
approx. 100
> 210
approx. – 30
59.0
7.3
approx. 100
> 220
approx. – 25
27.1
5.0
approx. 140
> 230
approx. – 50
38.1
6.5
approx. 140
> 240
approx. – 45
53.8
8.3
approx. 145
> 240
approx. – 45
70.2
9.9
approx. 140
> 240
approx. – 35
125.8
15.3
> 150
> 220
approx. – 30
184.5
20.8
> 150
> 220
approx. – 30
27.0
4.8
approx. 130
> 230
approx. – 50
40.9
6.2
approx. 130
> 240
approx. – 45
57.9
7.8
approx. 125
> 240
approx. – 45
78.5
10.0
approx. 130
> 240
approx. – 40
82.0
15.7
> 190
> 280
< – 35
103.0
19.7
> 190
> 280
< – 35
154.0
27.5
> 200
> 280
< – 35
227.0
40.3
> 220
approx. 250
approx. – 35
330.0
57.1
> 220
> 280
< – 30
11.0
3.1
approx. 150
approx. 200
approx. – 70
17.2
4.3
approx. 230
approx. 200
approx. – 55
61.7
14.7
> 245
approx. 200
approx. – 55
42.1
8.7
–
> 200
< – 30
91.7
13.1
> 140
> 200
< – 30
431.0
46.7
> 160
> 220
< – 20
206.1
24.2
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
Product survey
Lubricating greases
Klüber product
Base oil /
thickener
Consistency5)
Worked
penetration
DIN
ISO 2137
[0.1 mm]
approx.
Service
temperature
range
[°C]
approx.
2
265 – 295
– 40 up to 260
0 / 00
370 – 410
– 40 up to 120
DIN
51 818
24
Klüberalfa BHR 53-402
Perfluorinated
polyether oil/
Na complex soap
Klüberbio GM 32-2200
Rapidly biodegradable
Ester oil/
calcium soap
Klüberbio M 72-82
Rapidly biodegradable
Ester oil/
polyurea
2
265 – 295
– 40 up to 140
Klüberlub BE 41-542
Mineral oil/special
lithium soap
2
265 – 295
– 20 up to 140
Klüberlub BEM 41-122
Mineral oil/special
lithium soap
2
265 – 295
– 30 upp to 140
Special lubricating grease
with NSF H2 approval
Mineral oil/synth.
hydrocarbon oil/
polyurea
0/1
340 – 370
– 20 up to 160
Klübersynth LR 44-21
Mineral oil/synth.
hydrocarbon oil/
spec. lithium soap
1
310 – 340
– 50 up to 130
Food-grade lubricant
Synth.
hydrocarbon oil/
silicate
2
265 – 295
– 10 up to 150
Food-grade lubricant
Synth. hydrocarbon oil/aluminium
complex soap
1
310 – 340
– 40 up to 120
PETAMO GHY 441
Ester oil/
polyurea
1
310 – 340
– 30 up to 180
POLYLUB GLY 151
Mineral oil, synth.
hydrocarbon oil/
spec. lithium soap
1
310 – 340
– 50 up to 150
POLYLUB GLY 501
Mineral oil, synth.
hydrocarbon oil/
spec. lithium soap
1
310 – 340
– 40 up to 150
Density
Base oil
viscosity
DIN 51 757
DIN 51562
part 1
[g/cm3]
at
[mm2/s]
20 °C
at
approx.
40 °C
100 °C
approx.
approx.
1) 5)
,
Drop
point
DIN
ISO 2176
[°C]
approx.
1.82
400
40
not
measurable
0.89
220
28
> 130
0.94
100
28
0.93
540
1.1
Water
resistance
Apparent
viscosity
Klüber
DIN 51 807 viscosity
part 1
grades
3h/90 °C
see
below 6)
Colour
S
white
0 up to 40
E/L
lightbrown
> 220
1
L/M
reddish
brownbeige
32
> 230
0/1
S
brown
130
15
> 190
0.90
490
34.5
> 240
0/1
S
lightbrown
0.85
20
4.5
> 220
1
EL
beige
0.99
1300
100
without
0/1
S
beige
0.92
150
22
> 250
L/M
beige
0.97
435
36
> 250
0
L/M
beige
0.85
150
18
> 220
1
L
beige
0.88
500
40
> 250
0/1
L/M
beige
yellow
and 6) see page 30
25
Product survey
Lubricating pastes
Klüber product
Service
temperature
range1)
[°C]
approx.
Density
at 20 °C
[g/cm3]
approx.
Base oil
viscosity
DIN 51562
part 1
[mm2/s]
at 40 °C
approx.
DUOTEMPI PMY 45
NSF H2 approval
Mineral oil/synth.
hydrocarbon oil/
spec. Li soap/
solid lubricants
– 40 up to 140
1.2
55
Klüberpaste HEL 46-450
Ester oil/
polyglycol oil/
solid lubricant
– 40 up to 1000
1.43
42
Mineral oil/
calcium complex
soap/
solid lubricant
– 15 up to 150
1.38
46
Klüberpaste 46 MR 401
Polyglycol oil/
lithium soap/
solid lubricant
mixture
– 40 up to 150
1.23
360
NSF H1 approval
Synth. hydrocarbon oil/PTFE,
solid lubricant
– 45 up to 120
1.13
200
NSF H1 approval
Polyglycol oil/
silicate,
solid lubricant
– 30 up to 1200
1.58
360
Paraff. mineral oil/
silicate/
solid lubricant
MoS2
– 10 up to 450
1.6
70
UNIMOLY RAP
26
Base oil/
thickener
> 200 °C
dry lubrication
> 200 °C
dry lubrication
> 150 °C
dry lubrication
Drop
point
DIN
ISO 2176
1)
[°C]
Four ball
tester,
welding load
DIN 51 350
part 4
[N]
Flow
pressure
Consistency
Colour
DIN 51 805
at °C
[mbar]
> 190
> 3200
at – 35 °C < 1400
2/3
beige
> 250
> 5000
at – 35 °C 500
1/0
black
> 170
> 4000
–
3/2
beige
> 185
> 4400
at – 40 °C < 1600
1/2
whitish
> 240
> 3000
at – 45 °C < 1400
1
white
> 250
> 2400
at – 40 °C < 1400
2
white
–
> 2400
–
3/2
black
DIN 51 818
see page 30
27
Product survey
Bonded coatings
Klüber product
Service
temperature
range1)
[°C]
Colour
Solid
lubricant
Drying
or
baking
conditions
approx.
FLUOROPAN 340 N A/B
– 40 up to 230
black
– 40 up to 300
greyishblack
– 180 up to 450
grey
UNIMOLY C 220
Polytetrafluoroethylene
(PTFE)
dry:
5 min/100 °C
burning-in:
15 min/250 °C
Graphite
(C)
dry:
5 min/100 °C
burning-in:
15 min/220 °C
Molybdenum
disulphide
(MoS2)
dry:
5 min/20 °C
hardening:
30 min/20 °C
Tribo-system materials
Klüber product
Two-component
tribo-system material
28
Service
temperature
range1)
[°C]
approx.
Colour
– 40 up to 200
dark grey
Chemical
composition
Component A: epoxy resin, solid lubricant
mixture, ester oil; Component B: special
hardening agent, graphite, ester oil
Yield
[m2/l]
with a layer
thickness of
10 µm
Friction
coefficient
(Tannert 20 °C)
approx.,
Vmax = 0.243 mm/s,
F = 300 N
17
0.04
18
0.06
8
0.10
Friction coefficient acc. to Tannert
linear contact against steel
Vmax = 0.243 mm/s,
30 N/mm
approx.
1)
20 °C
0.05
120 °C
0.18
no stick-slip
no stick-slip
see page 30
29
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
DIN 51 818
(NLGI)
Worked penetration
DIN ISO 2137
[0.1 mm]
Texture
000
445 up to 475
fluid
00
400 up to 430
almost fluid
0
355 up to 385
extremely soft
1
310 up to 340
very soft
2
265 up to 295
soft
3
220 up to 250
moderate
4
175 up to 205
stiff
5
130 up to 160
very stiff
6
85 up to 115
extremely stiff
6)
30
Klüber viscosity
grade
Definition
EL
Extra light lubricating grease for extremely low torques, e.g. smooth running
grease
L
Light lubricating grease for low torques or high speeds in rolling bearings,
e.g. high-speed grease
M
Medium lubricating grease for standard requirements in the whole range of
grease lubrication
S
Heavy lubricating grease for applications subject to high loads or fluids,
e.g. high-pressure/sealing greases
ES
Extra heavy lubricating grease for applications requiring high torques or securing
effect, e.g. ocular grease or grease for valves and fittings
Publisher and Copyright:
Klüber Lubrication München KG
Reprints, total or in part, are permitted
if source is indicated and voucher copy
is forwarded.
9.28 e
Edition 04.08, replaces edition 05.01
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
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
www.klueber.com

Don`t lose your bearings

Transcription

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