Engineering Technology I:

Lubrication

Frontline Development
 PERFORMANCE OBJ ECTI VES

 Explain why different types and grades of lubricants are produced for different
applications

 How to find out what type and grade of lubricant to use

 Safety and storage of lubricants

 Selecting lubricating equipment for different tasks

 How to perform different lubricating procedures

 Contents
• Introduction To The Principles Of
Lubrication.
• Types Of Lubricants.
• Selection Of Lubricants.
• Choice Of Lubricant.
• Lubrication Methods.
• Lubricating Devices and Lubrication
Points.
• Safe Storage Of Lubricants.
• Safety and Handling of Lubricants.
 Introduction to Principles of Lubrication
1. I ntroduction To The Principles Of Lubrication.

Lubrication

 To ‘lubricate’ means to make smooth or slippery. I t also means to

"apply”.
 A ‘lubricant’ is a substance which will provide a smooth or slippery
surface or surfaces between two or more moving parts.
 A familiar example is the use of oil in a car’s engine to permit the
pistons to move smoothly in the cylinders. I n most cases, a lubricant
is an oil or grease.

Motion
BLOCK A

BLOCK B
  I f two metal surfaces rub together without a lubricant, heat is
generated due to friction.
 I n time, the two metal surfaces will weld together and become solid.
This is called SEI ZURE. We say that the two parts have “SEI ZED”
together.
Example of seized parts - eg. Bearings
 Oil film

BLOCK B

 The purpose of a lubricant (e.g. oil or grease) is to separate the surfaces

slightly.
 The friction between the surfaces now disappears and is replaced by the
“internal friction” of the lubricant.
 This is of a much lower value. I n preventing metal to metal contact the
lubricant produces an oil film between two surfaces (Block A and Block B)
when evenly spread.

 An efficient lubricant is one, which is able to hold its thickness of film, and is
not broken down under load or temperature. I t must also not offer too much
resistance to motion.

 The thicker the oil, the greater the fluid friction (resistance to motion of the
oil). The oil should therefore be “thick” enough to stop the film being
broken, but “thin” enough not to induce excessive fluid friction (resistance to
motion of the oil).

 A lubricant should also not “gum up” (when oil separates from its additives),
as it then loses its fluidity and collects dust and grit. This will then increase
friction and wear. I t should also be without any acidity
2. Types Of Lubricants

Lubricants may be classified as follows:

 Solid
 Semi-Solid
 Liquid
2.1 Solid

Several types are used, such as:

 graphite

 white lead

 talc or soapstone

 mica

Graphite is the most widely used, as it is not affected by acid and

heat. Solid lubricants are employed in bearings or such parts of
machinery, which are often neglected from a lubricating point of view,
and particularly those, which operate at low pressures and low speeds.

2.2 Semi-Solid (Grease)

Grease should only be used in special conditions, e.g. in cement mills,

collieries, etc. where there is dust and dirt. I t is used where spatting
or leakage is undesirable, such as in food or sweet factories. I t is used
on slow running bearings under heavy loads.Rough heavy machinery is
generally grease lubricated.
2.3 Liquid (Oil)

Classification

Oils may be classified as:

 animal
 vegetable or
 mineral

(a) Animal Oil

 lard
 sperm oil
 tallow, etc.

These oils are superior to mineral oils in the pressure they will withstand.
Unfortunately they are expensive, and sludge easily.

(b) Vegetable Oil

 Castor oil
 palm oil
 olive oil
 linseed

(c) Mineral Oil

I t occurs under the surface of the earth in the form of crude petroleum.
Special methods are used to refine and grade the oil. Mineral oils retain their
properties well in air and, if pure, do not gum or dry up.

A thin, light lubricant such as oil is chiefly used for high speeds and light
loads.
3. Selection of Lubricants.

The selection of lubricants will depend on the application and environment

they have to perform in.

There are three types:

 light oil – for light work

 medium oil – machinery;

 Heavy oil – gearboxes.

  medium oil – machinery;

 Heavy oil – gearboxes.

Commonly Used Lubricants I n Packaging (Chamdor 2011)

LUBE LUBRI CATI ON POI NT

Tellus S68 Pasteuriser, Palletisers, Decrowner hydraulics
Tellus S32 Hydraulic tensioners and air regulators
Omala 460 Bottle washer Main and Secondary gearboxes
Omala 220 Conveyor drives, Labeller carousel filler drives,
Depalletisers, Palletisers, Crate Stackers

Omala 150 Filler and Seamer

Omala 680 Crate Washer drives
Alvania EP2 All bearings, Uncaser / Packer heads, all central
lubricators

Cardium – Compound D Pallet transport chains

Spheerol FM2 Filler lift cylinders and crowner pistons
Tivella Oil WB (synthetic oil) Washer synchronous drives

4. Choice of Lubricant

 The correct lubrication of the machines and equipment in any

environment prevents breakdowns, minimises wear and tear, and
makes the equipment more pleasant to use.
 Also, the easily moving parts of the machine mean that it will require
less power to drive it, therefore adequate lubrication is important.
 When two bearing surfaces are properly lubricated a thin film of oil
separates the surfaces. One surface actually floats on this film which
is probably 0,025mm thick.
4.1 Correct Viscosity

 The lubricant must be the correct thickness (viscosity) for the bearing to
which it is applied. Too thick and it will cause drag resulting in loss of power
and over-heating.
 Oils tend to become thinner as they warm up, and this was the main reason
why thick oils were used in engines. Modern technology has resulted in
better oils being prepared where changes in viscosity due to temperature
fluctuations are kept to a minimum.
 I t is no longer so necessary to use thick oils in a hot environment and thin
oils in a cold environment.

4.2 Acidity

 Acidity arises when oil operates above its normal temperature,

poisonous vapours start to form making the oil acidic.
 Oils should be free from acids that can corrode the shaft.

4.3 Temperature

 I n order to prevent a lubricant from disintegrating (losing its properties) the

operating temperature of oil or grease should always be higher than the
minimum temperature reached.

4.4 Non-Abrasive

 Always make sure that lubricating equipment is clean and free from any dirt
or dust as this can enter parts such as bearings and can cause damage.

4.5 The information given by supplier:

 Type of lubricant and alternatives.

 Place of application.
 Method of application.
 Frequency of application will depend on the environment.

This information must be obeyed, as any deviation can lead to breakdown, loss of
guarantee rights, serious accidents, and a machine that is not working at maximum
efficiency.
  When there are a large number of machines of varying types in a workshop it
is not economical to stock all the various lubricants specified in the
handbook.
 Under these conditions, it is advisable to call in a reputable oil company to
carry out a LUBRI CATI ON SURVEY. They will draw up a chart
standardising on the minimum number of suitable lubricants
 will give effective service and they will give full instructions as to the
application of these lubricants.

5. Lubricating Methods

The different methods of lubricating machinery can be broken down into several
general categories. These may vary slightly, depending on whom you talk to. We
have selected three, based on the methods of lubrication. These are :

 Manual
 Natural
 Splash
 Pressure.

5.1 Manual Lubrication

 Manual lubrication of machinery can be discussed from two viewpoints;

depending on the type of lubricant you will be applying (oil or grease). I f
you were oiling a piece of equipment, you would use different methods than
if you were greasing it.

Manual oil lubricating is usually done with an oilcan of one sort or another.
 OI L CAN

 Manual grease lubrication is usually done with a pump-type of grease gun.

These grease guns may vary in design and construction, but their principles
of operation are the same.
 A grease gun has to increase the pressure of the fresh grease enough to
overcome any resistance of old grease in the fittings and the grease cavities
of the machinery.
 Usually old grease is forced out of the grease cavity by new grease coming
in. Another manual method of forcing grease into a grease cavity is
accomplished with the use of a screw-type grease cup.

Hand Grease Pump

5.2 Natural Lubrication

 Natural lubrication includes the various types of splash or bath and ring type
oilers. I n natural-type lubrication systems, a portion of the machine housing
is used as an oil sump.
5.3 Splash type
 The splash method of lubrication is probably the most commonly used of all
the natural methods.
 I n this form of lubrication a stream of oil is continually splashed round the
parts requiring it. Splash lubrication is generally used in the following ways:
ring oiling, oil bath with worm, splashing oil onto cylinders of petrol engines,
etc.

 The cylinders and many other parts of the engine obtain their oil by the
“splash” system. Oil is scooped up by the connecting rods as they move
around and a mist of oil vapour fills the entire inside of the engine to
lubricate various parts.

Splash lubrication

5.3.1 Oil bath lubrication

The worm is submerged in the oil bath and picks up some of the oil to lubricate the
bearings as well as the meshing faces of the drive.
 Oil Bath

5.4 Pressure or Force Feed Lubrication

5.4.1 Force Feed Lubrication

 This type of lubrication will only be efficient at low speeds.An oil or grease
gun can be used.
 The hole leading to the bearing surface is fitted with a nipple onto which the
oil gun is pressed and the lubricant forced to the bearing.
 A hand pump may be used to force the oil to the bearing surfaces at intervals
by the machine operator, say twice a day. Oil can be delivered to all bearing
surfaces by an oil pump, driven by the machine.

Force feed lubrication

5.4.2 Gravity Feed Oil Lubrication

 There are many examples of this method, but the siphon- wick and the sight-
feed lubricator are the most common.

Gravity – Feed Lubricator

5.4.3 Drip Feed Lubricators

 This is a device that shows the lubricant passing through a glass tube drop
by drop. The regulation of the oil is by means of the screwed sleeve
immediately below the feed handle. The handle and the needle valve are
pulled into the closed position and the screwed sleeve is just clear of the
handle.
5.4.4 Hand-Pumped Systems

 Ensure that there is sufficient oil in the reservoir before pumping.

 Pull the hand pump lever fully down each time the lubricant is required.
6. Lubrication Devices and Lubrication Points.

6.1 Grease Nipples

 The use of grease on machine tools is gradually diminishing as speeds

increase.
 I ts most usual application is to ball bearings and is gradually
reversed for electric motor bearings. I ts advantage is that only
occasional application is required.


Grease Nipple

6.2 Grease gun

 A grease gun can be used. The hole leading to the bearing surface is
fitted with a nipple onto which the grease gun is pressed and the
lubricant forced into the bearing.
6.3 Stauffer Grease Cup

 The knurled or fluted cap is filled with grease and screwed down, this
forces grease to the bearing surface. I t may be refilled by unscrewing
the cap.

 The disadvantage with this type of grease cup is that the feed is
intermittent and controlled by manual adjustment of the screw.

6.4 Tell-Tale Grease Cup

 The fluted upper cup carries a spring- loaded piston. I t has a smaller
diameter than the cap, thus preventing the spring action from
emptying the cap of its grease.
 The spring- loaded piston pushes the grease onto the part to be
lubricated. The height of the knob above the cap is a guide to when it
is necessary to refill the lubricator with grease
This type of cup is suitable only for the thinner grades of grease, and for short
direct feed ducts or pipes.
 Drum Pump

 Drum pump and bung taps are two important pieces of equipment that can be
used to get oil out of 210 litre drums.

 Drained old / used oil can be drained into a special drain unit / drum or into a
drain tin. Waste oil should be stored in drums or special storage containers.
Draining or discarding oil / grease / fuel etc. directly into the ground will
pollute the environment.
 The small bung on an oil drum should be loosened during pumping to allow for
breathing.

 Before opening any lubrication container, wipe-off any dirt / dust / grit etc.

 To prevent dirt / water etc. from entering lubricant containers always replace
lids, covers or bungs firmly.

Dipstick Sight Glass

 Dipstick, level indicator or sight gauge and level plugs are different devices
commonly used to allow us to check oil levels in machinery
 To prevent contaminants in a lubricant the following should be stored in a
clean environment.

- measuring jugs,
- filler caps,
- funnels ,
- dipstick tube.

 I t is recommended that oil be poured slowly into a machine to prevent a

blowback of oil. The dipstick should be held upright when reading the oil level.

 Before removing a dipstick for the first time wipe around the dipstick area to
prevent dirt entering the machine.

 The oil level is correct on a unit that has a level plug when; the plug is
removed and oil just trickles out.

 Oil seals will leak if the oil level is too high.

 An oil drain plug must be cleaned before being put back and also check /
renew a gasket or sealing washer.

 I f a drain plug is not securely tightened it will vibrate and fall out.

 I nformation about what type, grade and amount of oil you will need to
perform an oil change can be obtained from an oil chart and service manual.

 Before attaching your grease gun to a grease nipple clean the nipple and the
gun nozzle.

 When you see clean grease coming through an open joint that tells you that
you’ve injected enough grease.
7. Safe storage of lubricants.

 I t should now be apparent that the oil stores of a workshop can contain a
wide variety of oils and greases.
 I t should also be apparent that to mix these oils, to use the wrong oil, or
to allow water and dirt to contaminate the oil and grease, will lead to
serious trouble.
Therefore, it is essential that the various lubricants are properly stored. This
involves:

 Fire prevention precautions.

 Correct and easy identification.

 Methods of dispensing the lubricants without having to manhandle the drums

and barrels.

 An adequate quantity of measuring cans to prevent mixing and contamination.

 Light, dust-free surroundings.

 Proper lifting tackle, as full barrels are very heavy.

How to visually optimize your lubrication store.

 One of the best places to begin is with your lubricant inventory. I f you
create a system of well- tagged or color- coded lubrication points, you
will help your maintenance personnel and operators to clearly understand
what lubricants are appropriate for each respective application.
 However, the system must be applied as soon as lubricants are received
in the inventory, all the way through the supply chain to the specific
lubrication point on the industrial equipment, and finally to the
lubricant disposal. I n most facilities, lubricants are handled by many
different people in various locations.
 I f this process is done right, it will ensure that the right lubricant gets to
the right application. This will ensure a smoother overall operation in your
plant.

Optimisation of oil store

Note the different colour containers

8. Safety And Handling Of Lubricants.

 To prevent “dermatitis” (inflammation of the surface of the skin or skin

disease) we must use “barrier cream” whenever there is chance of touching oil
or grease.

 A “non- solvent” hand cleaner should be used to clean your hands after
working with grease or oil.

 You should not use petrol, paraffin or paint thinners to clean hands.

 I t is recommended to move 210 litre drums by a drum trolley.

 I f you have to roll a full 210 litre drum make sure that there are no sharp
objects on the way and do not roll up or down the slopes.

 Always wear plastic gloves when draining oil to prevent getting burnt.

 Always use a spatula when working with grease. Manually spilled oil or grease
should always be wiped up before someone slips.

 The safest method for the temporary storage of oil waste or rags is in a closed
metal container. This container should be kept outside the building away from
anything that could burn.

I MPORTANT NOTES ON LUBRI CATI ON

 The information of the product and lubricant type or grade can be found on
the lubricant pack / container.

 The system of rating used for heavy industry type lubricant is I .S.O.
(I nternational Standard Organisation).

 Most oil companies give us a lubricant chart to select a lubricant

Additional advantages of correct lubrication
Cooling Action of Lubricants

 Before we get involved in the cooling action of lubricants, it is important to

discuss the effect of heat on metal, since most of the surfaces you’ll be
lubricating will be made of metal.

.
Failed gears due to lack / insufficient lubrication

 Lubrication prevents excessive friction or minimizes the effects of friction so

that little heat is generated.
 I t is safe to say that without a lubricant, the heat developed in a machine
would soon cause that machine to stop.