Oils and Lubrication

LUBRICATION. AN OVERVIEW

The need for lubrication in mechanical systems is understood-and sometimes it can be taken
for granted. The following information covers some of the basic issues in lubrication, such as
making the choice between oil and grease for lubrication and the impact which oil-distribution
methods, viscosity and heat can have on the process. The following materials are contained in
Timken’s Lubrication Catalog and are used with permission.

The wide range of bearing types and operating conditions precludes any simple, all-
inclusive statement or guideline allowing the selection of the proper lubricant. At the design
level, the first consideration is whether oil or grease is best for the particular operation.
When heat must be carried away from the bearing, oil must be used. It is almost always
preferred for high-speed applications.

Oil lubrication

Oils used for bearing lubrication should be high-quality mineral oils or synthetic oils with
similar properties. Selection of the proper type of oils depends on bearing speed, load,
operating temperature and lubrication method. Some features and advantages of oil
lubrication, in addition to the above, are:

• Oil is a better lubricant for high speeds or high temperatures. It can be cooled to help
reduce bearing temperature.
• It is easier to handle and control the amount of lubricant reaching the bearing. It is
harder to retain lubricant inside the bearing.
• Lubricant losses may be higher than with grease.
• Oil can be introduced to the bearing in many ways, such as drip-feed, wick-feed,
pressurized circulating systems, oil bath or air-oil mist. Each is suited for certain
types of applications.
• Oil is easier to keep clean for recirculating systems.

Oil and bearings

Oil may be introduced to the bearing housing in many ways. The most common systems
are:

Oil bath. The housing is designed to provide a sump through which the rolling elements of
the bearing will pass. Generally, the oil level should be no higher than the center point of the
lowest rolling element. If speed is high, lower oil levels should be used to reduce churning.
Gauges or controlled elevation drains are used to achieve and maintain the proper oil level.
Circulating system. A typical circulating-oil system consists of an oil reservoir, pump, piping
and filter. A heat exchange may be required. This system has the advantages of:

• An adequate supply of oil for both cooling and lubrication.

• Metered control of the quantity of oil delivered to each bearing.
• Removal of contaminants and moisture from the bearing by flushing action. ·
Suitability for multiple bearing installations.
• Large reservoir, which reduces deterioration. Increased lubricant life provides
economical efficiency.
• Incorporation of oil-filtering devices.
• Positive control to deliver the lubricant where needed.

Oil-mist lubrication. Oil-mist lubrication systems are used in high-speed, continuous-

operation applications. This system permits close control of the amount of lubricant
reaching the bearings. The oil may be metered, atomized by compressed air and mixed with
air, or it may be picked up from a reservoir using a Venturi effect. In either case, the air is
filtered and supplied under sufficient pressure to ensure adequate lubrication of the
bearings. Control of this type of lubrication system is accomplished by monitoring the
operating temperatures of the bearings being lubricated. The continuous passage of the
pressurized air and oil through the labyrinth seals used in the system prevents the entrance
of contaminants from the atmosphere to the system.

The successful operation of this type of system is based upon the following factors:

• Proper location of the lubricant entry ports in relation to the bearings being
lubricated
• Avoidance of excessive pressure drops across voids within the system
• Proper air pressure and oil quantity ratio to suit the particular application
• Adequate exhaust of the air-oil mist after lubrication has been accomplished.

To ensure "wetting" of the bearings, and to prevent possible damage to the rolling elements
and rings, it is imperative that the oil-mist system be turned on for several minutes before
the equipment is started. The importance of wetting the bearing before starting cannot be
overstated, and it also has particular significance for equipment that has been idled for
extended periods of time.

Lubricating oils are commercially available in many forms for automotive, industrial, aircraft
and other uses. Oils are classified as either petroleum types (refined from crude oil) or
synthetic types (produced by chemical synthesis).

• Petroleum oils are made from a petroleum hydrocarbon derived from crude oil, with
additives to improve certain properties. Petroleum oils are used for nearly all oil-
lubricated applications of bearings.
• Synthetic oils cover a broad range of categories and include polyalphaolefins,
silicones, polyglycols and various esters.
Viscosity

The selection of oil viscosity for any bearing application requires consideration of several
factors: load, speed, bearing setting, type of oil and environmental factors. Since oil
viscosity varies inversely with temperature, a viscosity value must always be stated with the
temperature at which it was determined. High-viscosity oil is used for low-speed or high-
ambient-temperature applications. Low-viscosity oil is used for high-speed or low-ambient-
temperature applications.

There are several classifications of oils based on viscosity grades. The most familiar are
the Society of Automotive Engineers (SAE) classifications for automotive engine and gear
oils. The American Society for Testing and Materials (ASTM) and the International
Organization for Standardization (ISO) have adopted standard viscosity grades for
industrial fluids. Viscosity-classification comparisons In general, synthetic oils are less
prone to oxidation and can operate at extreme hot or cold temperatures. Physical
properties, such as pressure-viscosity coefficients, tend to vary between oil types. Use
caution when making oil selections. The polyalphaolefins (PAO) have a hydrocarbon
chemistry that parallels petroleum oil both in chemical structures and pressure-viscosity
coefficients. Therefore, PAO oil is mostly used in the oil-lubricated applications of bearings
when severe temperature environments (hot and cold) are encountered or when extended
lubricant life is required.

The silicone, ester and polyglycol oils have an oxygen-based chemistry that is structurally
quite different from petroleum oils and PAO oils. This difference has a profound effect on
its physical properties, where pressure-viscosity coefficients can be lower as compared
with mineral and PAO oils. This means that these types of synthetic oils may actually
generate a smaller elastohydrodynamic film thickness than a mineral or PAO oil of equal
viscosity at operating temperature. Reductions in bearing fatigue life and increases in
bearing wear could result from this reduction of lubricant film thickness.

Bearing lubrication oils

Industrial extreme-pressure (EP) gear oils should be composed of a highly refined

petroleum oil-based stock plus appropriate inhibitors and additives. They should not
contain materials that are corrosive or abrasive to bearings. The inhibitors should provide
long-term protection from oxidation and protect the bearing from corrosion in the presence
of moisture. The oils should resist foaming in service and have good water-separation
properties. An EP additive protects against scoring under boundary-lubrication conditions.
High-temperature and/or slow-speed applications generally require the higher-viscosity
grades. Low temperatures and/or high speeds require the use of lower-viscosity grades.

Grease lubrication

Grease lubrication is generally applicable to low- to moderate-speed applications that have

operating temperatures within the limits of the grease. There is no universal anti-friction
bearing grease. Each grease has limiting properties and characteristics.
Greases consist of a base oil, a thickening agent and additives. Conventionally, bearing
greases have consisted of petroleum base oils thickened to the desired consistency by
some form of metallic soap. More recently, synthetic base oils have been used with organic
and inorganic thickeners.

Using polyurea as a thickener for lubricating fluids is one of the most significant lubrication
developments in more than 30 years. Polyurea grease performance is outstanding in a wide
range of bearing applications and, in a relatively short time, it has gained acceptance as a
factory-packed lubricant for ball bearings.

Low temperatures

Starting torque in a grease-lubricated bearing at low temperatures can be critical. Some

greases may function adequately as long as the bearing is operating, but resistance to
initial movement may be excessive. In certain smaller machines, starting may be
impossible when very cold. Under such operating circumstances, greases containing low-
temperature oils generally are required if the operating temperature range is wide.

Calcium- and aluminum-based greases have excellent water resistance and are used in
industrial applications where water ingress is an issue. Lithium-based greases are
multipurpose and are used in industrial applications and wheel bearings.

Synthetic base oils, such as esters, organic esters and silicones, used with conventional
thickeners and additives typically have higher maximum operating temperatures than
petroleum-based greases. Synthetic greases can be designed to operate in temperatures
from -73 C (-100 F) to 288 C (550 F).

An important point concerning lubricating greases is that the starting torque is not
necessarily a function of the consistency or the channel properties of the grease. Starting
torque is more a function of the individual rheological properties of particular grease and is
best evaluated by application experience.

High temperatures

The high temperature limit for lubricating greases is generally a function of the thermal and
oxidation stability of the fluid and the effectiveness of the oxidation inhibitors. Grease
temperature ranges are defined by both the dropping point of the grease thickener and the
composition of the base oil.

A rule of thumb, developed from years of testing grease-lubricated bearings, indicates that
grease life is halved for every 10 C (50 F) increase in temperature. For example, if a
particular grease provides 2,000 hours of life at 90 C (194 F), by raising the temperature to
100 C (212 F), reduction in life to approximately 1,000 hours would result. On the other
hand, 4,000 hours could be expected by lowering the temperature to 80 C (176 F).

Thermal stability, oxidation resistance and temperature limitations must be considered

when selecting greases for high-temperature applications. In non-relubricatable
applications, highly refined mineral oils or chemically stable synthetic fluids are required as
the oil component of greases for operation at temperatures above 121 C (250 F).

The dangers of water

Water and moisture can be particularly conducive to bearing damage. Lubricating greases
may provide a measure of protection from this contamination. Certain greases, such as
calcium and aluminum-complex, are highly water-resistant. Sodium-soap greases are water-
soluble and should not be used in applications involving water.

Either dissolved or suspended water in lubricating oils can exert a detrimental influence on
bearing fatigue life. Water can cause bearing etching, which also can reduce bearing fatigue
life.The exact mechanism by which water lowers fatigue life is not fully understood. It has
been suggested that water enters microcracks in the bearing rings, which are caused by
repeated stress cycles. This leads to corrosion and hydrogen embrittlement in the
microcracks, reducing the time required for these cracks to propagate to an unacceptable-
sized spall.

Water-based fluids, such as water glycol and invert emulsions, also have shown a reduction
in bearing fatigue life. Although water from these sources is not the same as
contamination, the results support the previous discussion concerning water-contaminated
lubricants.
THE PROPERTIES OF LUBRICATING OILS

Why do we need to lubricate? In this first part of a two-part introductory primer on industrial
lubricants, we take a closer look at the need for lubrication and the key properties of
lubricating oils. Regardless if you’re a seasoned pro or a new aspiring talent in this industry,
this article will help you understand their significance when choosing the right lubes with the
right characteristics for various industrial activities.

Oft-regarded as the lifeblood of machinery, lubricants are an essential component across

multiple industrial activities. From bearings to engines to hydraulics, they are used to keep
industries running smoothly by:

• Lessening wear and tear

• Reducing friction
• Removing heat
• Preventing rust and corrosion
• Removing contaminants

Regardless if you’re a seasoned pro in the industry or a new aspiring talent, below is a
guide on the basics of mineral and synthetics lubricating oils, beginning with its properties,
to help you gain a firmer grasp of this essential industrial component.

1. Viscosity

Viscosity is defined as the fluid’s internal resistance to flow. The higher the viscosity of the
fluid, the slower it flows. If you want your film to stay put at lower speeds, you need higher
viscosity.

Considered the most important property of a lubricant, viscosity serves to form a lubricating
film, cool machine components, and seal and control oil consumption. It has to be balanced
for load, temperature and speed. Below is a table to illustrate how each factor affects how
high or low a viscosity should be.
Recognising Viscosity Designations

Viscosity is measured differently according to their designations by different groups:

Viscosity Chart

This chart illustrates the various lubricant viscosity grades, and if you read each line
horizontally, the viscosity designations are equal.
Viscosity Index (VI)
Viscosity Index (VI) is the rate of change of an oil’s viscosity with temperature. The higher
the VI, the less an oil’s viscosity changes with temperature.
Note: The numbers in the parenthesis are unitless numbers that show the difference
between viscosity at 40 degrees Celsius and 100 degrees Celsius.

In the graph above, notice that the slope of each line is different over the same temperature
range, depending on its viscosity: the lowest VI has the highest slope; the highest VI has
the least slope.

2. Thermal Stability

Thermal stability refers to the ability of lubricants to resist breakdown at high temperatures.
Poor thermal stability can result in sludge, deposits and increased viscosity.

3. Oxidation Stability

Oxidation stability refers to the ability of a lubricant to resist the chemical combination with
oxygen. It can result in the creation of sludge deposits and increased viscosity.

Oxidation stability is accelerated by heat, light, metal catalysts, acids formed by water
contamination and other contaminants.

4. Pour Point

Pour point is the lowest temperature at which an oil will

flow under prescribed test conditions. It is affected by
the amount of wax particles removed during the
processing of crude.
The more wax particles there are, the higher the pour point. The fewer wax particles there
are, the lower the pour point.

5. Demulsibility

Demulsibility is another important property of lubricating oils. It is the ability of an oil to

separate from water.

6. Flash Point

Flash point is determined by heating the oil until vapours form; a flame is then passed
across the oil. The flash point is the temperature at which the oil sparks, but a flame is not
sustained.

The flash point for lubricating oils is typically 204°C (400°F) or above.

7. Fire Point

Fire point is determined in a manner similar to flash point. Oil is heated until vapours form; a
flame is then passed over the oil. The fire point is the temperature at which the oil sparks
and the flame is sustained.

The fire point for lubricating oils is typically 371°C (700°F) or above.
HOW TO SELECT THE RIGHT BEARING LUBRICANT

Roller bearing freshly packed with

grease; Source: SKF
Bearing failure can be much more expensive than just the cost of buying a new bearing.
Maintenance costs and production losses due to machine downtime can add up quickly.
A leading cause of bearing failure is insufficient or improper lubrication, which can lead
to contamination or excess heat buildup.

Source: JRK Bearings

During operation, bearing balls and rollers generate friction due to a sliding action
between the rolling element and the bearing ring. The contact area of pure rolling
motion is actually relatively small compared to the sliding contact
area. Lubrication applied between these surfaces prolongs bearing life and minimizes
the heat due to this sliding friction. Excess heat can cause surface degradation or cage
breakage due to extreme stresses.

Prelubricated bearings

Many rolling element bearings are manufactured with integral double seals and are
“lubricated for life.” These bearings are pre-lubricated with grease by the manufacturer
and do not require routine maintenance.

Pre-lubricated bearings have some advantages and are desirable when the application
presents some challenges or makes relubrication impractical.
Advantages of pre-lubricated bearings include:

• Bearing already lubricated when purchased

• No risk of contamination with external mechanisms
• Lower assembly, purchasing and maintenance costs

Use pre-lubricated bearings if the application has the following limitations:

• The housing cannot be kept free from dirt, water and other contaminants
• Limited assembly space precludes the use of a grease-filled housing
• Relubrication with external lubricators is not feasible

Although they do not require relubrication, routine monitoring of pre-lubricated bearings

can avoid unexpected failures. Good preventive maintenance programs that combine
replacement of a failing bearing with other maintenance items is a cost-effective
practice. To detect a possible bearing problem as part of routine preventive
maintenance, inspect bearing points and compare to baseline measurements for
increases in vibration or excess heat generation.

Relubricatable bearings – Oil or grease?

Any bearing that does not contain integral lip seals will require an external lubrication
source. Lubrication is critical to maintaining a bearing’s anti-friction characteristics and
reducing the heat that is generated by excess sliding friction between the balls or
rollers, bearing cage and bearing rings.

When selecting the best lubrication for an application, design engineers must decide
between grease and oil. Different bearing types and applications factor into the
lubrication selection.

Lubrication can serve purposes beyond reducing the heat due to friction, which is a
common benefit of both oil and grease. A proper lubricant will also provide a load-
bearing film between the rings and rolling element, which helps minimize wear. Oil and
grease will also help keep moisture out and prevent corrosion. Most manufacturers will
display speed limits for both oil and grease in their specification tables.

The table below outlines some of the additional benefits unique to oil and grease.
Source: IEEE GlobalSpec

Oil

Oil is the ideal method of lubrication for rolling element bearings. However, it is not
practical for many applications. Several types of oil lubrication systems exist.

• Oil bath lubrication is a simple method of supplying lubrication to the bearing by

placing the bearing in a sealed housing filled to the middle of the lowest rolling
element. It requires minimum maintenance other than checking oil levels as well
as routine checks for contamination. Oil bath lubrication is suitable for low-speed
applications. Constant level lubrication systems will maintain a specified level of
lubricant in a housing.

• Oil splash lubrication is used in gearboxes and other low-speed applications

where a gear or rotating mechanical component splashes oil onto a bearing. Oil
splash lubrication is not recommended for high-speed applications.

• Circulating oil lubrication systems are closed-loop lubrication systems that

circulate oil from a pump through the bearing via a piping system. The oil exits
the bearing and returns to the storage tank, where it cools. Oil circulating
systems are suitable for high-speed applications.

• Oil-air lubrication is a precision oil delivery method where small droplets of oil are
metered at specific intervals into a constant flow of air that is directed at the
bearing. This provides a steady supply of oil to the bearing in high-speed
applications such as machine tool spindles. Oil-air systems are suitable for high-
speed applications. Direct oil-air lubrication is a variant of oil-air for high speeds
 where the lubrication is directed through an orifice in the outer bearing ring
directly to the surface of the bearing race.

• Oil mist lubrication systems provide atomized oil suspended in a volume of

pressurized air to fill a cavity with oil mist. As this method is less directed than an
oil-air system, one supply line can lubricate multiple bearings.

• Oil jet lubrication (also referred to as oil injection) is for extreme speed
applications, such as jet engine bearings. One or more nozzles provide a steady
stream of pressurized lubrication oil directly to the bearing. The velocity of the oil
must be high enough to break through the turbulence around the rotating
bearing.

• Oil drop lubrication provides metered drops of oil directly to the bearing at
specified intervals. Oil drop may be used in high-speed applications, but testing
should be performed to ensure the oil is actually able to reach the bearing
surface. Oil-air is preferred over oil drop for high-speed applications

Oil types

The two types of oil used for bearing lubrication are petroleum based and synthetic.
Synthetic fluids include synthetic hydrocarbons, diesters, polyesters, glycols, fluorinated
compounds, silicones and phosphate esters. Synthetic oils are more expensive than
petroleum oils and are typically only used in extremely high- or low-temperature
applications.

Viscosity

When selecting an oil type, the most important property to consider is viscosity.
Viscosity is the resistance to flow at a specific temperature. Lower viscosity oils will flow
more readily than thicker, high viscosity oils. Kinematic viscosity is typically represented
in either Saybolt universal seconds (SUS) or centistokes (cSt) at either 100° F (38° C)
or 210° F (99° C).

A Saybolt universal viscometer is used to measure kinematic viscosity in units of SUS. It

measures the time it takes a fluid at a controlled temperature to fill a 60 cc container.

A kinematic viscometer measures the time it takes a fixed amount of fluid to flow
through a calibrated capillary and is represented in centistokes (cSt). (Note: 1 cSt = 1
mm2/s)
SAE and equivalent ISO oil grades and viscosity; Source: IEEE GlobalSpec

Bearings with balls or rollers typically use an oil with a minimum viscosity of 70 SUS or
15 cSt. Note that viscosity decreases when heated and increases when cooled. Bearing
temperature at operating speed and load should be taken into consideration when
specifying oil viscosity.

Grease

Grease is a semi-fluid to a solid product of a thickening agent combined with a lubricant.

The lubricant may be a mineral oil, ester, organic ester, glycol or silicone. The
thickening agent may be a soap (lithium, sodium, barium, calcium or strontium), an
inorganic non-soap (microgel, carbon black or silica-gel) or an organic soap (urea
compound, terephthalate or organic dye).

Most bearing greases are comprised of a soap thickening agent combined with a
petroleum oil. Lithium based greases are very popular as bearing grease due to their
water resistance and performance characteristics in both high and low temperatures.
Greases comprised of synthetic lubricating fluids perform well in extreme low and high
temperature ranges.

NLGI grease grade and penetration number; Data source NLGI

Grease consistencies vary from a semi-fluid similar to a viscous oil to a solid that is
nearly as hard as a soft wood. Grease consistency is subject to change as the bearing
turns and the grease shears. This causes the temperature to increase and the grease to
soften.
Grease consistency is measured by a penetrometer. A penetrometer is an instrument
that drops a weighted cone onto a grease sample and measures the depth of
penetration. The National Lubricating Grease Institute (NLGI) provides standard grease
consistency grade.

Advancements in grease technology have contributed to the increase in popularity of

pre-lubricated bearings. One factor of greased bearings that must be considered is
starting torque, especially at low temperatures. A cold grease may resist starting torque.
This is more a function of the individual grease properties than it is the consistency of
the grease.

A good guideline is that grease life is halved with every temperature increase of 25° F
(14° C) and doubles with the same decrease in temperature.

For proper grease selection, refer to the bearing company catalog, or consult an
application engineer.

Dry lubrication

Dry lubricants are used in environments where grease or oil are not viable options. They
reduce the friction between the bearing surfaces and cannot be washed away. They do
not require oil or any other lubrication source during operation. Bearings can be
purchased with a dry lubricant or it can be applied to a standard ball or roller bearing
post-purchase. Unlike oil and grease, most end users do not have the ability to apply
dry lubricants so this is usually a process that is outsourced.

Solid film

Solid film, a dry lubricant, is a non-fluid coating that is applied to the bearing surfaces. It
is intended for extreme cases where the use of oil or grease is not possible. the two
most common types of dry film lubricants are graphite and molybdenum disulfide
(MoS2). Boron nitride and polytetrafluoroethylene (PTFE) are also forms of solid film dry
lubricants.

• Graphite should be used in an environment that has water vapor present as the
adsorption of water helps the graphite bond to the bearing surfaces.
• Molybdenum disulfide has a similar structure to graphite, but better lubrication
performance. MoS2 can also be used in vacuums.
• Boron nitride is a ceramic powder with extremely high temperature resistance
properties.
• PTFE has an extremely low coefficient of friction (as low as 0.04) and can be
operated in temperatures to 260° C.

Benefits of solid film lubrication include:

 • Reduced friction and wear
• Low heat generation
• Low startup torque
• Increased bearing life and performance
• Compatibility with corrosive chemicals and acids

Proper lubrication is critical to the performance and life of every rolling element bearing.
When selecting the best lubrication for your bearing application many variables must be
considered. Space constraints, maintenance requirements, bearing type and design,
operating parameters, environment, cost and other considerations must be factored into
the decision. If in doubt, contact an application engineer from a bearing manufacturer or
distributor for assistance.

Solid oil

Bearings with solid oil; Source SKF

Solid oil lubricant, a relatively new form of dry lubrication, is a porous polymer material
that is molded to the shape of the bearing and filled with oil to completely fill all free
spaces in the bearing. Solid oil bearings are lubricated for life and do not require
lubrication. Solid oil bearings are for extreme applications where the use of grease or oil
is not feasible.
Solid oil has many features and benefits, including:

• Has long lubricant life

• Contains a large amount of oil that cannot leak from bearing
• Furnishes a consistent supply of lubricant
• Is not affected by water
• Resists oxidation
• Has no lubricant churning