We have the solution...the future has a name. Reg.-Nr Reg.-Nr LUBCON Lubricants for High Speed Rolling Bearings

Transcription

1 We have the solution......the future has a nae Reg.-Nr Reg.-Nr LUBCON Lubricants for High Speed Rolling Bearings

2 Your Partner for the Lubrication of Bearings The LUBRICANT CONSULT GMBH is one of the leading developers and anufacturers of faous high perforance lubricants which guarantee the perfect lubrication of your high speed rolling bearings. This high efficiency of the lubricants is proven by long service life good running behaviour high operating reliability

3 Fro the Developent to the Application The extraordinary perforance of the LUBCON lubricating greases is the result of the clearly defined selection of the thickener and its portion, the type of the base oil and its viscosity as well as the selected additives. A quality and environent anageent introduced in June 1996 has strictly ensured that only raw aterials be used without any ingredients that are harful to the environent. In the production a technically sophisticated circulatory syste is used to preserve the environental resources as uch as possible. LUBCON products are not liable to identification arking. In any operating assays on test stands in the laboratory as well as in practice at faous rolling bearing anufacturers, the application ranges of the greases are thoroughly screened taking into account the different types of construction and sizes of the rolling bearings. LUBCON offers unique special lubricating greases with excellent operating properties and very good running ties for your high speed rolling bearings. For the three ost iportant operating paraeters, i. e. high teperature high load high speed the well-established LUBCON high perforance lubricating greases are indicated in tables and diagras listing various technical data, successfully passed test runs, copatibility with plastics as well as their resistance to water and aggressive edia. The selection of the appropriate lubricant is an iportant factor with regard to long-tie functioning, high operating reliability and efficiency of your bearings, therefore LUBCON offers you a free consultation and coplete assistance - before, during and after your purchase of LUBCON lubricants. Your very individual deands will be registered and translated into products that are especially developed for your copany. In this brochure you will find additional inforation on the running-in process necessary for the bearings, to be effected during operation at high speeds. Fig. 1: High speed spindle bearing (SKF, D-Schweinfurt) Please note: This brochure only contains product inforation. For specific inforation please refer to our technical data and safety data sheets. The indications ade represent the present state of developent and knowledge of LUBRICANT CONSULT GMBH. Subject to change. The products are subject to severe controls of anufacture and coply in full with the specifications set forth by our copany, but due to the ultitude of different influencing factors, we cannot assue any warranty for the successful application in each individual case. Therefore, we recoend to perfor field tests. We strictly refuse any liability. 3

4 Schedule of the Lubricating Greases The loads possibly occurring when using different types of bearing constructions are shown in the following table. Table 1: Technical Data TURMOGREASE Highspeed L 18 TURMOGREASE Highspeed L 5 THERMOPLEX TML TURMOGREASE Li 80 EP Base oil type PAO/Ester PAO/Ester Ester Min/SHC Thickener Li special Li special Li Li Service teperature range ( C) (140) Density +15 C DIN (g/l) Consistency Base oil viscosity DIN 5156 ( /s) +40 C/+100 C 18/4.5 5/6 55/9 8/1.5 Drop point ( C) DIN ISO 176 > +50 > +50 > +180 > +190 Speed factor. n d (in. ) Kula Kerola Kula Kerola Kula Kerola Kula Kerola Corrosion protection acc. to SKF Ecor DIN Water resistance DIN Resistance to bases and acids no no no no Copatibility with NBR, FKM, PTFE and PA 6.6 yes yes yes yes Oil separation DIN (%) at +40 C/+100 C.9/ /8.5.8/ /1.4 Content of solid foreign atter, particles 5 µ (g) < 5 < 5 < 5 < 5 FE9 test DIN 5181 F (h) 50 A/1.5/ > 800 A/1.5/60000 > 00 A/1.5/60000 > 400 A/1.5/ > 800 A/1.5/ > 100 A/1.5/ FE8 test DIN successful tests / / / / / / /50-45 VKA welding load DIN Pt. 4 (N) 00/400 00/ / /300 Start-torque ASTM D 1478 (N) 65/-40 C 150/-40 C Running-torque ASTM D 1478 (N) 6/-40 C 19.5/-40 C

5 Presentation of the FAG FE8 + FE9 Test Runs Friction oent of the bearing pair (N) Running tie (h) Diagra 1: FE8 test run with tapered roller bearing ( = 3131); axial load F a = 10 kn; speed n = 3000 in ; tie of operation 500 h Lubrication with TURMOGREASE Li 80 EP Table : Paraeters Test run 1 Test run FAG requireents Steady-state teperature in C Peak teperature in C Wear in g of - the rolling eleent - the cage - the inner ring - the outer ring Frictional behaviour over the tie (see diagra above) 14/11 15/11 4/4 1/ Running-in finished 10/8 43/9 4/1 0/1 Running-in finished < 35 <100 Evaluation: very good % of test bearing batch * * * * * F 50 = 11 h 05 F 10 = 33 h Bearing no. Running ties (h) , Running tie (h) Diagra : FE9 test run with angular contact ball bearings = ( 706 B), ounting type A, i. e. open bearing; axial load a F = 1,5 kn; speed n = 6000 in ; teperature +160 C Lubrication with THERMOPLEX TML Service life of the grease in the test bearings in h: according to the Weibull diagra F 50 = 11 h; F 10 = 33 h Requireent in acc. with FAG and DIN 5185 F 50 = 100 h Evaluation: fully eets the requireents 5

6 LUBCON lubricating Greases for High Speed Rolling Bearings The four LUBCON lubricating greases for high speed rolling bearings are suitable for the lubrication of standard steel-steel spindle bearings single and double row cylindrical roller bearings of a particularly high accuracy tapered roller bearings with increased operating precision high speed spindle bearings with sall balls of steel "hybrid bearings particularly efficient spindle bearings (x DF > 1.3 illions n. d ), consisting of siliciu nitride. Advantages of hybrid bearings: lighter than steel-steel spindle bearings, high hardness and theral resistance, good diensional stability at highest teperatures, good corrosion resistance, high odulus of elasticity, absence of agnetis. Application in the field: The lubricating greases TURMOGREASE Highspeed L 18 and TURMOGREASE Highspeed L 5 are used in spindle bearing arrangeents of achine tools, e. g. grinding, illing and otor spindle units (spindle units driven by an integrated otor). The lubricating grease TURMOGREASE Highspeed L 5 is regarded as universal grease for high speed rolling bearings; fro the FE8 test run (d = 60 ) successfully passed you can see that it is suitable as well for larger rolling bearings. For several years this grease has proven to be particularly favourable when used in high speed spindle bearings with ceraic balls (hybrid bearings). The application of TURMOGREASE Highspeed L 18 and TURMOGREASE Highspeed L 5 at oderate teperatures, e. g. +60 C or lower, leads to extreely high service lives. The soaps of these greases keep the oil output during the application on a low but sufficient level, the sae as with often low service teperatures. A lack of grease after a long service tie (noticeable by teperature peaks) will be copensated by an increased oil output and grease obility - without leading to a preature grease ageing. A running-in is required for such greases to ensure the distribution of the lubricating grease. After expiry of the grease service life, the bearings have to be cleaned, newly greased and again subitted to a running-in process. In a three-phase otor with frequency converter supply, the lubricating greases TURMOGREASE Highspeed L 5, THERMOPLEX TML and TURMOGREASE Li 80 EP are equally used because the speed factors prevailing here run up to 0.8 illion (in. ). Product Description: The lubricating greases THERMOPLEX TML and TURMO- GREASE Li 80 EP are equipped with a base oil of a higher viscosity and, in addition, contain EP substances to increase the load carrying capacity. The thickeners are noral lithiu soaps. Furtherore, the lubricating grease THERMOPLEX TML stands out for a particularly high upper liit of the service teperature of +160 C, with short peaks up to +180 C. Product Description: The lubricating greases TURMOGREASE Highspeed L 18 and TURMOGREASE Highspeed L 5 contain the base oil E/PAO (ester/poly-alpha-olefins) and show a low viscosity. The thickeners are special lithiu soaps. Fro the FE9 results it becoes obvious that a relatively high upper liit of the service teperature range of +10 C is found in both high speed lubricating greases. Application: TURMOGREASE Highspeed L 18 and TURMOGREASE Highspeed L 5 are preferably used in spindle bearings and cylindrical roller bearings of a bore size below d = 100 of the inner ring. The low viscosity base oil has proven of good results in the lubrication of high speed bearings. TURMOGREASE Highspeed L 18 is also particularly suitable for saller rolling bearings (d < 5 ) and very high speed. factors (above n d =.5 in ) as well as for the use at very low teperatures and applications requiring a very favourable frictional behaviour. Application: Both greases are equally suitable for high speed factors of. > 0.8 illion (in ). With such speed factors, perfor the running-in process to assure the grease distribution and refrain fro relubrication.. With speed factors below 0.8 illion (in ) you ight as well proceed to a relubrication. Owing to their special coposition, both greases are very well suitable for applications where higher loads and/or higher teperatures add to a high speed factor. The lubricating grease THERMOPLEX TML should be used particularly in such cases where very high teperatures prevail. These can occur when the heat discharge fro the bearing is hindered by the design of the ounting arrangeent, or when heat fro the environent is radiated towards the bearing. Due to its higher viscosity of the base oil TURMOGREASE Li 80 EP shows excellent properties even with larger spindle bearings (d > 100 ) at speed factors below 1 illion (in. ). 6

7 Handling and Running-in In order to achieve the best results for your copany with LUBCON lubricants, please observe the instructions for the lubrication and the running-in of the rolling bearings. Before the lubrication, largely reove the ostly ineral based preservation oil to avoid any weakening of the synthetic base oil of the lubricating greases. Only TURMOGREASE Li 80 EP contains a ineral base oil which is copatible with the standard preservation oils. Reoval of the Preservation Oil: Clean all bearing parts, also the spindle cage, with an appropriate cleansing agent (white spirit, alkaline cleanser). Then, after having thoroughly dried these parts, it is iportant to proceed iediately to the application of the lubricating grease in order to avoid any corrosion. Capped Bearings: The grease quantity should fill alost 30 % of the free bearings space. Upon deand, the bearing anufacturers or LUBCON indicate the grease quantity favourable for the lubrication of the different bearing constructions and sizes. Apply the grease as unifor as possible over the whole bearing surface. It is useful to take a grease gun for that purpose which LUBCON would like to quote and supply. Open Bearings: You ay count with a grease quantity of up to 100 % of the free bearing space in order to achieve an increase of the service life. The cage space adjacent to the bearing ust be large enough to easily receive the grease eerging fro the bearing. Reduction of the Grease Quantity by 30 to 50 %: to be effected in the interests of a fast and siple running-in process with lubricating greases causing teperature peaks during the running-in and distribution of the grease. Diagra 3, p. 8 shows the bearing teperature curve as a function of the operating ties of two bearings B 7006 C.T (arked with A and B) of a spindle lubricated with TURMOGREASE Highspeed L 5, degree of the grease filling 100 %, axiu target speed = 30,000 in. The running-in starts at a speed of 10,000 in, which is approx. one third of the axiu speed of operation. It can be proved (see p. 10, table 5, test ) that this lubricating grease leads to a very low bearing friction. When starting the spindle there are no teperature peaks to be observed, after a few inutes both spindle bearings have already reached a teperature which reains alost unchanged over hours. The speed raised up to the operational value of 30,000 in produces only a gradual increase of the teperature, after about one hour the steady state teperature of +4 C is nearly reached. Field Test with TURMOGREASE Highspeed L 5: At the Gildeeister copany a running-in without any probles was observed in larger spindle bearings d = 75 at speed factors below 1 illion (in. ) and showing siilar steady state teperatures of +35 to +44 C at the outer rings of the bearings. In the running-in process TURMOGREASE Highspeed L 5 was clearly superior copared to other copetitive products. During the first two service hours, the operational speed shall be liited to a value of 30 % of the axiu speed, then any running-in prescription will not apply for speed factors up to 1.3 illion (in. ) for steel-steel as well as for hybrid bearings. Diagra 4, p. 8 shows the teperature curve during a running- in process at a speed factor of 1.6 illion (in. ) in dependence on the operating tie of two hybrid bearings HC 7006 C.T. The running-in was started at a speed of 0,000 in and raised after just one hour to axiu speed of 40,000 in. With an alost copletely filled bearing, no perceptible teperature peaks occurred. Table 3, p. 8 shows you a siplified running-in prescription for a large speed factor range regarding the applied lubricating grease TURMOGREASE Highspeed L 5. Service Lives of Greased High Speed Rolling Bearings The rolling bearings operated at high speed factors, i. e. range fro 0.6 to.5 illion (in. ), are preferably lubricated by TURMOGREASE Highspeed L 18 and TURMOGREASE Highspeed L 5. After expiry of the grease service life, a relubrication should not be carried out because the new grease in addition to the used grease would lead to an overlubrication of the bearing and a new running-in would not be possible within an acceptable delay. Furtherore, in ost cases a sufficient space is issing to receive the displaced used grease. Therefore it is recoended to clean the bearing and to apply new grease. The grease service life is shown in the right part of the lubrication interval/grease service life diagra (diagra 5, p. 9). Upper range liit: applies to the particularly efficient ceraic hybrid spindle bearings. Lower range liit: applies to the standard steel-steel spindle bearings. The rolling bearings greased with THERMOPLEX TML and TURMOGREASE Li 80 EP ay be relubricated if the speed factor is below 0.6 illion (in. ). Make sure that the relubrication will be effected while the bearings are running at a low speed and that the lubrication of the bearing will be coplete. A sufficiently large space to receive the used grease ust be provided. The relubrication quantity is to be deterined according to table 4, p. 9.. In case of higher speed factors > 0.6 illion (in ), it is recoended to lubricate the bearings with new grease after expiry of the grease service life. The service life of the grease is to be deterined fro the coloured part of the diagra (diagra 5, p. 9). It has to be taken into account that the grease service life of various equally loaded bearings ay differ by approx. 1 : 3. If a high reliability is desired, the lower part of the range should be selected. TURMOGREASE Li 80 EP should not be used for ceraic hybrid spindle bearings and the lubricating grease THERMOPLEX TML only for such cases where teperatures above +60 C are to be expected. 7

8 Test Results and Running-in Prescription Diagra 3: Running-in n. d = 1.3 illion (in. ) 80 Running-in t L 40 ( C) 30 Bearing A B : :00 11:00 1:00 13:00 14:00 15:00 16: Tie of operation n = in n = in Test stand Rolling bearing Lubricating grease Filling degree of the free bearing space WS B7006C.T TURMOGREASE Highspeed L % Diagra 4: Running-in n. d = 1.6 illion (in. ) 75 Running-in t L ( C) 50 5 Bearing A B 0 10: :00 11:10 11:0 11:30 11:40 11:50 1:00 1:10 1:0 1:30 1: Tie of operation n = 0000 in n = in Test stand Rolling bearing Lubricating grease Filling degree of the free bearing space WS HC7006 C.T TURMOGREASE Highspeed L % Table 3: Running-in prescription for the lubricating grease TURMOGREASE Highspeed L 5. Speed factor (in ) Spindle bearing Grease filling degree in % of the free bearing space Running-in conditions: after start-up up to 1.3 illion steel-steel 30 to 100 two hours at 30% of the axiu speed up to 1.6 illion hybrid 30 to 100 two hours at 50% of the axiu speed 8

9 Lubrication Interval and Relubrication Quantity Chart Table 4: Relubrication quantities Relubrication quantity 1 for weekly or annual relubrication intervals = D B x [g] Relubrication interval x weekly 0.00 onthly annual Relubrication quantity for extreely short relubrication intervals = ( ) V [kg/h] Relubrication quantity 3 before starting reoperation after a standstill of severals years = D B 0.01 [g] V = free space in the bearing G 3 B (D - d ) 10 - [ ] d = diaeter of the bearing bore [] D = outer diaeter of the bearing [] B = bearing width [] G = bearing weight [kg] 3 Diagra 5: Lubrication interval/grease service life dependent on the value k. n. f d with the application range of the LUBCON lubricating greases for high speed rolling bearings. n = speed in in, d = reference circle of the bearing in h n d = 0.6. ill. (in ) Application range LUBCON lubricating greases for high speed rolling bearings Lubrication interval t f Application range lubricating greases THERMOPLEX TML and TURMOGREASE Li 80 EP Hybrid bearing Steel-steel bearing in k. n. d f k 1 f 0,75 0,9,5 Rolling bearing Cylindrical roller bearing of a higher diensional accuracy (N10 K.M1.SP) Spindle bearing (C) pressure angle 15 Spindle bearing (E) pressure angle 5 Tapered roller bearing of a higher diensional accuracy ( M.SP) 9

10 Results Obtained by LUBCON Lubricating Greases in Laboratory and Field Tests For high speed rolling bearings: TURMOGREASE High-speed L 18 and TURMOGREASE Highspeed L 5 The results of the 5 test runs indicated in table 5 are contained in the diagra 6. The diagra 6 is the basis for the coloured range in diagra 5, p. 9 regarding the LUBCON lubricating greases for high speed rolling bearings. In the diagra 6 the circle of the range of these results coplies with the requireent deanded by the rolling bearing anufacturer for hybrid bearings. The tie of operation achieved by steel-steel bearings in test is by approx. 10 ties higher than the ties reached by copetitive products. The tie of operation reached by hybrid bearings in test 3 is with ore than service hours extreely high, coparative values of lubricating greases of other anufacturers are not available, yet. Reason for such a high perforance of TURMOGREASE Highspeed L 5: The bearing lubricated with this grease causes less than half the friction loss copared to easured copetitive greases. Grease service life h Test No... n d = 0.6. illion (in ) Application range LUBCON lubricating greases for high speed rolling bearings Range for hybrid bearings Required by rolling bearing anufacturers for hybrid bearings Range for steel-steel bearings in k. n. f d Diagra 6: Laboratory and field results with LUBCON lubricating greases used in high speed rolling bearings Table 5: Results of various tests Test Test site/ Test bearing/ Grease/teperature ( C) Speed n. d k. n. f d no. test stand tie of operation (h) (in ) (in. ) (in. ) 1 GMN spindle SM 6005/>700 TURMOGREASE Highspeed L 18/60 > ill. 1.5 ill. IKMT TU Hannover spindle B 7008 C/>5000 TURMOGREASE Highspeed L 5/ ill ill. 3 FAG WS n HC7006C/> TURMOGREASE Highspeed L 5/ ill. 1.7 ill. 4 GMN spindle SM 6005/1500 TURMOGREASE Highspeed L 5/ ill ill. 5 FAG WS a B 705C TURMOGREASE Highspeed L 5/ ill ill. Other LUBCON Lubricating Greases for High Speed Rolling Bearings After long years of experience, alost all cases of application regarding high speed rolling bearings can be astered with the product line consisting of four base greases. Furtherore, there are cases where the lubricating grease should provide at least one ore characteristic in order to achieve an optiu result. Therefore, other lubricating greases were derived fro these base greases thus showing at least one odified paraeter. In addition to the existing properties at least one ore specification was obtained. For further details see table 6. Table 6: Other lubricating greases for high speed rolling bearings derived fro the base greases Base grease Derived lubricating greases Modified paraeter New product property TURMOGREASE Highspeed L 18 THERMOPLEX TML special thickener better frictional behaviour TURMOGREASE Highspeed L 5 TURMOGREASE Highspeed LC 5 base oil, thickener better resistance to water, bases and acids THERMOPLEX TML THERMOPLEX L 55 thickener better theral quality, THERMOPLEX HPL base oil higher operating perforance TURMOGREASE Li 80 EP TURMOGREASE L 80 EP+ thickener part, consistency better running-in behaviour, higher operating perforance 10

11 Test LUBCON Whatever you need - fro the consultation on tribologic questions to the setting into operation of the lubricant LUBCON is the partner at your side worldwide. And that is not yet all The TOTAL LUBE MANAGEMENT enables you to work even ore efficient and ore econoic as before. This perforance spectru includes ELABORATION of lubricant charts for your copany DELIVERY of the lubricants deterined in the lubricant chart LUBRICATION of the individual plant installations with the lubricants listed in the lubricant chart DOCUMENTATION of the lubrication processes CONCEPTION of the lubricating systes for oils and greases SETTING INTO OPERATION of the lubricating systes PROCUREMENT of production eans, e. g. grease guns, grease nipples, lubricant supply systes, etc. FILLING of sall series of rolling bearings with the greases indicated by you Did you know that LUBCON lubricants are applied for your safety worldwide every day? e. g. in single-lever ixers of water fittings in energy regulators in electric stoves in the AIRBUS in the ARIANE carrier rocket in the FORMULA 1 by Sauber-Petronas, Jordan and Benetton in vehicle coponents lubricated for life in the food production with specially approved (NSF-H1) food lubricants in large open gear drives of ceent ills, in sall gears of dental turbines in large bearings in the open pit ining, in iniature bearings of coputers in conveyor chains of paint dryers, in transport chains of refrigerating plants etc. LUBCON delivery syste:... at the agreed date always the desired LUBCON product available to you: l tubes, 400 l sprays, 400 l cartridges, 1 kg cans, 5 l canisters, 0 l canisters, 5 kg buckets, 5 kg buckets, 180 kg drus, 00 l drus or the 1000 l container are just a sall selection of the packing units possible... Fig. : Test Stand WS Design/Layout: Dipl. Designerin Andrea Dörn Nadja Grabowski, Marketing Text: Dr.-Ing. Erich Kleinlein Nadja Grabowski Tables, Diagras: Prof. Dr. A. Tönsann, FH, Gelsenkirchen 11

12 The World of the LUBCON Lubricants EUROPE Austria LUBRICANT CONSULT GMBH Office St. Gertraud GSM: Fax: E-ail: Belgiu Van Meeuwen Special Lubricants N.V. Tel.: Fax: E-ail: info@vaneeuwen.be Czech Republic LUBCON s.r.o. Tel.: Fax: E-ail: czechrepublic@lubcon.co Denark A.H. INTERNATIONAL A/S Tel.: Fax: E-ail: ahi@ahi.dk Finland Jukka Majuri Oy Tel.: Fax: E-ail: jukka.ajuri@lubcon.fi France LUBCON FRANCE S.A.R.L. Tel.: Fax: E-ail: france@lubcon.co Great Britain LUBCON Lubricants UK Ltd. Tel.: Fax: E-ail: uk@lubcon.co Italy LUBCON LUBRIFICANTI S.R.L. Tel.: Fax: E-ail: italia@lubcon.co EUROPE Netherlands Van Meeuwen Seertechniek B.V. Tel.: Fax: E-ail: info@vaneeuwen.nl Norway NORIKO AS Tel.: Fax: E-ail: bww@noriko.no Poland LUBCON POLSKA Sp. z o.o. Tel.: Fax: E-ail: polska@lubcon.co Slovenia LUBCON d.o.o. Tel.: Fax: E-ail: lubcon@lubcon.si Spain LUBRITEC, S.A. Tel.: Fax: E-ail: lubritec@lubritec.co Sweden Ringdahl Maskiner AB Tel.: Fax: E-ail: clas@ringdahl-askiner.se Internet: Switzerland LUBCON Lubricant Consult AG Tel.: Fax: E-ail: swiss@lubcon.co Turkey GEOCON Ltd. Þti. Tel.: Fax: E-ail: geocon@geocon.co.tr EUROPE Further Distributors Bulgaria Ireland Cyprus Portugal Greece Russia Hungary NORTH AMERICA United States LUBCON Turo Lubrication, Inc. Tel.: Fax: Toll free US+CAN: E-ail: inquiry@lubconusa.co Further Distributors Mexico SOUTH AMERICA Brazil Fuchs do Brasil S.A. Tel.: Fax: E-ail: fuchs@fuchsbr.co.br Further Distributors Ecuador AFRICA / MIDDLE EAST South Africa FOCHEM International (Pty) Ltd. Tel.: Fax: E-ail: info@focheinternational.co Further Distributors Egypt Saudi Arabia Israel Tunisia Iran UAE Pakistan ASIA/PACIFIC Philippines LUBCON Lubricant Asia Regional Headquarter E-ail: apsales@lubcon.co Further Distributors Australia Korea Bangladesh Malaysia China New Zealand Hong Kong Singapore India Taiwan Indonesia Thailand Japan Vietna LUBRICANT CONSULT GMBH Lubricants Lubrication Systes Gutenbergstraße Maintal GERMANY P.O. Box Maintal GERMANY Tel.: / Fax: / Eail: webaster@lubcon.co Release date: