lubricants
• Types of lubricants
• Properties of lubricants
• SAE rating of lubricants
Engine Lubrication systems
• Function of lubrication
Lubrication • Lubrication systems
• Engine performance &
& Lubrication
Engine Engine Cooling
Cooling • Need of cooling
• Disadvantages of
overcooling
• Cooling systems
Lubricants
What is a lubricant?
A lubricant is a substance that helps
to reduce friction between surfaces in
mutual contact, which ultimately
reduces the heat generated when the
surfaces move.
Formulation of lubricants
• Typically lubricants contain
90% base oil + 10% additives.
• Base Oil- petroleum fractions i.e.
mineral oils, vegetable oils,
synthetic oil (esters, silicones,
fluorocarbons.
Additives
Additives are used to impart
performance characteristics to the
lubricants.
Additives deliver –
• reduced friction and wear
• increased viscosity,
• improved viscosity index,
• resistance to corrosion and oxidation,
aging or contamination, etc.
Major types of additives –
• Pour point depressants
• Anti-foaming agents
• Viscosity Index improvers (VIIIs)
• Antioxidants
• Corrosion inhibitors
Essential properties of Lubricants –
• Viscosity – the more viscous the oil is, it can take up more bending load pressure
and provide adequate sealing of the piston.
• Viscosity Index (VI) – it is the rate of change of viscosity w.r.t. Temperature.
• Pour Point – it indicates the temperature below which the oil loses it fluidity and
will not flow or circulate in a lubricating system.
• Stability – the ability of an oil to resist oxidation that would yield acids, lacquers,
and sludge.
• Oilness – it is a measure of the protective layer of oil film in the boundary
lubrication region.
• Corrosiveness – lubricant must be corrosion resistance.
• Detergency – it is the property of lubricant to clean the carbon and other deposits.
• Flash point – the temperature at which a lubricant will ignite when heated and
mixed with air, but a flame is not sustained.
• Fire Point – lowest temp. required to produce a continuous flame above the oil.
Types of lubricants
Mineral Oil – this refers to the lubricating base oils derived from Crude Oil.
Several types of lubricant base oils are designated into different groups –
• Group I - Saturates < 90% and/or sulfur > 0.03%, and (SAE) viscosity index of 80
to 120. Manufactured by solvent extraction, solvent or catalytic dewaxing, and
hydro-finishing processes.
• Group II – Saturates > 90% and sulfur < 0.03%, and SAE viscosity index of 80 to
120. Manufactured by hydrocracking and solvent or catalytic dewaxing processes.
Group II base oil has superior anti-oxidation properties since virtually all
hydrocarbon molecules are saturated. It has water-white color.
• Group III – Saturates > 90%, sulfur < 0.03%, and SAE viscosity index over 120.
Manufactured by special processes such as isohydromerization. Can be
manufactured from base oil or slax wax from dewaxing process.
• Group IV – Polyalphaolefins (PAO)
• Group V – All others not included above, such as naphthenics, polyalkylene glycols
(PAG), and polyesters.
Synthetic oils – Petroleum-derived lubricant can also be produced using
synthetic hydrocarbons (derived ultimately from petroleum), "synthetic oils".
These include:
• Polyalpha-olefin (PAO)
• Synthetic esters
• Polyalkylene glycols (PAG)
• Phosphate esters
• Perfluoropolyether (PFPE)
• Alkylated naphthalenes (AN)
• Silicate esters
• Ionic fluids
• Multiply alkylated cyclopentanes
Solid lubricants
• PTFE: polytetrafluoroethylene (PTFE) .Its usable temperature range up
to 350 °C and chemical inertness make it a useful additive in special
greases, where it can function both as a thickener and a lubricant.
• Inorganic solids: Graphite, hexagonal boron nitride, molybdenum
disulfide and tungsten disulfide are examples of solid lubricants. Some
retain their lubricity to very high temperatures. Solid lubricants such as
graphite and molybdenum disulfide are widely used when normal
lubricants do not possess sufficient resistance to load or temperature
extremes.
• Metal/alloy: Metal alloys, composites and pure metals can be used as
grease additives or the sole constituents of sliding surfaces and bearings.
Lead, tin, zinc alloys and various bronze alloys are used as sliding
bearings, or their powder can be used to lubricate sliding surfaces alone.
Biolubricant
Biolubricants are derived from vegetable oils
and other renewable sources. They usually
are triglyceride esters (fats obtained from
plants and animals). For lubricant base oil
use, the vegetable derived materials are
preferred.
Common ones include –
• high oleic canola oil,
• castor oil,
• palm oil, sunflower seed oil and rapeseed
oil from vegetable,
• tall oil from tree sources.
Other naturally derived lubricants include –
lanolin (wool grease, a natural water
repellent).
SAE VISCOSITY NUMBER
The SAE viscosity number for lubricating oils is recommended by the
Society of Automotive Engineers.
• It depends solely on the viscosity of the oil.
• The different SAE numbers are 5W, 10W, 20W, 20, 30, 40 and 50.
• The SAE numbers followed by W indicate the (suitability of oil for
use ) in winter and the viscosity is determined at 0°F (-17.8°C).
• The SAE numbers without W are applied to oils commonly used
under warmer conditions and the viscosity is determined at 210°F
(98.9°C).
• Each number represents a viscosity range expressed in minimum
and maximum Saybolt universal seconds (SUS) at a particular
test temperature.
• The increasing numbers indicate increase in viscosity.)
Saybolt Universal Viscosity (SUS)
The time in seconds required for 60 Cubic Centimetres of a fluid to Flow
through the orifice of the Standard Saybolt Universal Viscometer at a
given temperature under specified conditions.
Table – 1 (SAE Classification of lubricating oils)
SAE Viscosity Range (SUS)
Viscosity 0°F (-17.8°C) 210°F (98.9°C)
No.
MIN. MAX. MIN. MAX.
5W – 6,000 – –
10W 6,000 12,000 – –
20W 12,000 48,000 – –
20 – – 45 58
Functions of lubrication
Reducing frictional resistance – Lubricant reduces friction power by
reducing wear between the rubbing and bearing surfaces, thereby increasing the
power output and the engine service life.
Cooling – A lubricant also acts as a coolant, carrying heat away from the bearings,
cylinders and pistons.
Sealing – The lubricating film on the cylinder wall acts as a seal to prevent the gases
of combustion from being blown by the piston rings and entering the crankcase.
Cleaning – A lubricant cleans carbon and other deposits from the surfaces of the
piston, piston rings and bearings. It also eliminates dust and other contaminants.
Reduction in noise – A lubricant cushions the parts against vibration and impact,
thus reducing the engine noise.
Protection against corrosion and wear – A lubricant protects the metallic
surfaces against the corrosive action of combustion products such as water, SO ₂, etc.
Lubrication Systems
The basic types of lubricating systems are:
1. Petrol lubrication system
2. Wet-sump lubrication system
3. Dry-sump lubrication system
Petrol Lubrication System - The fact that the petrol and oil supplies
seemed to be almost inseparably intermingled, deliberate pre-mixing of
the oil and fuel resulted in the adoption of the petrol lubrication system.
• The lubricant is mixed with the fuel in the supply tank and after
emerging from the carburetor jet in droplets it is carried into the inlet
ports along with the fuel-air mixture.
Advantages - low cost, simplicity, coupled with the fact that oil supply is
metered quite closely to the requirements of the engine. The oil supply is
regulated by the throttle opening and is therefore proportional to the load or
output.
Disadvantages - A large portion of oil is wasted, it causes deposits on
Wet-sump Lubrication System
There are three types of wet-sump lubrication systems-
• splash
• pressurized
• combination of above two
Splash system -
Many small four-stroke engines used in lawn mowers, golf carts, etc. use
splash distribution of oil.
The oil is pumped by a low pressure oil pump from the large capacity oil
sump to small troughs placed under each connecting rod. Oil levels in these
troughs are maintained constant by supplying excess of oil and providing
an overflow to each trough.
The caps on the big-end bearings of the connecting rods are usually
provided with scoops or dippers. When the piston reaches BDC, the
corresponding connecting rod scoop dips into the trough and directs the oil
through a hole in the cap to the big-end bearing.
Working of splash lubrication system -
Pressure- Feed Lubrication System
The splash and pressure lubrication system
Dry-Sump Lubrication System
ENGINE PERFORMANCE AND LUBRICATION
• The viscosity of the lubricating oil has a considerable effect on the
engine performance.
• If the viscosity is too high, there will be loss of power in shearing and in
pumping the oil. It will result in reduced torque and power output of the
engine, and increased fuel consumption.
• On the other hand, if the viscosity is too low, there will be poor sealing
between the piston rings and the cylinder walls. It will result in increase
in blowby with a consequent increase in oxidation of the crankcase oil,
and increased oil consumption.
• Large variation in Viscosity index results in ineffective lubrication and
increase wear of engine components.
• Increase in engine speed & load decreases the lubricant’s viscosity.
• Engine components can bring physical and chemical changes in the oil.
• Oil can be contaminated by foreign matter. This may corrode the engine.
ENGINE COOLING
About 35% of the total chemical energy that enters an engine as fuel is converted to
useful crankshaft work, and about 30% of the fuel energy is carried away from the
engine to the exhaust.
NECESSITY OF ENGINE COOLING
1. The peak gas temperature during the combustion process of an IC engine is of the
order of 2500 K. The temperature of the inside surface of the cylinder walls is
usually kept below 200°C to prevent deterioration of the oil film.
2. High temperatures are produced in the cylinders of the engine as a result of the
combustion process. A large portion of the heat generated in the combustion
chamber is transferred to the cylinder head and walls, and piston and valves.
3. The temperature of the cylinder head must also be kept below 220°C. If the cylinder
head temperature is high, this may lead to overheated spark-plug electrodes
causing preignition in SI engines.
4. Spark plug and valves must be kept cool to avoid knock and preignition problems
which result from overheated spark-plug electrodes or exhaust valves. Preignition
results in a loss of efficiency and increases the cylinder head temperature.
DISADVANTAGES OF OVERCOOLING
1. Starting of the engine will be difficult at low temperatures. The engine
must be kept sufficiently hot to ensure smooth and efficient operation.
2. Vaporization of the fuel will be reduced at low temperatures, preventing
formation of a homogeneous mixture with air. It may cause poor combustion and
also increase fuel consumption.
3. Excessive cooling provided to the combustion chamber walls will lower the average
combustion gas temperature and pressure and reduce the work per cycle
transferred to the piston. Thus, the specific power and efficiency gets reduced.
4. Friction will be increased because of higher viscosity of lubricating oil at lower
temperatures.
5. The sulphureous and sulphuric acids are formed from the oxidation of Sulphur
present in the fuel during the combustion process. These acids may condense at low
temperatures and corrode the cylinder surfaces. To prevent condensation of acids,
the coolant temperature should be greater than 70°C.
Thus, removing heat is highly critical in preventing an engine and engine lubricant
from thermal failure. On the other hand, it is desirable to operate an engine as hot as
possible to maximize thermal efficiency.
Cooling Systems
There are 2 basic types of cooling systems used in reciprocating IC engines:
1. Direct or Air-Cooling system
2. Indirect or Liquid Cooling system
Air Cooling System
Liquid Cooling Systems
1. Direct or Non-Return Systems
2. Thermosyphon or natural circulation system
3. Forced or pump Circulation System
4. Evaporative cooling System.
Thermosyphon or natural circulation system
Pump Circulating Cooling System
Evaporative Cooling System
When the coolant vaporizes, it absorbs the latent heat of vaporization from
the metal surface to be cooled
