7/27/2019 The Hidden Dangers of Lubricant Starvation.doc http://slidepdf.com/reader/full/the-hidden-dangers-of-lubricant-starvationdoc 1/21 The Hidden Dangers of Lubricant Starvation • • • • Jim Fitch, Noria CorporationTags: industrial lubricants For those who strive for lubrication-enabled reliability (LER), more than 95 percent of the opportunity comes from paying close attention to the “Big Four.” These are critical attributes to the optimum reference state (ORS) needed to achieve lubrication excellence. The “Big Four” individually and collectively influence the state of lubrication, and are largely controllable by machinery maintainers. They are well-known but frequently not well- achieved. The “Big Four” are: 1. Correct lubricant selection 2. Stabilized lubricant health
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7/27/2019 The Hidden Dangers of Lubricant Starvation.doc
The first three of the “Big Four” have benefited from considerable industry attention,
especially in recent years. Conversely, the last one has gone relatively unnoticed yet is noless important. Therefore, it will be the central focus of this article.
Over the past few decades, researchers and tribologists have compiled countless listings
that rank the chief causes of machine failure. We’ve published many of these in Machinery
Lubrication magazine. The lists ascribe the causes of abnormal machine wear to the usual
suspects: contamination, overheating, misalignment, installation error, etc. There’s typically
a lubrication root-cause category that is a catch-all for one or more causes that can’t be
easily specified or named. I’ve seen terms used like “inadequate lubrication” and “wrong
lubrication.”
Understandably, it is difficult for failure investigators and analysts to trace back the exactsequence of events beginning with one or more root causes. Evidence of these causes is
often destroyed in the course of failure or in a cover-up during the cleanup and repair.
Having led several hundred such investigations over the years, I’ve learned that one root
cause in particular is too often overlooked - lubricant starvation.
81%of lubrication professionals have seen the
effects of lubricant starvation in the machines
at their plant, according to a recent survey at
machinerylubrication.com
Although most everyone knows about this in principle and realizes the common sense of
adequate lubricant supply, it is frequently ignored because many typical forms of lubricant
starvation are largely hidden from view. For instance, who notices the quasi-dry friction that
accelerates wear each time you start an automobile engine? This is a form of lubricant
starvation. It’s not a sudden-death failure, but it is a precipitous wear event nonetheless.
Each time controllable wear goes uncontrolled, an opportunity is lost to prolong service life
and increase reliability.
The Nature of Lubricant Starvation
Machines don’t just need some lubricant or any lubricant. Rather, they need a sustained and
adequate supply of the right lubricant. Adequate doesn’t just mean dampness or the nearby
presence of lubricant. What’s defined as adequate varies somewhat from machine to
machine but is critical nonetheless. High-speed equipment running at full hydrodynamic film
has the greatest lubricant appetite and is also the most punished when starved. Machines
running at low speeds and loads are more forgiving when lube supply is restricted. Even
these machines can fail suddenly when severe starvation occurs.
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• Cold Starts - Cold wintertime conditions slow the movement of oil in the engine
during start-up. This can induce air in the flow line due to cold-temperature suction-
line conditions.
• Low Oil Pressure - This can result from numerous causes, including worn bearings,pump wear, sludge and extreme cold. Oil pressure is the motive force that sends oil
to the zones requiring lubrication.
• Dribbling Injectors - Fuel injector problems can wash oil off cylinder walls and
impair lubrication between the piston/rings and the cylinder wall.
Common Signs of Lubricant Starvation
•
Clogged Spray Nozzles and Orifices - Nozzles and orifices direct oil sprays tocylinder walls, valves and other moving components. Sludge and contaminants are
able to restrict oil flow.
Starved Journal and Tilting-Pad Thrust Bearings
• Oil Groove Problems - Grooves and ports channel oil to the bearing load zones.
Grooves become clogged with debris or sludge, restricting oil flow.
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• Entrained Air and Foam - Oil pumps and flow meters perform poorly (or not at all)
when sumps become contaminated with air (Figure 4).
• Lack of Flow Measurement - Components sensitive to oil supply require constant
oil flow measurement.
• Defective or Miscalibrated Flow Meters - Flow meters, depending on the type
and application, can present a range of problems regarding calibration.
• Low Oil Pressure - Oil follows the path of least resistance. Line breaks and openreturns starve oil from higher resistance flow paths and the machine components
they serve.
Starved Spray-Lubed Chains and Open Gears
• Defective Auto-lube Settings - This relates to correctly setting the lube volume
and frequency.
• Defective Spray Targets/Pattern - The oil spray needs to fully wet the target
location. Spray nozzles can lose aim and become clogged (Figure 8).
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Not contained in the ISO classification is Erosion from particles and Cavitation.
Wear mechanisms can also be thought of as occurring in two separate categories: contact
and noncontact modes. Contact wear requires the components to have direct metal-to-
metal contact for wear to occur. Noncontact modes do not require the surfaces to come into
direct contact for them to wear; in other words, a full fluid lubricant film may exist.
Subsurface Fatigue
Subsurface fatigue is a form of wear that occurs after many cycles of high-stress flexing of the metal. This causes cracks in the subsurface of the metal, which then propagate to the
surface, resulting in a piece of surface metal being removed.
It begins with inclusions or faults in the bearing metal below the surface. Subsurface
microcracks form due to long-term repeated load cycles and stress (500,000 psi), causing
elastic deformation (flexing) of the metal. This is typical in all rolling bearing elements and
races and gear teeth, all of which operate in the elastohydrodynamic (EHD) lubrication
regime. The contact stress is concentrated at a point below the metal surface.
These microcracks normally propagate to the surface, which eventually results in a piece of
the surface material being removed or delaminated. They appear as surface damage orwear (large pits) referred to as spalling. Other terms for subsurface fatigue include flaking,
peeling and mechanical pitting. A full oil film exists and no metal-to-metal contact or surface
damage is needed. Subsurface fatigue is not a common issue if better quality metals are
used in bearing manufacture. Most bearings will fail by another mechanism first.
Subsurface fatigue failure is the result of a bearing living out its normal life span based on
the load, speed and lubricant film thickness that it is exposed to. The L10 fatigue life of a
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bearing is the average time (in hours or cycles) to fail 10 percent of a set of identical
bearings under certain conditions. An estimate of the L10 life can be calculated, providing a
rating life of a bearing.
Surface-initiated Fatigue
This begins with reduced lubrication regime and a loss of the normal lubricant film. The oil
film is reduced to boundary or a mixed regime. Some metal-to-metal contact and sliding
motion occurs. Surface damage occurs. The high points of the metal surface asperities are
removed, which initially appear as a matted or frosted surface. This is not smearing, as inadhesion (discussed below). This type of surface damage is usually visible with a
magnification of three to five times.
The surface damage is coupled with the cyclic loading of the rollers rolling over the race.
This creates asperity microcracks and microspalling. The cracks start at the surface and
migrate down into the metal. An edge of metal is created at the surface which flexes at the
edge of the surface crack. This creates a cold worked edge which is lighter in color. The
cracks propagate and may intersect within the metal, and a piece of surface material is then
removed. Flaking, mechanical pitting and micropitting are other names used to describe
spalling.
Surface fatigue can also occur as a result of plastic deformation (described below).
Contaminant particles in the oil enter the high-load rolling contact area between rollers and
the race, or between gear teeth, and cause some form of surface damage - a dent.
Improper handling of bearings can cause similar surface damage.
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These round-bottomed dents often have a raised berm around their edges. The raised berm
of metal acts as a point of increased load or stress, or creates a reduced lubrication regime
(mixed or boundary), and leads to a lower surface fatigue life. Improved filtration reduces
plastic deformation, and therefore indirectly reduces the occurrence of surface fatigue.
Notice that the term "contact fatigue" is not used by ISO. This is a vague term sometimesused to describe both forms of fatigue. It does not specify whether metal flexing damage
started in the subsurface or from some initial surface damage. It encompasses any change
in the metal structure caused by repeated stresses concentrated at a microscopic scale in
the contact zone between the rolling elements and raceways, and between gear teeth.
Abrasive Wear
Abrasive wear is estimated to be the most common form of wear in lubricated machinery.
Particle contamination and roughened surfaces cause cutting and damage to a mating
surface that is in relative motion to the first.
Three-body abrasion occurs when a relatively hard contaminant (particle of dirt or wear
debris) of roughly the same size as the dynamic clearances (oil film thickness) becomes
imbedded in one metal surface and is squeezed between the two surfaces, which are inrelative motion. When the particle size is greater than the fluid film thickness, scratching,
ploughing or gouging can occur. This creates parallel furrows in the direction of motion, like
rough sanding. Mild abrasion by fine particles may cause polishing with a satiny, matte or
lapped-in appearance. This can be prevented with improved filtration, flushing and sealing
out small particles.
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Two-body abrasion occurs when metal asperities (surface roughness, peaks) on one
surface cut directly into a second metal surface. A contaminant particle is not directly
involved. The contact occurs in the boundary lubrication regime due to inadequate
lubrication or excessive surface roughness which could have been caused by some other
form of wear. Higher oil viscosity, increased metal hardness and even demagnetizing
bearings after induction heating during installation may help to reduce two-body abrasion.
Adhesive Wear
Adhesive wear is the transfer of material from one contacting surface to another. It occurs
when high loads, temperatures or pressures cause the asperities on two contacting metal
surfaces, in relative motion, to spot-weld together then immediately tear apart, shearingthe metal in small, discrete areas.
The surface may be left rough and jagged or relatively smooth due to smearing/deformation
of the metal. Metal is transferred from one surface to the other. Adhesion occurs in
equipment operating in the mixed and boundary lubrication regimes due to insufficient lube
supply, inadequate viscosity, incorrect internal clearances, incorrect installation or
misalignment. This can occur in rings and cylinders, bearings and gears.
Normal break-in is a form of mild adhesive wear, as is frosting. Scuffing usually refers to
moderate adhesive wear, while galling, smearing and seizing result from severe adhesion.
Adhesion can be prevented by lower loads, avoiding shock loading and ensuring that thecorrect oil viscosity grade is being used. If necessary, extreme pressure (EP) and antiwear
(AW) additives are used to reduce the damage.
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CorrosionMoisture corrosion involves material removal or loss by oxidative chemical reaction of the
metal surface in the presence of moisture (water). It is the dissolution of a metal in an
electrically conductive liquid by low amperage and may involve hydrogen embrittlement. It
is accelerated, like all chemical reactions, by increased temperatures. No metal-to-metal
contact is needed. It will occur with a full oil fluid film.
Corrosion is often caused by the contamination or degradation of lubricants in service. Most
lubricants contain corrosion inhibitors that protect against this type of attack. When the
lubricant additives become depleted due to extended service or excessive contamination by
moisture, combustion or other gases or process fluids, the corrosion inhibitors are no longer
capable of protecting against the acidic (or caustic) corrosive fluid and corrosion-induced
pitting can occur. The pits will appear on the metal surface that was exposed to the
corrosive environment.
This may be the entire metal surface or just the lower portion of the metal that may have
been submerged in water not drained from the oil sump or at the roller/race contact points.
Generally, an even and uniform pattern of pits will result from this form of attack. Mild
forms of moisture corrosion result in surface staining or etching. More severe forms are
referred to as corrosive pitting, electro-corrosion, corrosive spalling or rust.
Frictional corrosion is a general form of wear caused by loaded micromovements orvibration between contacting parts without any water contaminant being present, although
humidity may be necessary. It may also be referred to as fretting wear. It includes both
fretting corrosion and false brinelling, which in the past were often considered to be the
same mechanism.
Fretting corrosion is the mechanical fretting wear damage of surface asperities
accompanied and escalated by corrosion, mostly oxidation in air with some humidity
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present. It occurs due to many oscillating micromovements at contacting interfaces between
loaded and mating parts in which the lubricant has not been replenished (an unlubricated
contact). Adhesion is occurring and it is generally considered more severe than false
brinelling.
It usually appears as a reddish-brown oxide color (rust without water being present) onsteel and black on aluminum. Metal wear debris flakes are created or shed off.
Fretting corrosion occurs on many mechanical devices such as gear teeth and splines, not
just rolling element bearings, and can occur on surfaces other than the rolling contact. In
bearings, it is also associated with bearing fit on the shaft and in the housing. It occurs
where there is not any large relative motion between the mating parts such as between the
shaft and the inner race and between the housing and the outer race. Fretting corrosion can
occur on materials that do not oxidize.
False brinelling occurs due to micromovements under cyclic vibrations in either static or
rotating boundary lubrication contacts. Mild adhesion of the metal asperities is occurring.
Shallow depressions or dents are created in which the original machining marks are worn off
and no longer visible due to the wearing damage of the metal. False brinelling occurs on the
rolling elements and raceway, similar to small-scale plastic deformation or brinelling (see
below) and hence the name "false brinelling".
False brinelling is usually associated with static nonrotating equipment and, thus, the wear
appears at the roller contacts with the exact same spacing as the rollers. The depressions in
the metal can appear shiny with black wear debris around the edges. If the equipment is
rotating, the wear appears as a gray, wavy washboard pattern on the raceway. Reduced
bearing life or failure ultimately occurs, sometimes in a catastrophic fashion, through
surface fatigue initiating in these damaged surface layers.
An example of false brinelling occurs in standby electric motors and pumps (and others)
which sit idle for periods of time, but are subjected to vibration from the plant floor up
through the load-bearing rolling elements of the bearings. Antiwear additives may be
beneficial in reducing the wear damage.
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This type of wear occurs when electric current passes between two metal surfaces (for
example, bearing roller and race) through the oil or grease film. It is subdivided based on
the severity of the damage. Electrical erosion should not be confused with erosion caused by
particles (discussed below).
Excessive voltage (electrical pitting) is caused by a high electrical current or amperage
passing through only a few asperities on the metal. Voltage builds up and then arcs, causing
localized heating/melting and vaporization of the metal surface. This causes deep, largecraters or pits in the metal surfaces, which may correspond to the spacing between the
rolling elements of the bearing. It is possibly due to welding in the area and inadequate
grounding or insulation. It may also be referred to as electrical pitting, arcing or sparking.
Current leakage (electrical fluting) is a less severe form of damage caused by a lower
continuous electrical current. The damage may be shallow craters that are closely positioned
and appear dark gray in color. If the electrical discharge occurs while the bearing is in
motion, with a full fluid film, a washboard effect or grooves appear on the entire bearing
raceway and is called fluting or corduroying.
Plastic DeformationThis is the denting, indentations or depressions in the race or rollers caused by impact or
overloading. The surface metal flows, causing irreversible deformation (not wear). The
machining marks are still visible in the bottom of the dent. The dents often have a raised lip
which increases stresses and leads to surface-initiated fatigue (surface cracks) and eventual
pit formation or adhesive wear. Plastic deformation consists of three subcategories.
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Overload or true brinelling is characterized by static or shock loading, or impact from
operational abuse, causing a permanent dent in the metal without cutting or welding of the
metal. An example occurs in roller bearings when impact causes the rollers to create a
series of dents in the bearing race surface at intervals that match the roller spacing exactly.
Some people consider denting from the impact of hammering on a bearing as overload;
others may consider it as an indentation from handling.
Indentation from debris is a form of plastic deformation but it is caused by a particle
trapped within the dynamic clearances between two machine elements and being over-
rolled. The force causes a round-bottom dent to form in the race or rolling element. Cracks
may propagate down into the metal.
Indentation from handling is similar to that from debris, but results from a bearing being
dropped or hammered, causing localized overloading. It can also be due to nicks from hard
or sharp objects.
It is common to encounter erosion from particles in the oil and cavitation, although this is
not included in the ISO standard for rolling bearings.
Erosion
Erosion could be considered a form of abrasive wear. It occurs principally in high-velocity,
fluid streams where solid particle debris, entrained in the fluid (oil), impinges on a surface
and erodes it away. Hydraulic systems are an example where this type of wear may occur.
Flow rates have a significant influence on these wear rates, which are proportional to at
least the square of the fluid velocity. Erosion typically occurs in pumps, valves and nozzles.
Metal-to-metal contact does not occur. The mechanism of erosion is used to an advantage
in water-jet cutting.
Cavitation
This is a special form of erosion in which vapor bubbles in the fluid form in low-pressure
regions and are then collapsed (imploded) in the higher-pressure regions of the oil system.
The implosion can be powerful enough to create holes or pits, even in hardened metal if the
implosion occurs at the metal surface. This type of wear is most common in hydraulic
pumps, especially those which have restricted suction inlets or are operating at high
elevations.
Restricting the oil from entering the pump suction reduces the pressure on the oil and, thus,
tends to create more vapor bubbles. Cavitation can also occur in journal bearings where thefluid pressure increases in the load zone of the bearing. No metal-to-metal contact is
needed to create cavitation.
Just to be clear, pitting is a general term used in failure analysis to describe almost any
small, rough-bottomed, circular potholes in the metal surface. Pits can be caused by
mechanical pitting (fatigue or cavitation), chemical pitting (corrosion) or by electrical pitting
(stray arcing), all of which are described above.
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