1-3-2-齒輪潤滑的新標準解析

EnergolGR-XPAnewstandardingearlubrication齒輪潤滑的新標準Gearlubrication

齒輪潤滑Themainfunctionofagearoilistoseparatethetoothsurfacesandremovefrictionalheat齒輪油的主要功能是分隔齒輪接觸表面，并散熱Splashlubricationisusuallysufficientforlowspeedgears-pitchlinevelocitybelow15m/s飛濺潤滑通常有效地用于節(jié)線速度低于15m/s的低速齒輪副Jetspraylubricationforhigherspeeds噴射潤滑用于高速齒輪副Gearfailures

齒輪的失效Definition-agearpairHSAnotfaileduntilitcannolongerberun定義—齒輪副不能再運轉Usuallyoneormoreteethbreakpreventingtransmissionofmotionorteethbecomesobadlydamagedthatvibrationandnoiseareunacceptable通常是一個或多個齒發(fā)生斷裂，使齒輪不能傳送動力；或者是齒輪損壞嚴峻產(chǎn)生巨大的振動和噪音Gearfailuresarerare齒輪的失效通常較少Typesofgeartoothdamage

齒輪損壞的類型Micro-pitting微點蝕Pitting點蝕Scuffing咬接Slowspeedwear

低速磨損Corrosion

腐蝕Plasticdeformation

塑性變形Breakage斷裂FZGgeartestrig

FZG

齒輪試驗裝置Widelyusedforpracticaltestingofgearlubricants廣泛用于齒輪油的應用試驗Loadcarryingcapacity(scuffingtest)承載性能（咬接試驗）Pitting

點蝕Micro-pitting微點蝕Slowspeedwear低速磨損Efficiency/energysaving效率/節(jié)能性Pitting

點蝕Themostcommontypeofgearfailure齒輪失效最常見的形式Smallparticlesbreakawayleavingsmallcavitiesorpitsonthetoothsurface小顆粒崩裂在表面留下小坑或點蝕Afatiguephenomenonthatinvolvescontactstress,materialproperties,heattreatmentandalubricant這是涉及到接觸應力、材料特性、熱處理和潤滑油的乏累現(xiàn)象Scuffing

咬接Resultofdisruptionofthelubricantfilm潤滑油膜裂開的結果Metaltometalcontactroughensandtearsthetoothsurfaces金屬間的干脆接觸使齒輪表面變粗糙，造成撕裂Apartfromloadingandslidingvelocity,thelubricantisthemajorfactorinfluencingscuffing除去負載和滑動速度的影響，潤滑油是主要的因素Micro-pitting

微點蝕Alsoknownasgreyflecking,greystaining,greyfrostingandgreyspotting又被稱為灰斑、灰污、灰霜或灰點Appearsasgreylinesorspotsontheflanksofhardenedgearteeth在硬化齒面的中部形成的灰線或坑Consistsofnumerous,verysmallmicro-pits10-20micronswideandsimilardepth包含有大量的、特殊小的、寬度和深度約10-20微米的微點蝕Doesnotalwaysleadtogearfailureandcanbecontrolledwithsuitablelubricants通常不會導致齒輪的失效，并可通過運用適當?shù)臐櫥图右韵拗芃icro-pittingcont….

微點蝕（續(xù)）Micro-pittingisincreasinglyregardedasaprecursortoothermodesoffailuresuchasmacro-pitting,scuffing,toothfractureaswellasincreasednoiseandvibration越來越多的人認為微點蝕是其它失效形式的先兆，如：點蝕、咬接、齒輪斷裂、不斷增大的噪音和振動Somemanufacturershavenowintroducedspecifictestsforassessingthemicro-pittingresistanceoflubricantsintotheirapprovalprocedure現(xiàn)在很多制造商為了評價潤滑油抗微點蝕的實力，已在他們的認可程序中加入了特定的試驗Industrialgearlubricants

工業(yè)齒輪油Usuallycompriseofbaseoilplusadditives通常包含了基礎油和添加劑Baseoilscanbemineraloilorsyntheticfluidsormixturesofboth基礎油可以是礦物油、合成油或二者的混合物Lubricantcharacteristicsaredeterminedbytheformulationofthebaseoilandtheadditives潤滑油的特性由基礎油和添加劑的配方確定Vitalcharacteristics

最重要的性能Satisfactoryviscosityatoperatingtemperatureandstart-up在操作溫度和起動溫度下合適的粘度Adequatewearprotection足夠的抗磨損實力Oxidativeandthermalstability氧化和熱穩(wěn)定性Non-corrosiveandrustprotection抗腐蝕性和防銹性Resistanttofoamingandformingemulsions抗泡性和抗乳化性Sealandpaintcompatibility密封件和油漆的相容性Industrialspecifications

工業(yè)規(guī)格AGMA250.04USSteelNo.224DIN51517part3DavidBrownFlenderFlenderGloballythelargestOEMofindustrialgeartransmissions全球最大的工業(yè)齒輪傳動裝置的制造商FlenderwasthefirstOEMtointroducemicro-pittingresistancerequirementforapprovinggearlubricantsFlender是第一個在潤滑油認可中引入抗微點蝕要求的制造商Theyareconvincedthatlubricantsmeetingthisrequirementarenecessarytomaintainthereliabilityandservicelifeoftheirgearunits.他們認為為了保證齒輪裝置的牢靠性和運用壽命，齒輪油必需滿足這些要求OilrequirementsforuseinFlendergearunits

Flender齒輪裝置的用油要求DIN51517part3FlenderfoamtestFlender抗泡試驗Compatibilitywithmaterialsofconstruction-elastomerseals,sealantsandpaints與結構材料相容—彈性密封、密封件和油漆FZGscuffingtestsFZG抗咬接試驗Greyfleckingresistance(GFR)test抗微點蝕（GFR）試驗Flendergreyfleckingresistance(GFR)test

Flender抗微點蝕（GFR）試驗BasedontheFZGmicro-pittingtest基于FZG抗微點蝕試驗c/8.3/90andjetspraylubricationc/8.3/90和噴射潤滑Certificatedtestgears-Ra>0.5microns試驗認可的齒輪副--Ra>0.5微米Progressiveloadingtest-16hperstage漸進性負載試驗—每級16小時Endurancetest-80hperstage耐久性試驗--每級80小時Assessestoothinvoluteprofilechange評價齒面的輪廓變更FlenderGFRapprovalcriteria

FlenderGFR試驗的認可標準Progressiveloadstagetest

漸進性負載試驗Profiledeviation<7.5micronsafterloadstage10在10級后輪廓變更<7.5微米Endurancetest

耐久性試驗Profiledeviation<20microns輪廓變更<20微米EnergolGR-XPresultsinGFRtest

安能高GR-XP的GFR試驗結果Progressivetest-

profiledeviation<7.5micronsafterloadstage10漸進性負載試驗—在負載10級后輪廓變更<7.5微米Endurancetest-

profiledeviation13.6microns

耐久性試驗--輪廓變更13.6微米一般的承載實力試驗—Timken試驗一般的承載實力試驗—四球試驗承載實力–更合理的圖形1承載實力試驗—更合理的圖形2ASTMD2893氧化試驗--油品壽命熱穩(wěn)定性試驗–清潔性Competitor

ACompetitor

BCompetitor

CCompetitor

DEnergolGR-XPEnergolGR-XP-thebenefits

安能高GR-XP—好處Premiumqualitymineraloilbasedindustrialgearoilwithenhancedmicro-pittingresistanceandEPperformance高級的礦物油基工業(yè)齒輪油，增加的抗微點蝕性和極壓性能ApprovedbyFlender(Germany)Flender(Germany)認可ApprovedbyHansen,DavidBrownHansen,DavidBrown認可Suitablefortemperaturesupto120℃適用于高至120℃的油溫EnergolGR-XPbenefit–superiorwormgearperformance

安能高GR-XP的好處—在蝸輪蝸桿齒輪中的優(yōu)異性能EnergolGR-XP320

test20026711:50-250°c:150n:2hz.010020030000.050.10.1501020304050temperature/°Cfrictioncoefficientpd/mvGeneralGearOil1

test20026705:50-250°c:150n:2hz.010020000.050.10.1501020304050temperature/°Cfrictioncoefficientpd/mv300Plinttest(variabletemperature,bronzetosteel)

Plint試驗（變溫條件，青銅與鋼）Plinttest(variabletemperature,bronzetosteel)

Plint試驗（變溫條件，青銅與鋼）GeneralGearOil2

test20026706:50-250°c