A gearbox is a mechanical piece of machinery that is designed to transfer energy from one device to another and is used to increase/decrease torque while reducing/increasing speed. There are many different types of gearboxes in use today, which can be broadly differentiated into industrial gearboxes and automotive gearboxes.
This blog is focused on the important criteria that need to be considered when recommending a lubricant for an industrial gearbox.
Potenza’s Industrial Gear Oils (IGO) are utilised in industrial gearboxes that are found across the spectrum of industries in local and international markets and meet all international specifications.
IGO can be divided into four categories. Namely:
- Sulphur additive-based mineral oils – conventional IGO
- Zinc-based mineral oils – for use in gearboxes that contain yellow metals
- Polyalphaolefins (PAO) – synthetic gear oils
- Polyalkylene glycols (PAG) – synthetic gear oils
The correct IGO recommendation is very important as the different IGO base oil categories are not necessarily compatible, and mixing the different base oil groups could lead to catastrophic failure of the gearbox. For example, PAG-based gear oils are not compatible with any of the other groups of IGOs.
When recommending a lubricant, it is important to know which product is in use in the gearbox. This is needed in order to avoid failure, as mentioned above. In addition, the details of the gearbox need to be investigated to determine if the current product is the correct product. The Potenza Oil ethos of “the correct product, in the correct application, at the right time and in the right volume” is key for all lubricant recommendations.
The factors that need to be investigated when making an IGO recommendation include the operating conditions of the gearbox and the environment in which the gearbox functions. These include,
- Temperature – ambient and range between cold and hot temperatures in operation
- Speed – the operational speed of the gearbox
- Gear ratio – the magnitude of the reduction in the gearbox
- Drive motor size – the power that the gearbox operates under
- Type of lubrication – splash and/or spray lubrication
- Output shaft diameter – Can be used for indication purposes in recommending the correct viscosity of lubricant for the gearbox
The Potenza IGO range consists of products with different viscosity grades. The viscosity of a lubricant is defined as the lubricant’s resistance to flow. IGOs are blended using different viscosity base oils to reach defined ISO viscosity grades. The Potenza IGO range consists of the ISO viscosity grades ranging from 68cSt to 1500cSt.
The viscosity is vital for the correct functioning of the lubricant in the application due to the different functions that the lubricant performs in operation.
If a lubricant with a viscosity that is too low is recommended, boundary lubrication will occur, leading to metal-to-metal contact, which leads to premature wear and gearbox failure. If a lubricant with a viscosity that is too high is recommended the lubricant will not be able to dissipate heat effectively which will lead to oxidation of the lubricant, reducing heat dissipation, leading to sludge formation and failure of the gearbox.
Typically, the safest choice is the recommended manufacturer’s lubricant which is approved for the gearbox.
However, as the leading supplier of metalworking fluids and lubricants in the Southern African market, Chemical Solutions and Innovations can provide you with expert advice, and high-quality products suited for your specific need. Contact our team today, and let us assist you.