Tribological Investigation of the Polymer-Based Lubrication System Using a Laboratory Reciprocating Bench Test

Abstract

Flooded oil lubrication systems are commonly utilized for many manufacturing processes. However, there is an increasing concern with the flooded lubrication systems due to their biological and environmental impact as well as their maintenance and disposal cost. Polymer-based material, a sponge-like solid lubricant allowing the oil to weep out while in use, provides a promising alternative environmentally benign lubrication solution to satisfy the lubrication requirements for some manufacturing processes. In addition, it can minimize contamination of the coolant system, reduce waste processing and disposal costs, and alleviate the in-plant safety hazard from oil leakage on floor surfaces.

The goal of this study is to develop and improve the current lubrication system by applying a polymer-based near-dry lubrication system in order to replace the oil-flooded transfer line lubrication systems currently in production use. Using a laboratory reciprocating bench test based on the design of experiments, this study characterized the tribological performance of the polymer-based lubrication system under a variety of operating conditions, identified the main factor that impacts the tribological performance of the polymer-based lubrication system, and developed a model to predict the wear loss of the polymer-based lubricant plate. These results provide the guidelines for possible applications of the polymer-based lubrication system used in the manufacturing process.

KEY WORDS:

• Tribological Performance
• Reciprocating Test
• Design of Experiments
• ANOVA
• Lubricant Application Method: Oil-Soaked Polymer Sponge

ACKNOWLEDGMENTS

The authors wish to thank Dr. Michael L. McMillan, Dr. James A. Spearot, Angelo Quintana, Brian Taylor, Bob Kubic, and Curtis Wong for their support and help in performing the experimental studies.

Presented at the World Tribology Congress in Washington, DC

September 12-16, 2005

Manuscript approved June 27, 2007

Review led by Dong Zhu