469592090-Automotive-Lubrication-System.ppt

Dissertation

1. Lubrication Systems

2. Introduction
Themainfunctionanautomobilelubricationsystemis
tocirculateanddeliveroiltoallthemovingpartsofan
engineinordertolessenfrictionbetweensurfacesthat
comesincontactwitheachother.Thelubricationsystemof
anautomobileactstoreduceenginewearcausedbythe
frictionofitsmetalparts,aswellastocarryoffheat.
Anautomobile'slubricationsystemreferstothesetof
interactingautomotivepartswhicharedesignedtosupply
cleanoil(thelubricant)atthecorrecttempandprtodifferent
partsoftheengine.Thuspreventinganydamagetothe
engineduetooverheatingbythecontinuousmetal-to-metal
contactbetweenitsparts.

3. Engine Oil/ Lubricating Oil
Engine/Lubricatingoilisoneofthemanyproduct
thatcomesfromcrudeoil.Engineoilmusthave
certainpropertiessothatitcanefficientlywork
withintheenginemovingparts.TheAPIclassifies
engineoilasstandardorS-classforpassengercar
andascommercialorC-classforheavyduty.

4. Purpose of Lubricating Oil
a.Theoillubricatesmovingpartstoreducewear.
b.Astheoilmovesthroughtheengine,theoilpicksup
heat.
c.Oilfillstheclearancesbetweenbearingsandrotating
journals.Servesasacushionbetweenimpactingparts
d.Theoilhelpsformagas–tightsealbetweenpiston
ringsandcylinderwalls.
e. The oil acts as a cleaning agent.

5. Classification of Lubricants
Animal
Vegetable
Mineral
Synthetic
1.Types of Lubricant according to state:
a. Fluid
b. Semi-fluid
c. Solid
2. Types of Lubricant according to sources:

6. Animal Lubricants
Lubricantswithanimalorigin:
–Tallow
–Tallowoil
–Lardoil
–Neat’sfootoil
–Spermoil
–Porpoiseoil
Thesearehighlystableatnormaltemps
Animallubricantsmaynotbeusedforinternal
combustionbecausetheyproducefattyacids

7. Vegetable Lubricants
Examples of vegetable lubricants are:
–Castor oil
–Olive oil
–Cottonseed oil
Animalandvegetableoilshavealowercoefficientof
frictionthanmostmineraloilsbuttheyrapidlywear
awaysteel

8. Mineral Lubricants
Theselubricantsareusedtoalargeextentinthe
lubricationofaircraftinternalcombustionengines.
oAdvantageofMineralOils:
a.Cheaperandmoreplentiful.
b.Freefromacidwhenproperlyrefined.
c.Greaterchemicalstabilityathighertemp.
d.Lesstendencytoformemulsionswith
water.

9. Theseoilsaremadebychemicalprocessesanddonot
necessarilycomefrompetroleum.Thereareseveraltypes.
Themostcommonismadefromcarboncompoundsand
alcohols.Anotherismadefromcoalandcrudeoil.Synthetic
oiltoleratesheatbetterthanotheroilswhileproducingless
sludgeandcarbondeposits.Anengineusingsyntheticoil
cansafelyrunlongerbetweenoilchanges.
oBecauseofthehighoperatingtempsofgas-turbine
engines,itbecamenecessarytodeveloplubricantswhich
wouldretaintheircharacteristicsattempsthatcause
petroleumlubricantstoevaporateandbreakdown.
Synthetic Lubricants

10. Synthetic Lubricants
oSyntheticlubricantsdonotbreakdowneasilyanddo
notproducecokeorotherdeposits
oSyntheticoilsofferbetterprotectionagainstenginewear
andcanoperateathighertemp.Theyhavebetterlowtemp
viscosity,arechemicallymorestableandallowforcloser
tolerancesinenginecomponentswithoutlossoflubrication.

11. Lubricating oil Properties
Gravity
Flash Point
Viscosity
Cloud Point
Pour Point
Carbon-Residue Test
Ash Test
Precipitation Number
Corrosion and
Neutralization Number
Oiliness
Extreme-Pressure
(Hypoid) Lubricants
Chemical and Physical
Stability

12. Gravity
The gravity of petroleum oil is a numerical value which
serves as an index of the weight of a measured volume
of this product
There are two scales generally used by petroleum
engineers:
–Specific-gravity scale
–American Petroleum Institute gravity scale

13. Flash Point
Theflashpointofanoilisthetemperaturetowhichthe
oilmustbeheatedinordertogiveoffenoughvaporto
formacombustiblemixtureabovethesurfacethatwill
momentarilyflashorburnwhenthevaporisbrought
intocontactwithaverysmallflame

14. Viscosity
Viscosity is technically defined as the fluid friction of an
oil.
To put it more simply, it is the resistance an oil offers to
flowing.
Heavy-bodied oil is high in viscosity and pours or flows
slowly.

15. Cloud Point
Thecloudpointisthetempatwhichtheseparationof
waxbecomesvisibleincertainoilsunderprescribed
testingconditions.
Whensuchoilsaretested,thecloudpointisslightly
abovethesolidificationpoint.

16. Pour Point
Thepourpointofanoilisthetempatwhichtheoilwill
justflowwithoutdisturbancewhenchilled.

17. Carbon-Residue Test
Thepurposeofthecarbon-residuetestistostudythe
carbon-formingpropertiesofalubricatingoil.
Therearetwomethods:
–TheRamsbottomcarbon-residuetest.
–TheConradsontest

18. Ash Test
Theashtestisanextensionofthecarbon-residuetest
Ifanunusedoilleavesalmostnoash,itisregardedas
pure
Theashcontentisapercentage(byweight)ofthe
residueafterallcarbonandallcarbonaceousmatter
havebeenevaporatedandburned

19. Precipitation Number
TheprecipitationnumberrecommendedbytheASTMis
thenumberofmillilitersofprecipitateformedwhen10ml
oflubricatingoilismixedwith90mlofpetroleum
naphthaunderspecificconditionsandthencentrifuged.

20. Lubricant Requirements and
Functions
a.Properviscosity.Engineoilshouldhavetheproper
viscositysoitflowseasilytoallmovingengineparts.
b.ViscosityIndex.Howmuchtheviscosityofanoil
changeswithtemp.VIimproversareaddedtotheengineoil
soitsviscositystaysnearlythesame,hotorcold.
c.ViscosityNumber.Thereareseveralgradesofsingle
viscosityoilisusedsuchasSAE5W,SAE10W,SAE20,
SAE30etc.

21. d.MultipleViscosityOil.Itallowstheoilviscosityto
remainrelativelyunchanged,hotorcold.Amultiple
viscosityoilgradedasSAE5W–30.
e.Corrosionandrustinhibitors.The abilityto
preventtheformationofrustandcorrosion.
f.FoamingResistance. Theabilitytolubricate
withoutfoaming.
g.Detergent–Dispersants.Theabilitytokeepinternal
enginepartsclean.
Lubricant Requirements and
Functions

22. h.ExtremePressureResistance.Additivesputintothe
oilimprovetheresistanceofoilfilmtopenetration.
i.Energyconservingoils.Reducepowerlossesfrom
internalfrictionandprovidesabetterfueleconomy.
j. SyntheticOil. Toleratesheatbetterthanother
oilswhileproducinglesssludgeandcarbondeposits.
Lubricant Requirements and
Functions

23. AdditivesofLubricatingOil
Toachievedesirablecharacteristicsthemineralbased
lubricatingoilsareaddedwithcertainoilsolubleorganic
compoundstheseareknownasadditives.
Typeofadditives
a. Oxidation and Corrosion Inhibitors.
b. Detergent Additives
c.Anti-foaming Additives
d. Extreme Pressure Additives
e. Pour Point Improver
f. Viscosity Index Improvers
g. Others

24. Grading of Lubricant
TheSocietyofAutomotiveEngineers(S.A.E)has
developedandclassifiedthegradingofthelubricatingoils
accordingtotheirviscosity.
ThegradingisexpressedforexampleeitherSAE10W
orSAE10.
SAE10suffixedbyWmeanstheseoilcanbeusedin
winterseason.OntheotherhandSAE10forsummer
season.
Nowadaysmultigradeoilsareavailable.Theseoilsare
expressedas10W/30.

25. Selection of Lubricant
a.Incaseofselectionoflubricant,it'sgradingshouldbe
consideredfirstthenit'sservicerating.Itisindicatedby
A.P.I(AmericanPetroleumInstitute).
b.Oilswithsamegradingmayhavedifferentservicerating
dependingonit’sservicecondition.
c.TheserviceratingsforpetrolengineoilsareSA,SB,
SC,SDandsoon.OilswithSAdesignationsarestraight
mineraloil.
d.TheserviceratingsfordieselengineoilsareCA,CB,CC,
CD,CE,CFandsoon.

26. Selection of Lubricant

27. Purpose of Lubrication System
a.Supplieslubricatingoiltoallmovingpartsinthe
engine.
b.Tocool,clean,lubricateandsealtheengine.
c.Italsoremovescontaminantsfromtheoil.

28. Type of Lubricating System
Wet sump system
Dry sump system

29. Wet Sump System

30. Oilpumpsucksoilfromthe
bottomoftheoilpanthrough
atube,andthenforced
throughanoilfilterandpr
feedtothemainoilgalleries.
Fromthemainoilgalleries,
theoilpassesthroughfeed-
holesintodrilledpassagesin
thecrankshaftandontothe
big-endbearingsofthe
connectingrod.
Wet Sump System

31. Thecylinderwallsandpiston-pin
bearingsarelubricatedbyoilfling
dispersedbytherotatingcrankshaft.
Theexcessbeingscrapedoffbythe
lowerringinthepiston.Ableedor
tributaryfromthemainsupply
passagefeedseachcamshaft
bearing.Anotherbleedsuppliesthe
timingchainorgearsonthecamshaft
drive.Theexcessoilthendrainsback
tothesump,wheretheheatis
dispersedtothesurroundingair.
Wet Sump System

32. Advantage:
Simpledesign.
Usingasinglepumpandnoexternalreservoir.
Thereisnoneedforhosesortubesconnectingthe
enginetoanexternalsumpwhichmayleak.
Wet Sump System

33. Drysumpsystem

35. Drysumpsystem
Inadrysumpsystem,extraoilisstoredinatankoutside
theengineratherthanintheoilpan.Thereareatleasttwo
oilpumpsinadrysump-onepullsoilfromthesumpand
sendsittothetank,andtheothertakesoilfromthetankand
sendsittolubricatetheengine.Theminimumamountofoil
possibleremainsintheengine.
Inadrysumpsystem,theoilfallstothebottomofthe
engineintoanoilcollectionpan.Ascavengepumpthen
pumpsittoanoiltankwhereitisstoreduntilthenormaloil
pumpcollectsitandpumpsitthroughthefilterandenginein
thenormalway.

36. Becausethereisnooilstoragesumpundertheengine,
theenginecanbemountedmuchlowerthaninawetsump
system.
Theoiltankcanbepositionedawayfromtheengine
whereitcangetbestcooling.
Andtheamountofoilinthesystemcanbemuchgreater
thaninthewetsumpsystem.
Drysumpsystem

37. Drysumpsystemshaveseveralimportant
advantagesoverwetsumps:
 Becauseadrysumpdoesnotneedtohaveanoilpan
bigenoughtoholdtheoilundertheengine,themainmass
oftheenginecanbeplacedlowerinthevehicle.Thishelps
lowerthecenterofgravityandcanalsohelpaerodynamics
(byallowingalowerhoodline).
Theoilcapacityofadrysumpcanbeasbigasyou
want.Thetankholdingtheoilcanbeplacedanywhereon
thevehicle.

38. Inawetsump,turning,brakingandaccelerationcan
causetheoiltopoolononesideoftheengine.Thissloshing
candipthecrankshaftintotheoilasitturnsoruncoverthe
pump'spick-uptube.
Excessoilaroundthecrankshaftinawetsumpcanget
ontheshaftandcuthorsepower.Somepeopleclaim
improvementsofasmuchas15horsepowerbyswitchingto
adrysump.
Drysumpsystemshaveseveralimportant
advantagesoverwetsumps:

39. Components of Lubrication System
Oil Pan / Sump
Oil Strainer
Oil Pump.
Pr Regulating Valve.
Oil Filter.
Oil Passages or Galleries
Oil Pressure relive valve.
Oil Level Indicator.
Oil Coolers.
Oil Pressure Warning Lamp.
Oil Change Indicator.

41. OilPan/Sump
Theoilpan/sumpattachesto
thecrankcase.Itservesasthe
reservoirfortheengineoil.Itis
designedtoholdtheamountof
oilthatisneededtolubricatethe
enginewhenitisrunning,plusa
reserve.Theoilpanhelpstocool
theoilthroughitscontactwiththe
outsideair.

42. OilStrainer
Itusuallycontainsafilter
screen,whichissubmerged
intheoilatalltimes.The
screenservestokeeplarge
particlesfromreachingthe
oilpump.

43. OilPump
Theoilpumpistheheartofthelubricationsystem.Itis
usuallylocatedintheoilpan.
ToSupplyoiltothevariousmovingpartsintheengine.
Tomakesurethepartsarelubricated,anadequate
amountofoilmustbedeliveredtotheparts.

44. TypesofOilPump
 GearType.Hasa
pairofmeshinggears.As
thegearunmeshed,the
spacebetweentheteethfill
withoilfromthepumpinlet.
Thegearmeshandforce
theoiloutthroughthepump
outlet.

45.  RotorType.Hasan
innerrotorandanouterrotor,
whichisdrivenbytheinner
rotor.Astherotorsturn,the
spacesbetweenthelobesfill
withoil.Whenthelobesofthe
innerrotormoveintothespaces
intheouterrotor,oilisforced
outthroughthepumpoutlet.
TypesofOilPump

46. Vane Type

47. Plunger Type Pump

48. OilFilter
Theoilfilterhasapleated–
paperfilteringelement.Underpr
fromtheoilpump,oilflows
throughafiltertoremoveany
impuritiesthatmighthave
becomesuspendedintheoil.
Itallowstheoiltopassthroughwhiletrappingparticles
ofdirtandcarbon.
Italsoincreasestheusablelifeoftheoil.

49. Oilfiltersareequippedwitha
springloadedby-passvalveto
allowoiltobypassthefilter,ifthe
filterisclogged.
Oilfilteralsohaveacheck
valvethathelptopreventoil
drainagefromthefilterwhenthe
engineisnotrunning.
OilFilter

50. Oil Pressure Relief Valves
Theprreliefvalveisusedto
preventdamagetoanengine
duetotoomuchoilpressure.
Onceoilprexceedsapreset
limit,thespring-loadedPrRelief
Valveopensandallowsthe
excessoiltobypasstherestof
thesystemandreturndirectlyto
thesump.

51. OILGALLERIES
Thesegalleriesconsistof
interconnectedpassage
thathavebeendrilled
completelythroughthe
engine blockduring
manufacturing.Theout
sideendofthepassages
blockedoffsotheoilcan
beroutedthroughthese
galleriestovariouspartsof
theengine.

52. OilPressureGauge/Indicator
Indicatestheengineoilpratalltimesoritcanbea
warninglightthatwillcomeonthedashboardin
frontofthedriverwhenevertheengineisrunning
withinsufficientoilpr.

53. OilLevelIndicator/Dipstick
Thedipstickisusedtomeasurethelevelofoilin
theoilpan.Theendofthestickismarkedto
indicatewhentheengineoilleveliscorrect.To
determinetheoillevel,pulloutthedipstickandsee
howhightheoilreachesthedipstick.Markings
usuallyindicateFULLorADDOIL.

55. Multi-viscosity Oil
Incertaincircumstances,allsingle-gradeoils
haveshortcomings
Incold-weatherstarts,singlegradeoil
generallyflowsslowlytotheupperreaches
andvitalpartsoftheengine
Multi-gradeoilshaveviscositycharacteristics
thatallowforbetterflowcharacteristicsat
enginestart

56. Characteristics of Lubrication
Systems
PressureLubrication
SplashLubricationandCombinationSystems
PrincipalComponentsofaLubricationSystem
OilCapacity

57. Pressure Lubrication
Inapressurelubricationsystem,amechanical
pumpsuppliesoilunderpressuretothe
bearings
Oilflowsintotheinletofthepumpthroughthe
pumpandintoanoilmanifoldwhichdistributes
ittothecrankshaftbearings

58. Splash Lubrication and
Combination Systems
Althoughpressurelubricationistheprinciple
methodoflubricationonallaircraftengines,
someenginesusesplashlubricationalso
Splashlubricationisneverusedbyitself
Alllubricationsystemsarepressuresystemsor
combinationpressure/splashsystems

60. Components of Lubrication
Systems
Plumbing for Lubrication
Systems
Temperature Regulator
(Oil Cooler)
Oil Viscosity Valve
Oil Pressure Relief
Valves
Oil Separator
Oil Pressure Gauge
Oil Temperature Gauge
Oil Pressure Pumps
Scavenge Pumps
Oil Dilution System

61. Plumbing for Lubrication Systems
Oilplumbingisessentiallythesameasisused
inoilandhydraulicsystems
Whenthelineswillnotbesubjecttobending,
aluminumtubingisused
Synthetichoseisoftenusedneartheengine
andotherplacesontheaircraftthataresubject
tovibrationorothermovement

62. Temperature Regulator (Oil Cooler)
Anoiltemperatureregulatorisdesignedto
maintainthetemperatureoftheoilforan
operatingengineatthecorrectlevel
Theseregulatorsareoftencalledoilcoolers
sincecoolingofengineoilisoneoftheirmain
functions

63. Oil Viscosity Valve
Theoilviscosityvalveisgenerallyconsidered
apartoftheoiltemperatureregulatorunitand
isemployedinsomeoilsystems
Theviscosityvalveconsistsessentiallyofan
aluminumalloyhousingandathermostatic
controlelement
Theoilviscosityvalveworkswiththeoilcooler
valvetomaintainadesiredtemperatureand
keeptheviscositywithinrequiredlimits

64. Oil Pressure Relief Valves
The purpose of the oil pressure relief valve is
to control and limit the lubricating pressure in
the oil system
This is necessary to prevent damage caused
by excessive system pressure and to ensure
that engine parts are not deprived of fuel due
to a system failure

65. Oil Separator
Airsystemswhereoilofoilmistispresentmay
requiretheuseofanoilseparator
Theseareoftenusedonvacuumpumpoutlets
Theoilseparatorcontainsbaffleplateswhich
causetheairtoswirlanditdepositsonthe
baffles

66. Oil Pressure Gauge
Anoilpressuregaugeisanessential
componentofanyengineoilsystem
Thesegaugesgenerallyuseabourdontubeto
measurethepressure
Theyaredesignedtomeasureawiderangeof
pressures

67. Oil Temperature Gauge
Thetemperatureprobefortheoiltemperature
gaugeintheoilinletlineorpassagebetween
thepressurepumpandtheenginesystem
Onsomeinstallationsthetemperatureprobeis
locatedintheoilfilterhousing
Thesearenormallyelectricorelectronic

68. Oil Pressure Pumps
Oilpressurepumpsmayeitherbeofthegear
typeorvanetype
Thegeartypepumpisusedinthemajorityof
reciprocatingenginesandusesclosefitting
gearsthatrotateandpushtheoilthroughthe
system

69. Scavenge Pumps
Scavengepumpsaredriveninthesame
mannerasthepressurepumpsbuthavea
greatercapacity
Thishighercapacityisbecausetheoilinthe
sumpisfoamywhichmeansithasamuch
greatervolumethanair-freeoil

70. Oil Dilution System
The purpose of the oil dilution system is to
provide thinner oil during engine start
This allows faster lubrication of engine
components
Oil dilution is accomplished by pumping a small
amount of fuel into the oil

71. Sludge Chambers
Some reciprocating engines have sludge
chambers which are in the hollowed out
connecting-rod journals
These journals accumulate carbon sludge and
dirt particles as they are designed to
During engine overhaul these must be
replaced

72. Crankcase Ventilation

73.  Duringnormaloperation,asmallamountofunburned
fuelandexhaustgasesescapearoundthepistonringsand
enterthecrankcase,referredtoas"blow-by".
Ifthesegaseshadnocontrolledescapemechanism,
thegasketjointswouldleak(asthey"foundtheirownway
out").
also,ifthegasesremainedinthecrankcaseand
condensed,theoilwouldbecomedilutedandchemically
degradedovertime,decreasingitsabilitytolubricate.
Condensedwaterwouldalsocausepartsoftheengineto
rust.
Crankcase Ventilation

74. Tocounterthis,acrankcaseventilationsystemexists.
Inallmodernvehicles,thisconsistsofachanneltoexpelthe
gasesoutofthecrankcase,throughanoil-separatingbaffle,
tothePCVvalve,intotheintakemanifold.
Inanon-turboengine,theintakemanifoldisatalower
pressurethanthecrankcase,providingthesuctiontokeep
theventilationsystemgoing.Aturboengineusuallyhasa
checkvalvesomewhereinthetubingtoavoidpressurizing
thecrankcasewhentheturboproducesboost.
Crankcase Ventilation