Greases are solid to semi-fluid products consisting of a fluid lubricant and a thickener. They typically contain 80-87% oil, 8-15% thickener, and 5% additives. Greases stay in place to seal and lubricate, unlike oils which can run away. Greases are used when intermittent lubrication is needed or operating conditions are extreme. Grease properties like penetration, drop point, and resistance to water washout are tested. Greases are formulated with base oils, thickeners like metal soaps, and performance additives. They are tested for properties like anti-wear protection and corrosion resistance. Proper grease storage and avoiding contamination are important.

1. Greases
Product Knowledge
Presented by : RAJIV RANJAN

2. Presented by : RAJIV RANJAN
What is a grease ?
 A solid to semi-fluid product
consisting of a fluid lubricant and a
thickener
 It usually contains additives to
enhance performance
 Typical grease contents
 oil 80-87%
 thickener 8-15%
 additives 5%
Oil
Thickener
Additives

3. Presented by : RAJIV RANJAN
Lubricating greases vs. Oils
Oils
 Fluid
 Run away
 remove heat (cool)
 remove debris (clean)
 remove particles
(clean)
 Classification
 Viscosity (SAE)
Greases
 Semi-fluid / semi-solid
 Stay in place
 Seal
 no cooling / no
cleaning
 Classification
 Consistency (NLGI)

4. Presented by : RAJIV RANJAN
When to lubricate with grease ?
• To decrease dripping and splattering of lubricant
• To decrease frequency of lubrication
• To seal out contaminants
• For intermittent operation
• To suspend solid additives
• Under extreme operating conditions
• high temperature
• high pressure
• shock loading
• slow speed / high pressure
• Machine badly worn
• When noise reduction is very important

5. Presented by : RAJIV RANJAN
How grease works ?
• Consider Grease as a Sponge
• 3-D network of thickener particles
• Thickener particles adhere to each other due to
chemical attractive forces
• Pores filled with oil/additives

6. Presented by : RAJIV RANJAN
GRADE
NUMBER
STRUCTURE
PENETRATION
(WORKED) mm/10
CONE SINKING
DEPTH
SEMI FLUID
SEMI FLUID
VERY SOFT
SOFT
MEDIUM SOFT
MEDIUM
STIFF
VERY STIFF
VERY STIFF
445 - 475
400 - 430
355 - 385
310 - 340
265 - 295
220 - 250
175 - 205
130 - 160
85 - 115
000
00
0
1
2
3
4
5
6
NLGI number

7. Presented by : RAJIV RANJAN
Rolling Element Bearings
Ball bearing
General purpose bearings
Cylindrical roller bearing
Wheel bearings on cars
Bearings on gearboxes
Taper Roller Bearing
Wheel bearings on trucks & LCVs

8. Presented by : RAJIV RANJAN
Wheel Bearing Lubrication
Two basic types
 Oil Lubricated
 Grease Lubricated
Grease-Lubricated Wheel Bearings
HCV Hub-Cut section Taper roller bearings

9. Presented by : RAJIV RANJAN
CHASSIS GREASE
Pumpability
Good water resistance
“Stay put” anti-squeeze property
Anti-rust properties
Cost Grease nipple

10. Presented by : RAJIV RANJAN
Grease formulation
Grease = Base oils + Thickeners +
Additives
The thickeners most used in grease
production:
 Metal soaps (Li, Ca, Na)
 Metal complex soaps (Li, Ca, Al)
 Inorganic thickeners (bentonites,
silicates)
 Others (polymers, polyurea)

11. Presented by : RAJIV RANJAN
Additives in greases
 Antiwear
 EP additives
 Antioxidants
 Tackiness agents
 Corrosion inhibitors
Compatibility with thickener systems is
of prime importance

12. Presented by : RAJIV RANJAN
Anti-Wear Additives
Zinc based

13. Presented by : RAJIV RANJAN
Extreme Pressure (EP) Additives
Sulfur-Phosphorus Compounds (S-P)

14. Presented by : RAJIV RANJAN
Other Additives
 Anti oxidants
 Reduce ill effects of oxidation
 Tackifiers
 Improve adherence
 Corrosion inhibitors

15. Presented by : RAJIV RANJAN
How is grease produced ?
Reactor
(Pressurised)
Homogenisation
(milling)
& Deaeration
Base
Oil
(Major portion)
Fatty
Acids
Alkali
Finishing
Kettle
Base
Oil
(Minor portion)
Additives
Heating/cooling
jacket
Filling
Hot
Oil

16. Presented by : RAJIV RANJAN
Performance testing
 Penetration
 Mechanical stability
 Oil separation
 Drop point
 Water resistance
 Extreme pressure
performance
Four Ball weld load test

17. Presented by : RAJIV RANJAN
PENETRATION
Penetration is the depth, in tenths of millimeters,
to which a standard cone sinks into the grease under
prescribed conditions.

18. Presented by : RAJIV RANJAN
Penetration Contd...

19. Presented by : RAJIV RANJAN
Worked Penetration
 Worked to X strokes
 X – 10,000

20. Presented by : RAJIV RANJAN
Drop Point
• Determines the temperature
at which a soap thickened
grease passes from solid to a
semi-solid state.
• Measured in deg C

21. Presented by : RAJIV RANJAN
Drop Point contd ….

22. Presented by : RAJIV RANJAN
 SIGNIFICANCE
 Directional change in
consistency while in service
 Measure of shear stability
 50 gm grease in a tube with 5
Kg weight and rotated
 2 hrs, 20-35 deg C
 Low shear
 MEASURED AS
 Change in cone penetration
value (in %)before & after
test
Roll stability

23. Presented by : RAJIV RANJAN
Heat stability -Oil Separation (Conical Sieve) Method)
 SIGNIFICANCE
 Co-relates with oil
separation in storage
 100 deg C, 30 hrs
 MEASURED AS
 Loss of oil mass

24. Presented by : RAJIV RANJAN
Copper Corrosion ASTM
 Temperature 100°C
 Duration 24 h
 Copper strip in a tube with grease ,compare with the
standard

25. Presented by : RAJIV RANJAN
Wheel Bearing grease leakage test
 SIGNIFICANCE
 Measures leakage tendency of
grease
 CONDITION
 Wheel-hub assembly under rotation
 660 rpm, 6 hrs
 113 Deg C
 MEASURED AS
 Mass of grease + oil leaked out in
gms

26. Presented by : RAJIV RANJAN
Resistance to water washout Test
 SIGNIFICANCE
 Resistance of the grease to getting
washed out by water
 CONDITION
 600 rpm
 Water impinge at 5 ml/sec
 1 hr
 MEASURED AS
 Grease mass loss (%)

27. Presented by : RAJIV RANJAN
Emcor Rust Test
 SEVERE TEST
 10gm grease+20ml water
 3 days run
 108 hrs stop
 SIGNIFICANCE
 Corrosion prevention in the
presence of distilled water
 MEASURED AS
 Visual rating system for pass
/ fail
 No. of rust spots

28. Presented by : RAJIV RANJAN
Results
No corrosion – 0 Rating
Traces – 1 Rating (<3 Spots)
Light – 2 Rating (< 1%)
Moderate – 3 Rating (1-5%)
Heavy – 4 Rating (5-10%)
Severe – 5 Rating (>10%)
Emcor Rust Test Contd...

29. Presented by : RAJIV RANJAN
Extreme Pressure & Anti-wear Properties
 4 ball weld load test
 Wear Scar Dia

30. Presented by : RAJIV RANJAN
Key selling points -
• Superior shock load protection and Better anti-wear
performance
• Superior corrosion protection
• Better lubricity
• Excellent resistance to water washout
• Superior control on oil bleeding under operation
• Superior heat stability
• Extremely high structural strength
• Lower leakage tendency under storage
• Longer life

31. Presented by : RAJIV RANJAN
STORAGE AND HANDLING
Storage of barrels-Inside storage ideal
Grease surface in barrels to be convex
Contamination
Water
Solids
Other Lubricants
Dust – the largest enemy of grease

32. Presented by : RAJIV RANJAN
Market Practices
• Poor quality hub grease
• Frequent breakdown
• Bearing failure
• Frequent re greasing
• Used grease/’Batata Grease’ for chassis
greasing

33. Thank You !
RAJIV RANJAN
rajivranjan926@gmail.com