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Basics of Coolant Management

Industrial Lubricants are always a vast and interesting subject to discuss and share. Broadly Industrial Lubricants can be discussed in two verticals – one is of course Factory, Plant & Machinery [ FPM ] products like Hydraulics, Gear Oils, Compressor Oils, etc. Another is Lubricants used in processing. In the later segment, one of the most sensitive portfolios is water extendable cutting coolants used in metal processing industries. Many technical publications and in-depth experiences are shared for the maintenance of cutting coolants. However, today's effort is to address the basics of maintenance of Soluble cutting coolants either mineral based conventional high oil content products or new generation semi-synthetic products. Before going into maintenance practices let us have a quick look at the composition and chemistry of Cutting coolants. New generation cutting oils are a complex combination of Lubricity components blended with Emulsifiers, Co-emulsifiers, Corrosion Inhib

Relation Between Friction, Wear & Lubricants

(R.S) What is Friction:-   Friction is the resistance to motion and wear is the loss of material as a result of friction, contact fatigue and corrosion. Reducing friction is a key objective of lubrication, but there are many other benefits of this process. Lubricating films can help prevent corrosion by protecting the surface from water and other corrosive substances. Different Types of Friction:- Sliding Friction:-  The term sliding friction refers to the resistance created by two objects sliding against each other. This can also be called kinetic friction. Sliding friction is intended to stop an object from moving.    Rolling Friction:-  In simple words Rolling friction is the force resisting the motion when a body rolls on a surface.     Also there some more types of friction is there like Boring Friction, Mix of Sliding & Rolling Friction, Internal Friction of a deform-able body. Majorly in all types of application, we can see these types of friction & the main purpose of

Can Lubricants Increase Friction?

  Lubricants like any types of greases & oils usually used to reduce the effect (heat generated when the surface move) of friction or we can say that its decrease the friction between surfaces in mutual contact rather increasing friction. A good lubricants or proper lubrication process does not only reduce friction but also it has multi functional tasks mentioned below. 1st & for most lubricants used to separate or lubricate two moving surfaces. 2nd A good lubricant or if you have selected proper lubrication process then lubricants can be a good sealant & can be used for sealing process. 3rd one of the major role of lubricants is to reduce the heat generated by two moving surfaces in mutual contact. Lubricants can act as coolant. Last but not the least Lubricating oils & greases can also protect material from different types of foreign particles, which can damage the materials like bearing, gears etc. & protects from oxidization and corrosion. To clarify how lubrica

Grease Lubricating System Used in Different Types of Stone Crusher

We have already discussed Basics of Lubricants where we have discussed regarding what is Lubricating Oil & Lubricating grease and the basic difference between Lubricating Oil & grease, also discussed what is viscosity & what is NLGI grade. Here we are trying to discuss all regarding the Grease Lubrication system used in different types of stone crusher. Before understanding, which lubrication system is good for crusher bearing lubrication, we need to understand the application & crusher working principle.

What is crusher & crusher working principle.

Stone Crushers or Rock Crushers are mainly used in mining industry to reduce the size of stones into smaller rocks, gravel, sand or rock dust. Also in some industry, crushers are also used to reduce the size of waste material into smaller one, so that recycling or disposal of the waste material will be easy. Additionally rock breakers are normally installed next to a crusher to reduce oversize material, which is normally too large for a crusher. Crushers are used to reduce particle size enough so that the material can be processed into finer particles in a SAG Mill followed by a Ball Mill.

Different types of Crushers:-

Mainly crushers can be classified in two main groups as per their working principle.

  1.     Compressive crushers that compress or press the material until it breaks into parts.
  2.     Impact crushers using the principle of quick & high impacts to crush the material into parts.

Different types of Compressive crushers:- JAW Crusher, Gyratory crushers, cone crushers:-

You can say that this is the first stage primary crusher used to break big stones into a size that rocks can be transported through conveyors to the next crushing stage. As the name suggest itself, jaw crushers breaks stones and other materials need to break between a fixed and a moving jaw. The jaw which is mounted on a pitman is moving and it has a reciprocating motion, and the other jaw fixed & stays as it is. When the material runs between the two jaws, the jaws compress larger rocks into smaller pieces. Like JAW crushers Gyratory crushers also used mostly in primary stage to break big stones in smaller pieces. Cone crushers are resemble gyratory crushers from technological point of view, but cone crushers are popular in secondary stage and quaternary stages of cursing stones.

Impact crushers (Hammer Crusher):-

Impact crushers are also crushing machines like compressive crushers but this type of crushers use sudden high impact on stones to reduce their size instead pressing the material until it breaks into parts.This type of Impact crushers can be used in any stage of the crushing process.

As per the working principle of Impact / Hammer crushers, they can be classified into two main types.
  1.     Horizontal shaft impact (HSI) crushers.
  2.     Vertical shaft impact (VSI) crushers.
Now we have discussed basics of different types of crushers. Now as per the working principle of different types of crushers, we need to think from Lubrication point of view.

So, As per the working principles of different types of crushers, there are some criticalities as per lubrication point of view.

Lubrication Criticality of Crushers Bearing:-

  1.     Very high & shock load on bearings.
  2.     Very high chances of metal-to-metal point contact on bearings due to shock load.
  3.     Very dusty environment.
  4.     Grease should have good sealing property also to reduce contamination from foreign particles.

Crusher Bearing failure reasons:-

Poor or inadequate lubrication is one of the major reason of bearing failure in all types of crushers. Normally, the Original Equipment Manufacturer (OEM) collaborates with the bearing & lubricants manufacturer to develop a recommended re-lubrication schedule. Operators and maintenance people should follow the OEM provided re-lubrication recommendation chart which normally written in the product catalog book or product maintenance book to maximize the bearing life.

In addition, it should be take care not to over lubricate the bearings. In grease lubrication systems, if bearings are over lubricated then due to lubricant churning excessive heat can generate inside the bearing & breaks down the lubricants film and this can cause premature bearing failure. In addition, it should be noted that mixing of different greases or other lubricants should also be avoided, as this can result in breakdowns and may cause premature failure.

In addition to that, Damage of crusher bearing is a result of Grease contamination & improper lubrication result to metal-to-metal contact & wear.

Common reasons of Metal-to-Metal contact & wear is as include:

  • Abrasive wear and debris denting inside of the bearing caused by contamination of lubricants.
  • Excessive shock loads or vibrations in the application or use of a wrong viscosity grease or grease viscosity reduction due to excessive temperature inside the bearing or all of these reasons can result in metal-to-metal contact & wear in the bearing. 
  • Fretting or fretting corrosion, which typically results from a loose fit of bearing inside hosing or in the shaft, leading to relative motion between the bearing and the shaft or housing.

Recommended Grease Lubrication for different types of stone crusher:-

To help to protect crusher bearings from failure, it is a critical to use the right lubricant products. Original Equipment manufacturers (OEM) of different types of crushers should recommend or maintenance peoples should check for lithium or calcium based greases that have a min base oil viscosity of ISO 220 to 460 centistokes (cSt) at 40 degree centigrade and that grease should contain extreme pressure (EP) additives. In some cases, also operators can look for greases that contain a molybdenum disulfide (Mos2) to protect against adhesive wear inside of the bearing. It is highly recommended that crusher bearings should be frequently re-lubricate to ensure proper lubrication or use high viscosity oil based grease to increase re lubrication interval. So that film thickness of grease can withstand the shock load coming in the bearing during operation.

Oil Lubrication system for different types of crusher:

Normally in most of industry, operating an oil-lubricated crusher with contaminated lubricating oil (old, dirty oil) is a common mistake followed by maintenance peoples. As a thumb rule, operators should use gear lubricants added with extreme pressure additive with a minimum oil viscosity of 22 cSt at the bearing operating temperature. This typically demands an AGMA 3 EP or 4 EP gear oil which Exhibit high Timken OK loads and excellent results on the FZG and Four Ball Wear Test addition to that gear oil should meets or exceeds DIN 51517 Part 3, U.S. Steel 224, AGMA 9005-E02, ISO 12925-1 CKC/CKD, David Brown S1.53.101, GM LS-2 EP Gear Oil. OEM should also recommend a routine oil-sampling checkup program to effectively monitor oil and crusher condition.

How to fill grease at stone crusher? 


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  1. Great Post. I am thankful to you for sharing this post. This is very useful for me and as well as for others. Your article is very well written and unique. please keep sharing such posts.Paving Contractors


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