Maintaining the right levels and viscosity in industrial processes is crucial for optimal performance and efficiency. Proper viscosity ensures that fluids flow smoothly and effectively, reducing friction and wear on components, which can lead to longer lifespans and lower maintenance costs.

In manufacturing, the correct viscosity of materials can affect product quality, consistency, and processing times, Furthermore, monitoring and adjusting these parameters can enhance safety by preventing leaks or failures in machinery, ultimately contributing to the overall reliability and sustainability of operations.

 

This Engineering Hacks blog is the second in our ‘Setting up to ensure machine health’ series for MSC Priority Club members – helping you to get more out of your machines for less.

 

In this article, we’ll explore why ensuring that your machines are running with the optimal level and viscosity of oil is so important and how to monitor and keep your process running.

 

Maintaining the right oil levels

 

Insufficient lubrication within a machine can lead to parts rusting as well as wear and tear resulting from friction between moving components, such as gears and spindles.

 

A machine that is struggling to move due to a lack of lubrication will also use more energy to perform the same tasks. Costs are therefore increased via replacing worn parts and increased energy consumption.

 

 

Unbalanced tooling leading to ‘wobble’ when running at high speeds will create natural wear - and whilst tool setup of this nature is certainly not advisable – even the effects of this can be reduced slightly by efficient lubrication.  (We will be sharing best practice regarding optimising tool selection and setup later in this series).

 

 

Oil viscosity

 

Every machine will have a manufacturers recommendation for the oil viscosity to be used with it. These recommendations align machine capability with the appropriate oil.

 

It is important to stick to these recommendations, as not doing so will create issues with machine performance.  For example, an oil that is too thick will risk clogging up the machine, whilst an oil that is too thin will not provide sufficient lubrication.

 

As a guide, viscosity is higher within heavier duty oils and heavier duty, higher pressure oils are required when machining larger components and components with a requirement for increased strength/ durability.

Viscosity is a measure of an oil's resistance to flow and is one of the most important factors in lubricants. Oil thins (viscosity decreases) with increasing temperature and thickens (viscosity increases) with decreased temperature.

 

Viscosity affects heat generation in bearings, cylinders and gear sets related to an oil's internal friction. It governs the sealing effect of oils and the rate of oil consumption, as well as determines the ease with which machines may be started or operated under varying temperature conditions, particularly in cold climates.

This explains why an oil will flow much more easily in summer at a temperature of +25 degrees C than it will flow in winter at a temperature such as -25 degrees C.

However, not all oils respond in the same way and many oils contain an ability to resist changes in viscosity due to a change in temperature. This is referred to as the oil's viscosity index or VI. The higher the VI of an oil, the less its viscosity is altered by temperature changes.

The benefits of oils with a higher VI include a general increase in viscosity at higher temperatures, which results in lower oil consumption and less wear and a reduced viscosity at lower temperatures.

Oil selection

MSC stocks a comprehensive range of high-quality lubrication products including Gear Oils, Hydraulic oils, Slideway oils and more. From lubricants and grease to oils and lubrication equipment, we have everything you need to keep your machinery running smoothly.

Browse our selection now and ensure optimal performance and longevity with our reliable lubrication solutions from leading brands such as Exol, Rocol, Mobil and Castrol. See the full range here www.mscdirect.co.uk/lubrication