ASTM D5182-97(2008)
(Test Method)Standard Test Method for Evaluating the Scuffing Load Capacity of Oils (FZG Visual Method)
Standard Test Method for Evaluating the Scuffing Load Capacity of Oils (FZG Visual Method)
SIGNIFICANCE AND USE
The transmission of power in many automotive and industrial applications is accomplished through the use of geared systems. At higher operating speeds it is well known that the lubricant/additive system can be a significant factor in preventing scuffing (adhesive wear) damage to gears. This test method is used to screen the scuffing load capacity of oils used to lubricate spur and helical (parallel axis) gear units.
The test method is limited by the capabilities of the equipment (test rig and gears), and the performance observed may not directly relate to scuffing performance observed with spiral bevel on hypoid gearing. It is also limited to discriminating between oils with mild EP additives or less. Lubricants containing higher levels of additives, that is, those meeting the requirements of API GL4 or GL5, generally exceed the maximum load capacity of the test rig and, therefore, cannot be distinguished for their scuffing capabilities by this test method.
SCOPE
1.1 This test method, the Forschungstelle für Záhnräder und Getriebebau (Research Site for Gears and Transmissions) Visual Method, commonly referred to as the FZG Visual Method, is intended to measure the scuffing load capacity of oils used to lubricate hardened steel gears. Scoring, a form of abrasive wear, is also included as a failure criteria in this test method. It is primarily used to assess the resistance to scuffing of mild additive treated oils such as industrial gear oils, transmission fluids, and hydraulic fluids. High EP type oils, for example, those oils meeting the requirements of API GL-4 and GL-5, generally exceed the capacity of the test rig and, therefore, cannot be differentiated with this test method.
1.2 The values stated in SI units are to be regarded as standard. No other units of measurement are included in this standard.
1.3 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use. For specific safety information, see Section 7, Section 8, 9.2, 9.3.1, and Annex A1.
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Standards Content (Sample)
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Designation: D5182 − 97(Reapproved 2008)
Standard Test Method for
Evaluating the Scuffing Load Capacity of Oils (FZG Visual
Method)
This standard is issued under the fixed designation D5182; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope 2.2 DIN Standard:
DIN 51 354 Teil 1 FZG Zahnrad Verspannungs Prüf
1.1 This test method, the Forschungstelle für Záhnräder und
maschine—Allgemeine Arbeitsgrundlagen
Getriebebau (Research Site for Gears and Transmissions)
Visual Method, commonly referred to as the FZG Visual
3. Terminology
Method, is intended to measure the scuffing load capacity of
3.1 Definitions:
oils used to lubricate hardened steel gears. Scoring, a form of
3.1.1 See also Terminology G40.
abrasive wear, is also included as a failure criteria in this test
3.1.2 abrasive wear—wear due to hard particles or hard
method. It is primarily used to assess the resistance to scuffing
protuberances forced against and moving along a solid surface.
of mild additive treated oils such as industrial gear oils,
3.1.3 adhesive wear (scuffıng)—wear due to localized bond-
transmission fluids, and hydraulic fluids. High EPtype oils, for
ing between contacting solid surfaces leading to material
example, those oils meeting the requirements ofAPI GL-4 and
transfer between the two surfaces or loss from either surface.
GL-5, generally exceed the capacity of the test rig and,
therefore, cannot be differentiated with this test method. 3.1.4 scoring—a severe form of wear characterized by the
formationofextensivegroovesandscratchesinthedirectionof
1.2 The values stated in SI units are to be regarded as
sliding.
standard. No other units of measurement are included in this
3.1.5 scratches—the result of mechanical removal or
standard.
displacement, or both, of material from a surface by the action
1.3 This standard does not purport to address all of the
of abrasive particles or protuberances sliding across the sur-
safety concerns, if any, associated with its use. It is the
faces.
responsibility of the user of this standard to establish appro-
priate safety and health practices and determine the applica- 3.2 Definitions of Terms Specific to This Standard:
bility of regulatory limitations prior to use. For specific safety 3.2.1 polishing—a mild form of abrasive wear resulting in
information, see Section 7, Section 8, 9.2, 9.3.1, and Annex minor loss of material and typically characterized by a smooth
A1. finish and removal of all or part of the initial grinding marks.
4. Summary of Test Method
2. Referenced Documents
4.1 An FZG Gear Test Machine is operated at constant
2.1 ASTM Standards:
speed (1450 rpm) for a fixed period (21700 revolutions—
D235 Specification for Mineral Spirits (Petroleum Spirits)
approximately 15 min) at successively increasing loads until
(Hydrocarbon Dry Cleaning Solvent)
the failure criteria is reached; the initial oil temperature is 90°C
G40 Terminology Relating to Wear and Erosion
beginning at load stage four (see Table 1). The test gears are
examined initially and after the prescribed duration at each
load stage for cumulative damage (scuffing) to the gear tooth
This test method is under the jurisdiction of ASTM Committee D02 on
flanks.
Petroleum Products and Lubricantsand is the direct responsibility of Subcommittee
D02.L0.11 on Tribiological Properties of Industrial Fluids and Lubricates.
5. Significance and Use
Current edition approved May 1, 2008. Published September 2008. Originally
´1
approved in 1991. Last previous edition approved in 2002 as D5182–97(2002) .
5.1 The transmission of power in many automotive and
DOI: 10.1520/D5182-97R08.
industrial applications is accomplished through the use of
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on Available from Beuth Verlag GmbH (DIN-- DIN Deutsches Institut fur
the ASTM website. Normung e.V.), Burggrafenstrasse 6, 10787, Berlin, Germany.
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D5182 − 97 (2008)
TABLE 1 Standard Load Stages for FZG Scuffing Test
Total
Torque Tooth Hertzian
Load Work Load Clutch
on Normal Contact
A
Stage Trans- Loaded with
Pinion Force Pressure
mitted
(N·m) (N) (N/mm ) (kW·h)
1 3.3 99 146 0.19 H1
2 13.7 407 295 0.97 H2
3 35.3 1044 474 2.96 H2+K
4 60.8 1799 621 6.43 H2+K+W1
5 94.1 2786 773 11.8 H2+K+W1+W2
6 135.5 4007 929 19.5 H2+.+W3
7 183.4 5435 1080 29.9 H2+.+W4
8 239.3 7080 1232 43.5 H2+.+W5
9 302.0 8949 1386 60.8 H2+.+W6
10 372.6 11029 1539 82.0 H2+.+W7
11 450.1 13342 1691 107.0 H2+.+W8
12 534.5 15826 1841 138.1 H2+.+W9
A
where:
H1 = load lever H1 (light),
H2 = load lever H2 (heavy),
K = support rod for weights, and
A. Diagram of a Typical FZG Test Rig
W1 to W9 = weights for loading (supplied with test rig).
geared systems. At higher operating speeds it is well known
that the lubricant/additive system can be a significant factor in
preventing scuffing (adhesive wear) damage to gears. This test
method is used to screen the scuffing load capacity of oils used
to lubricate spur and helical (parallel axis) gear units.
5.2 The test method is limited by the capabilities of the
equipment (test rig and gears), and the performance observed
may not directly relate to scuffing performance observed with
spiral bevel on hypoid gearing. It is also limited to discrimi- B. Schematic Section of an FZG Test Rig
nating between oils with mild EP additives or less. Lubricants
FIG. 1 FZG Test Rig
containing higher levels of additives, that is, those meeting the
requirements of API GL4 or GL5, generally exceed the
maximum load capacity of the test rig and, therefore, cannot be 6.2 Test Gears—The test gearset (pinion and gear) are
distinguished for their scuffing capabilities by this test method. commonly referred to as type A profile and conform to the
information supplied in Table 2. A schematic of the profile is
shown in Fig. 2. Both sides of the test gear flanks can be used
6. Apparatus
for testing purposes since only one side is loaded during the
6.1 FZG Gear Test Rig:
6.1.1 A more complete description of the test rig and
TABLE 2 Detail Data for the “A” Profile Gears
operating instructions may be found in the instruction manuals
available from the manufacturers/suppliers identified in
Parameter Value Units
A2.1.2.
Center Distance 91.5 mm
Effective Tooth Width 20.0 mm
6.1.2 The FZG gear test rig utilizes a recirculating power
Pitch Circle Diameter:
loop principle, also known as a four-square configuration, to
Pinion 73.2 mm
provide a fixed torque (load) to a pair of precision test gears.A
Gear 109.8 mm
Tip Diameter:
schematic of the test rig is shown in Fig. 1A and Fig. 1B. The
Pinion 88.7 mm
drive gearbox and the test gearbox are connected through two
Gear 112.5 mm
torsional shafts. Shaft 1 contains a load coupling used to apply Module 4.5 mm
Number of Teeth:
the torque through the use of known weights hung on the
Pinion 16
loading arm.
Gear 24
6.1.3 The test gearbox contains heating and cooling ele- Profile Modification
Pinion/Gear 0.8635/−0.5103
ments to maintain and control the temperature of the oil. A
Pressure Angle
temperature sensor located in the side of the test gearbox is
Normal/Working 20/22.5 degrees
used to control the heating/cooling system as required by the Hardness
Rockwell C 60 to 62
test operating conditions.
Surface Roughness
6.1.4 The test rig is driven by an electric motor capable of
Ra 0.3 to 0.7 µm
delivering at least 5.5 kW at 1440 rpm.
D5182 − 97 (2008)
9.3 Assembly of Test Gears—The test gears, spacers, and
bearings are heated on a hot plate or other device to approxi-
mately 60 to 80°C. Install the test gears on the shafts with the
alignment marks in the position shown in Fig. 3. Complete the
assemblyofthegearboxwiththeappropriatespacers,bearings,
and front cover.
9.3.1 It has been found critical for correct results that the
test gears are properly aligned on their respective shafts.
(Warning—Misalignment can lead to erratic or lower fail
loads due to uneven distribution of the load on the tooth.)
9.4 Test Oil—Add 1.25 L of test oil to the test gearbox
(approximately to the centerline of the shafts).
FIG. 2 Schematic of A Profile Test Gears
9.5 Final Assembly—Secure the top of the test gear case in
place with the 6 bolts. Connect the heater to its power source.
evaluation. It should be noted that these gears have been
10. Procedure
designedwithalargeprofilemodificationwhichincreasestheir
10.1 Prior to starting a test apply load stage 12 to the system
sensitivity to adhesive wear modes of failure.
for2to3minwithoutrunningthemotor(Table1).Thisisdone
6.3 Timer Mechan
...
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