Analisis Minyak Pelincir Baru Untuk Kereta Dengan Menggunakan Four-Ball Tester

(1)

‘Saya / Kami akui bahawa telah membaca

karya ini dan pada pandangan saya / kami karya ini

adalah memandai dari segi skop dan kualiti untuk tujuan penganugerahan

Ijazah Sarjana Muda Kejuruteraan Mekanikal (Struktur dan Bahan)’

Tandatangan

:

Nama Penyelia I

:

Tarikh

:

Tandatangan

:

Nama Penyelia II

:

(2)

ANALISIS MINYAK PELINCIR BARU UNTUK KERETA

DENGAN MENGGUNAKAN FOUR-BALL TESTER

MUHAMMAD AZUAN FAUZAN BIN PUNIJAN

Laporan ini dikemukakan sebagai

memenuhi sebahagian daripada syarat penganugerahan

Ijazah Sarjana Muda Kejuruteraan Mekanikal (Struktur & Bahan)

Fakulti Kejuruteraan Mekanikal

Universiti Teknikal Malaysia Melaka

(3)

“Saya akui laporan ini adalah hasil kerja saya sendiri kecuali ringkasan dan

Petikan yang tiap-tiap satunya saya telah jelaskan sumbernya”

Tandatangan :

Nama Penulis :

MUHAMMAD AZUAN FAUZAN BIN PUNIJAN

(4)

DEDICATION

I would like to dedicate this project to my beloved family:

Punijan Bin Munijo (Father)

Arfiah Bt. Ab. Hamid (Mother)

And also to my brother and sisters:

Muhammad Azrul Hafiz

(5)

iv

ACKNOWLEDGEMENT

Firstly, I would like to say thank to my supervisor, En Norazmmi Bin

Masripan and Dr. Ir Hady Effendi for his personal input, enthusiasm, encouragement

and many constructive comments and remarks while doing this report.

I would like to say thank to all the lab technician, En Azrul Syafiq Mazlan

that has been guided me on using the Four Ball Tester and sharing some knowledge

and comment in order to completing this report.

(6)

v

ABSTRACT

Tribology is a study focusing on friction, wear and lubrication of interacting

surface in relative motion. In this case we are study on lubricant. The function of

lubricant is to control friction and wear in a given system. Based on the study we can

relate to the performance of the lubricant. Rather that that we also can predict the quality

of the lubricant that can be reflects to its resistance to degradation on service.

Four Ball Tester machine was used to examine the properties of the lubricant.

This machine is used to study the effect of the temperature and applied load on the

performance of the lubricant. Therefore, we can get the relationship between the

temperature and the applied loads with the performance of the lubricant.

(7)

vi

ABSTRAK

Tribologi adalah kajian mengenai geseran, kehausan dan pelinciran terhadap dua

permukaan yang bersentuhan pada gerakan relatif. Untuk masalah ini, kita mengkaji

mengenai minyak pelincir. Kegunaan minyak pelincir adalah utntuk mengawal geseran

dan kehausan pada sesuatu sistem. Berdasarkan daripada kajian tersebut kita dapat

kaitkan dengan prestasi minyak pelincir tersebut. Selain itu, kita akan dapat mengkaji

kualiti minyak pelincir yang bertindak balas dengan pengurangan gred semasa operasi.

Mesin ‘Four-Ball Tester’ digunakan untuk melakukan eksperimen terhadap

cirri-ciri minyak pelincir. Mesin ini digunakan untuk mengkaji hubung kait antara suhu, dan

pemberat terhadap prestasi minyak pelincir. Oleh yang demikian, satu hubung kait

antara suhu dan pemberat terhadap prestasi minyak pelincir dapat dihasilkan.

(8)

vii

TABLE OF CONTENTS

CHAPTER

TOPIC

PAGE

SUPERVISOR COMFIRMATION

TITLE PAGE

i

DECLARATION PAGE

ii

DEDICATION

iii

ACKNOWLEDGEMENT

iv

ABSTRACT

v

ABSTRAK

vi

TABLE OF CONTENTS

vii

LIST OF TABLES

x

LIST OF FIGURES

xi

LIST OF SYMBOLS

xv

CHAPTER 1

INTRODUCTION

1

1.1

Background

1

1.2

Important Of Project

2

(9)

viii

CHAPTER

TOPIC

PAGE

1.1

Scope

3

1.2

Summary Project

4

CHAPTER 2

LITERATURE REVIEW

5

2.1

Function of Engine Lubricant

5

2.2

Lubricant Composition

6

2.3

Mineral Oils

7

2.4

Synthetic Oils

14

2.5

Lubricant Additives

18

2.6

Physical Properties of Lubricant

27

CHAPTER 3

METHADOLOGY

33

3.1

Scope of the experiment

33

3.2

Terminology

34

3.3

Summary of test method

36

3.4

Significant and Use

37

3.5

Apparatus

37

3.6

Material

40

3.7

Preparation on Apparatus

40

3.8

Procedure

41

(10)

ix

CHAPTER

TOPIC

PAGE

CHAPTER 4

RESULTS AND ANALYSIS

43

4.1

Table of Car Engine Oil

43

4.2

Analysis data Experiment

49

CHAPTER 5

DISCUSSION

60

CHAPTER 6

CONCLUSION AND

63

RECOMMENDATION

REFERENCES

65

(11)

x

LIST OF TABLES

NO.

TITLE

PAGE

2.1

Some Commonly Used Dispersants

25

2.2

SAE Classification of Engine Oils

30

4.1

Scar Diameter and Applied Load for

43

Normal Lubricant (X-Brand)

4.2

44

Semi-synthetic Lubricant (X-Brand)

4.3

45

Fully-synthetic Lubricant (X-Brand)

4.4

46

Normal Lubricant (Y-Brand)

4.5

47

Semi-synthetic Lubricant (Y-Brand)

4.6

48

Fully-synthetic Lubricant (Y-Brand)

(12)

xi

LIST OF FIGURES

NO

TITLE

PAGE

2.1

Schematic Diagram of a Crude Oil Distillation

10

Process

2.2

Types of Mineral Oils

13

2.3

Typical Chemical Structure of the Most Common

17

Synthetic Lubricants

2.4

Adsorption Lubrication Mechanism By

18

Boundary Additives

2.5

Chemical Structure of Zinc Dialkyldithiophospate

19

(ZnDDP)

2.6

Influence of Load and Temperature on the

19

Effectiveness of ZnDDP on Wear Rates

2.7

Schematics Variation of Friction and Wear with

20

Oil Viscosity

2.8

Structure of Dibenzyldisulphide

21

2.9

Effect of Oxidation on the Viscosity and Acidity of a

22

(13)

xii

NO

TITLE

PAGE

2.10

The Chemical Structure of an Anti-Oxidant

22

Additives

2.11

Operating mechanism of Rust Inhibitors

23

2.12

Anti-Rust Additives

24

2.13

Synthesis and Function of Sulphonate

26

Detergents

2.14

Schematic Representation of the Fluid Separating

28

Two Surfaces

2.15

Viscosity-Temperature graph for Monograde and

31

Multigrade Oils

2.16

Graph for Determination of the constant,C

32

3.1

Schematic Plot of Scar Diameter versus

34

Applied Load

3.2

Sectional View of Four Ball Tester

37

3.3

Four Ball Machine Model

38

3.4

Working Area

38

3.5

Collet Master

38

3.6

Ball pot Mounting Seat

39

3.7

Microscope

39

3.8

Timer

39

(14)

xiii

NO

TITLE

PAGE

4.2

Scar on the steel ball for Semi-synthetic Lubricant

44

(X-Brand)

4.3

Scar on the steel ball for Fully-synthetic Lubricant

45

(X-Brand)

4.4

Scar on the steel ball for Normal Lubricant (Y-Brand)

46

4.5

Scar on the steel ball for Semi-synthetic Lubricant

47

(Y-Brand)

4.6

Scar on the steel ball for Fully-synthetic Lubricant

48

(Y-Brand)

4.7

Graph of Scar diameter versus applied load for

49

Normal Lubricant (X-Brand)

4.8

50

Semi-synthetic Lubricant (X-Brand)

4.9

51

Fully-synthetic Lubricant (X-Brand)

4.10

52

All lubricant (X-Brand)

4.11

53

Normal Lubricant (Y-Brand)

(15)

xiv

NO

TITLE

PAGE

4.13

54

Fully-synthetic Lubricant (Y-Brand)

4.14

Graph of scar diameter versus applied load for

55

All Lubricant

4.15

Graph comparison for X and Y Lubricant for

56

Normal Lubricant

4.16

Graph comparison for X and Y Lubricant for

56

Semi-synthetic Lubricant

4.17

Graph comparison for X and Y Lubricant for

57

Fully-synthetic Lubricant

4.18

The comparison on the frictional torque for

58

Normal Lubricant

4.19

The comparison on the frictional torque for

58

Semi-synthetic Lubricant

(16)

xv

LIST OF SYMBOLS

F

=

Force (N)

A

=

Area (m

2

)

u

=

Velocity (ms

-1

)

h

=

Height (m)

η

=

Dynamic Viscosity (Pas)

τ

=

Shear stress (Pa)

υ

=

Kinematic viscosity (m

2

/s)

ρ

=

Fluid density (kg/m

3

)

(17)

1

CHAPTER 1

INTRODUCTION

1.1

BACKGROUND

In this project, the properties and the behavior of the lubricant are been

studied. Furthermore, the relationship of the lubricant performance with load are

been gather from the experiment. Rather than that, the performance of the lubricant

before done a maintenance are also been study. To observe the relationship of the

lubricant between load and diameter scar we will used the Four Ball Tester machine.

From the study, as the viscosity is higher, it will affect the performance of the

lubricant. There are 3 type of lubricant for car engine:

i.

Regular oil

ii.

Semi synthetic oil

iii.

Fully synthetic oil

These are the lubricant that will be used in the experiment and make a differentiation

based the performance. From the observation the fully synthetic lubricant should

(18)

2

before maintenance. Same goes to other lubricant oils; we will observe how the

lubricant will react with the high temperature and extreme load.

We will know how far the lubricant performance by seeing the wear and scar

on the ball from the Four Ball Tester machine. The maximum load and maximum

temperature can be determined as the steel ball is weld together.

1.2

IMPORTANT OF PROJECT

This experiment and analysis is important in order to understand the behavior

of the lubricants. It also helps to determine the maximum load that the lubricant can

endure during operating.

When all the behavior of the lubricant under certain condition can be

determined, it will help:

i.

Prevent the engine from wear

ii.

Prolong the life time of engine

(19)

3

1.3

OBJECTIVE

i.

Determine the relationship between the lubricant performance and the

applied load

ii.

Determine the performance of the lubricant before maintenance by

identify the maximum load that the lubricant can sustained.

iii.

Make a comparison between X and Y Lubricant and analyze the

performance of the lubricant

1.4

SCOPE OF THE PROJECT

i.

Doing the literature review for the properties of the lubricant and

types of wear.

ii.

To perform the experiment of Four Ball Tester to get the relationship

between the performances of the lubricant and applied load.

(20)

4

1.5

PROJECT SUMMARY

This project is about doing the experiment using the Four-Ball Tester

machine and doing analysis the data from the experiment. From the data, a graph for

diameter scar versus applied load is plot. Based from the graph plot, the performance

of the lubricant can be determined by comparing the diameter of the scar.

Besides that, the maximum load for the lubricant can be sustained before

failure can be calculated. Therefore, the relationship between the applied load and

the size of the scar can be determined. Different lubricant will give a different

maximum load that the lubricant can be sustained. It is due to the additives added in

(21)

5

CHAPTER 2

LITERATURE REVIEW

2.1

FUNCTION OF ENGINE LUBRICANT

The lubrication of the engine appears frequently to have been afterthought in

the engine design process. Therefore, several experiments are done to develop a

better performance of lubricant. The lubricants are needed to fulfill several important

functions rather than controlling friction and wear.

Furthermore, they are used to protect the engine against rusting and other

types of corrosion. For long term use, it keeps the internal surfaces of the engine

clean and in shape by minimizing the deleterious effects of combustion product and

other contaminant that can enter the engine. According to J.C Bell, the lubricant also

is a primary medium for cooling the piston, where it also plays a part in completing

the seal between the piston, piston-ring and cylinder surfaces against leakage of the

(22)

6

The lubricant must perform these functions for long period of hours between oils

changes, under extreme and operating conditions. Such as in a high speed driving,

under heavily loaded condition that can cause thermal stressing and oxidation of the

oil. Even in temperate climates it may occasionally be necessary to start the engine at

sub-zero temperatures. The lubricant oil must remain fluid under all these conditions

in order to perform its functions efficiently.

2.2

LUBRICANT COMPOSITION

There is some question that still has to answer, what is the chemical

composition of the lubricant? How to differentiate several of lubricant? What are the

different between mineral and synthetic oils? What are the additives used in oils?

Will the composition of the lubricant differ depending to application?

Oils can be divided into two different origins, the biological and non

biological and it provide a vast array of hydrocarbon compounds. These substances

are usually present as complex mixture and used for many purpose such as to control

of wear and friction. Lubricants made from mineral oils are partly refined and partly

impure. The balance between impurity and purity is critical to oxidation stability of

the oil and it varies depending on the applications.

Chemicals which are deliberately added to oil in order to improve its

properties are called additives. Additives can radically change the properties of a

lubricant and are essential to the overall performance of the lubricant. They also

dictate specific characteristics of the lubricant such as:

i.

Corrosion tendency

(23)

7

iii.

Oxidation

iv.

Wear and friction

There are two fundamental aspect of lubricant performance:

i.

Achieving the required level of friction and wear rates

ii.

Maintaining the standards in spite of continuous degradation of the

lubricant.

Additives present in the oil also deteriorate during operation since they react with the

metallic parts if the machinery and with the environment. The degradation of the

lubricant is inevitable and must be postponed until the required lifetime is achieved.

In fact, a large part of lubricant technology is devoted to the preservation of

lubricating oils when in use.

2.3

MINERAL OILS

Mineral oils are the most commonly used lubricants. They are manufactured

from crude oil which is mined in various part of the world. There are certain

advantage and disadvantage of applying mineral oil to lubricate specific machinery.

These must be carefully consideration when selecting a lubricant and designing a

lubrication system. The cost of mineral oils is low and even with the rapid

(24)

8

2.3.1 Sources of Mineral Oils

The theory states that the mineral oils are the result of decomposition of

animal and plant matter in salt water.

Over time they were buried and compressed.

Under these conditions the organic matter transformed into tar-like molecules called

kerogen. As the temperature and pressure increased the kerogen gradually

transformed into the complex hydrocarbon molecules which are the basic

constituents of crude oil. When the temperature and pressure became sufficiently

high methane was produced from the kerogen or crude oil and hence natural gas is

often found together with crude oil.

2.3.2 Manufacture of Mineral Oils

According to the G.W.Stachowiak and A.W. Batchelor, crude oil has a very

complex structure which is separated into a number of fractions by a distillation

process which is called fractional distillation. The process of fractional distillation

involves heating the crude oil to turn into a vapor which is then passed through a tall

vertical column (fractional tower), containing a number of trays at various levels.

The vapor passes through the column and at each successive tray the temperature

gradually drops. The fraction whose boiling point corresponds to the temperature at a

particular tray will condense. In this manner the most volatile compounds will

condense at the highest trays in the column while those with the highest boiling

points condense at the lower trays. The condensed fractions are then tapped.

There are certain temperatures limits to which crude oil can be pre heated. If

the temperature is too high then some of the crude may decompose into coke and

tarry matter. This problem is overcome by employing another distillation tower

which operates at a lower pressure. By lowering the pressure the heavy fractions of

crude can be vaporized at much lower temperatures. Thus in the manufacture of

mineral oils and petroleum fuels distillation takes place at atmospheric pressure and