How Temperature Impacts the Performance of Industrial Gear Oils

One of the most prominent factors that can affect the performance of industrial gear oils is temperature. It is highly important to maintain the temperature to get peak performance. After all, industrial gear oils play a vital role in maintaining the smooth and efficient operation of heavy machinery. These oils ensure peak performance in manufacturing, mining, construction, and energy production fields. Gear oil radically reduces friction, wear, and corrosion in gears and bearings. They provide necessary lubrication under high pressures and loads.

However, as hinted before, such smooth operation can be drastically affected by temperature. The heat generated from heavy load and stress directly impacts the viscosity, oxidation stability, and overall effectiveness of the oil. Therefore, to ensure that the oil does not lose its lubrication necessary steps need to be taken. So, in this blog, we aim to guide you in learning how temperature impacts the performance of industrial gear oils. Plus, the steps you can take to manage these effects for optimal machinery performance.

How Temperature Affects the Viscosity in Industrial Gear Oil?

What makes gear oil so important for industrial machinery is its viscosity. But what exactly is viscosity? Well, it is the resistance of a fluid to flow. In heavy machinery, the viscosity of the oils provides a vital protective layer or film between gears and bearings. This prevents any direct metal-to-metal contact, helping to avoid any wear and tear. However, the viscosity of a gear oil can change with varying temperatures.

Especially, if the temperature rises, the viscosity of industrial gear oils decreases. It becomes thinner and loses its capability to provide a protective layer. Therefore, you run into the issue of machine parts having direct contact causing damage to them. Furthermore, lead-bearing capacity also takes a massive hit. Lastly, with high heat, the oil completely breaks down. All of this can lead to costly repair of the operating machines as well as delays in production.

Low temperatures also have adverse effects on gear oil’s viscosity. Towards cooler temperatures, the oil tends to get thicker which hinders its proper flow. This disrupts proper flow in the various parts of the gear system. This poor lubrication leads to higher energy consumption as the machine needs to work harder to move thicker oil. Such poor lubrication causes damage to the machine, leading to delays and costly repairs.

Oxidation and Oil Degradation at High Temperatures

Temperature also highly influences oxidising in the gear oil. The chemical reaction of oxidation occurs when the oil is exposed to oxygen over time. Rising temperature accelerates this process, leading to the breakdown of oil molecules. This breakdown forms sludge, varnish, and acids. Such formation then proceeds to make the oil lose its lubrication and cause higher friction between gears.

Such by-products also act as deposits that clog gears and bearings. Causing a reduction in their efficiency and increasing the likelihood of failure. Finally, the acids formed during oxidation can corrode metal surfaces, further damaging the gear system. Therefore, how to prevent this? Antioxidant elements are often used in industrial gear oils to slow this process down. But, even these antioxidants lose their effectiveness due to high temperatures.

Thermal Degradation and Impact on Gear Oil Life

Temperature also initiates thermal degradation in industrial gear oils. This happens due to the oil being exposed to a high temperature that pushes it beyond its thermal stability limits. Breakdown on the molecular level causes the oil to lose its lubrication. Moreover, the additive properties of gear oil, which has anti-wear agents, extreme pressure (EP) additives, and rust inhibitors also get affected by heat.

Therefore, it is pretty evident that the life expectancy of industrial gear oils depends upon the range of temperature. For example, with an increase of 10°C in operating temperature, the life of the oil is typically reduced by half. This indicates that the typical gear oil is designed to last about 10,000 hours at 80°C or only last 5,000 hours at 90°C. In simple words, the higher the temperature rises, the gear oil loses its lifespan further.

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How Can You Prevent Such Rapid Degradation?

There are things that you can do to prevent such rapid degradation of industrial gear oils. For starters, there are specific gear oils that work well in high temperatures. We have high-performance synthetic gear oils that are designed to withstand a wide range of temperatures compared to conventional mineral-based oils. They have relatively better thermal stability, resist oxidation, and maintain their viscosity at extreme temperatures.

Another thing that can be done to prevent overheating is temperature monitoring. Make sure that you are monitoring the temperature by installing sensors that can alarm you for overheating issues. This way you will know the imminent threat and control the heat before any damage takes place. You can also take your chance by installing a cooling system in your machinery. Heat exchangers or fans can help dissipate excess heat and keep temperatures within acceptable limits.

Maintain the oil filtration and check for debris or particles regularly. Do replacement of the filters to remove contaminants and oxidized oil products. You can also take the manufacturer’s recommendation on oil change interval. Finally, keep using antioxidants to slow down the oxidation process and extend oil life. Furthermore, see if the industrial gear oils have anti-wear formulated in them. They help protect metal surfaces even under high-temperature conditions. Lastly, use extreme pressure (EP) additives to enhance the oil’s ability to handle heavy loads and prevent wear.

Conclusion

Before we conclude, use synthetic gear oil that has better a low pour point and is ideal for cold temperatures due to staying fluid. Furthermore, try installing pre-heating systems to warm up the industrial gear oils before starting the machinery. This ensures better lubrication from the moment the equipment is activated.

But, with all that being said, to keep your heavy-duty machines running at their peak, combating the temperature is the most important aspect. Therefore, try to keep these factors in mind and keep paying attention to better thermals and industrial gear oils management to improve overall operational efficiency.