非公路运输自卸车辆齿轮油的研究
摘要
介绍了非公路运输自卸车辆齿轮油的研制。该齿轮油主要用于在低速大负荷工况下运转的自卸车辆变速器齿轮。由于自卸车辆的工作环境恶劣、矿区内粉尘浓度大,并且车辆承载运输量大、作业强度高,导致齿轮在运转过程中所承受的压力较大,而且齿轮箱内温度较高,对齿轮油极压抗磨性能和高温抗氧化性能要求较高。非公路运输自卸车辆在用齿轮油使用性能无法满足其对齿轮油性能的要求,齿面出现不同程度的粘着磨损现象。需要研制一种非公路运输自卸车辆专用齿轮油,能够满足齿轮在苛刻工作环境下对齿轮油使用性能的要求。
非公路运输自卸车辆齿轮油的研制主要从基础油和添加剂两个方面着手,选择的基础油分别为100℃运动黏度大于10mm2/s的韩国双龙石蜡基基础油600SN以及由新疆克拉玛依石化公司生产的100℃运动黏度大于29mm2/s的光亮油。论文将两种基础油以不同比例调和后加入黏度指数改进剂T604A,对不同方案进行100℃运动黏度、黏度指数、开口闪点以及倾点等理化指标的测试,选择符合85W/90 GL-5齿轮油标准要求一组调和后作为本试验基础油。根据非公路运输自卸车辆齿轮的特殊工作环境和工作特点,选择能够改善油品性能的极压抗磨剂、抗氧剂、防锈剂、抗乳化剂等。分别对各种添加剂与基础油进行感受性试验,并考察添加剂之间的配伍性,从而确定各添加剂的加量范围,并通过正交试验确定添加剂的最佳加量。
使用石油产品运动黏度测定器、克利夫兰开口闪点测试器、石油产品低温性能测试仪分别对研制油100℃和40℃黏度、黏度指数、闪点和倾点等理化指标进行了测试。针对非公路运输自卸车辆变速器齿轮磨损严重的问题,使用四球试验机和梯姆肯试验机进行了齿轮油抗磨性能的测试,考察齿轮油的摩擦学性能；针对齿轮长时间大负荷运转导致油温过高的现象,通过实验室模拟试验对研制油的抗氧化性能进行了研究。使用铜片腐蚀测定仪考察了研制油的抗腐蚀性能；使用抗乳化测定仪考察研制油的抗乳化性能。
通过上述各项试验证明：所研制的自卸车辆齿轮油较85W/90 GL-5重负荷车辆齿轮油具有更好的极压抗磨性能、高温抗氧化性能、抗腐蚀性能以及抗乳化性能。能够满足非公路运输自卸车辆对齿轮油使用性能的要求。
This paper introduced the development of gear oil of off-highway dump truck, which is used in dump truck gear with low speed and high-load condition. Because of the poor working condition and large concentration of dust as well as the large carrying and high operation, the gears is bearing high pressure and high temperature of gearbox during operation. There has a high requirement on extreme pressure and antiwear property of gear oil as well as oxidation resistance in high temperature. The in-use gear oil cannot meet the requirements on service performance of gear oil, and different degrees of adhesive wear phenomena occurred in the surface of gears. The research must be done to develop a kind of special gear oil used in off-highway dump truck that can meet the requirement on service performance of gear oil during harsh working condition.
We can do the development of off-highway dump truck gear oil mainly from two aspects such as base oil and additives. The base oil we use in this paper is Paraffinic Base Oil 600SN, which is made in Ssangyong, and its kinematic viscosity is greater than 10mm2/s in 100 centigrade. And another base oil is 150BS bright stock made in Karamay Petrochemical Company, whose kinematic viscosity is greater than 29mm2/s in 100 centigrade. After being mixed in different proportions we should add Viscosity Index Improver T604A to the mixture. Then we can test the physicochemical indexes of different schemes such as kinematic viscosity in 100 centigrade, viscosity index, open flashing point and pour point. Choose a set of base oil that can meet the requirement of 85W/90 GL-5 gear oil to be the base oil of this test. According to the special working environment and characteristics of off-highway dump truck, the additives we choose is respectively ep antiwear additives, antioxidant, rust inhibitor, emulsion inhibitor and so on. They must be able to improve the performance of gear oil. Some studies were done on sensitivity between additives and base oil as well as compatibility of additives to insure the range of addition amount. And the optimum addition amount determined from orthogonal test.
The physicochemical indexes such as kinematic viscosities in 100 and 40 centigrade, viscosity index, open flashing point and pour point were tested with kinematic viscosities testing instrument of petroleum products, Cleveland Open Flash Point Tester and Low Temperature Performance Tester. According to severe wear of transmission gear of off-highway dump truck, the tests were done with four-ball-wear machine and Timken tester to detect antiwear properties and investigate tribological properties of gear oil. In view of the phenomenon of extremely high oil temperature caused by long-time and heavy-load working, we should test the oxidation of development oil through laboratory simulation test, the corrosion resistance through Copper Strip Corrosion Tester as well as demulsibility through Emulsification-resistive Tester.
It is showed that, this gear oil used in the dump truck is better than 85W/90 GL-5 gear oil on extreme pressure and antiwear property, high temperature oxidation resistance, corrosion resistance and demulsibility. It can meet the requirements to using performance of off-highway dump truck's gear oil.
非公路运输自卸车辆齿轮油的研制主要从基础油和添加剂两个方面着手,选择的基础油分别为100℃运动黏度大于10mm2/s的韩国双龙石蜡基基础油600SN以及由新疆克拉玛依石化公司生产的100℃运动黏度大于29mm2/s的光亮油。论文将两种基础油以不同比例调和后加入黏度指数改进剂T604A,对不同方案进行100℃运动黏度、黏度指数、开口闪点以及倾点等理化指标的测试,选择符合85W/90 GL-5齿轮油标准要求一组调和后作为本试验基础油。根据非公路运输自卸车辆齿轮的特殊工作环境和工作特点,选择能够改善油品性能的极压抗磨剂、抗氧剂、防锈剂、抗乳化剂等。分别对各种添加剂与基础油进行感受性试验,并考察添加剂之间的配伍性,从而确定各添加剂的加量范围,并通过正交试验确定添加剂的最佳加量。
使用石油产品运动黏度测定器、克利夫兰开口闪点测试器、石油产品低温性能测试仪分别对研制油100℃和40℃黏度、黏度指数、闪点和倾点等理化指标进行了测试。针对非公路运输自卸车辆变速器齿轮磨损严重的问题,使用四球试验机和梯姆肯试验机进行了齿轮油抗磨性能的测试,考察齿轮油的摩擦学性能；针对齿轮长时间大负荷运转导致油温过高的现象,通过实验室模拟试验对研制油的抗氧化性能进行了研究。使用铜片腐蚀测定仪考察了研制油的抗腐蚀性能；使用抗乳化测定仪考察研制油的抗乳化性能。
通过上述各项试验证明：所研制的自卸车辆齿轮油较85W/90 GL-5重负荷车辆齿轮油具有更好的极压抗磨性能、高温抗氧化性能、抗腐蚀性能以及抗乳化性能。能够满足非公路运输自卸车辆对齿轮油使用性能的要求。
This paper introduced the development of gear oil of off-highway dump truck, which is used in dump truck gear with low speed and high-load condition. Because of the poor working condition and large concentration of dust as well as the large carrying and high operation, the gears is bearing high pressure and high temperature of gearbox during operation. There has a high requirement on extreme pressure and antiwear property of gear oil as well as oxidation resistance in high temperature. The in-use gear oil cannot meet the requirements on service performance of gear oil, and different degrees of adhesive wear phenomena occurred in the surface of gears. The research must be done to develop a kind of special gear oil used in off-highway dump truck that can meet the requirement on service performance of gear oil during harsh working condition.
We can do the development of off-highway dump truck gear oil mainly from two aspects such as base oil and additives. The base oil we use in this paper is Paraffinic Base Oil 600SN, which is made in Ssangyong, and its kinematic viscosity is greater than 10mm2/s in 100 centigrade. And another base oil is 150BS bright stock made in Karamay Petrochemical Company, whose kinematic viscosity is greater than 29mm2/s in 100 centigrade. After being mixed in different proportions we should add Viscosity Index Improver T604A to the mixture. Then we can test the physicochemical indexes of different schemes such as kinematic viscosity in 100 centigrade, viscosity index, open flashing point and pour point. Choose a set of base oil that can meet the requirement of 85W/90 GL-5 gear oil to be the base oil of this test. According to the special working environment and characteristics of off-highway dump truck, the additives we choose is respectively ep antiwear additives, antioxidant, rust inhibitor, emulsion inhibitor and so on. They must be able to improve the performance of gear oil. Some studies were done on sensitivity between additives and base oil as well as compatibility of additives to insure the range of addition amount. And the optimum addition amount determined from orthogonal test.
The physicochemical indexes such as kinematic viscosities in 100 and 40 centigrade, viscosity index, open flashing point and pour point were tested with kinematic viscosities testing instrument of petroleum products, Cleveland Open Flash Point Tester and Low Temperature Performance Tester. According to severe wear of transmission gear of off-highway dump truck, the tests were done with four-ball-wear machine and Timken tester to detect antiwear properties and investigate tribological properties of gear oil. In view of the phenomenon of extremely high oil temperature caused by long-time and heavy-load working, we should test the oxidation of development oil through laboratory simulation test, the corrosion resistance through Copper Strip Corrosion Tester as well as demulsibility through Emulsification-resistive Tester.
It is showed that, this gear oil used in the dump truck is better than 85W/90 GL-5 gear oil on extreme pressure and antiwear property, high temperature oxidation resistance, corrosion resistance and demulsibility. It can meet the requirements to using performance of off-highway dump truck's gear oil.
引文
[1]胡邦喜.设备润滑基础[M].北京：冶金工业出版社,2002
[2]邵昀启.可降解重负荷球磨机专用油的研制[D].广西大学,硕士学位论文,2008,5
[3]许汉立.内燃机润滑油产品与应用[M].北京：中国石化出版社,2005,1
[4]王毓民 王恒.润滑材料与润滑技术[M].北京：化学工业出版社,2005,2
[5]黄文轩.润滑剂添加剂应用指南[M].北京：中国石化出版社,2007,3
[6]刘淑芝 张红梅.汽车用油品知识300问[M].北京：化学工业出版社,2005,2
[7]刘维民 夏延秋.齿轮传动润滑材料[M].北京：化学工业出版社,2005,7
[8]刘会军.汽车齿轮油的发展与选用[J].汽车技术,2001：38-40
[9]伏喜胜.国内外车辆齿轮油发展动态[J].润滑油,1995,3：14-18
[10]GB/T7631.7-1995润滑剂和有关产品(L类)的分类第7部分：C组(齿轮)[S]
[11]赵昱东.国外大型矿用汽车研制与发展[J].有色矿山,2000,(2)：33-36
[12]蔡淑华 唐树为 宋镇廉.齿轮传动润滑及其用油[M].北京：中国石化出版社,1998,9
[13]刘瑞堂.机械零件失效分析[M].哈尔滨工业大学出版社,2003,9
[14]朱旬 秦剑秋等.润滑方式对低速重载齿轮磨损性能的影响[J].润滑与密封,1997,(1)：13-14
[15]马鸣 李光谨.柴油机齿轮失效分析[J].柴油机设计与制造,2007,(2)：35－39
[16]陈一永 张家玺.汽车变速器齿轮副磨损分析及改善措施[J].润滑与密封,2006,8(8)：181-182
[17]王成焘 姚振强 陈铭.汽车摩擦学[M].上海：上海交通大学出版社,2002
[18]林子光 徐大耐.齿轮传动的润滑[M].1980,11
[19]GB/T265-1988石油产品运动粘度测定法和动力粘度计算法[S]
[20]郎全栋 董元虎.汽车运行材料[M].北京：人民交通出版社,2002
[21]李敏 迟克彬等.润滑油基础油生产工艺现状及发展趋势[J].炼油与化工,2009.(4)：5-7
[22]S J Miller. Process for producing lube oil from solvent refined oils by isomerization over a silicoal uminophosphate catalyst: US,5413695[P].1995,5
[23]张德义.加快我国加氢工艺和技术的发展[R].加氢协作组第四届年会报告,2001：1-9
[24]Xiao J R, Winslow P, James Z N. Base stock lube oil manufacturing process:WO,9802502[P].1996,1
[25]祖德光.进一步发展我国润滑油基础油生产技术的意见[J].润滑油,1999,14(2)：4-9
[26]章文译.亚洲Ⅱ/Ⅲ类基础油需求将增长[J]石油化工要闻,2009,(1)：7-9
[27]GB/T12583－1998润滑剂极压抗磨性能测定法(四球法)[S]
[28]GB/T5096-1985石油产品铜片腐蚀试验法[S]
[29]GB/T7305-2003石油和合成液水分离性测定法[S]
[30]张景河.现代润滑油与燃料添加剂[M].北京：中国石化出版社,1991
[31]李云雁 胡传荣.试验设计与数据处理[M].北京：化学工业出版社,2005,3
[32]马成良 张海军等.现代试验设计优化方法及应用[M].河南：郑州大学出版社,2007,9
[33]王娇.甲醇汽油发动机润滑油研究[D].长安大学,硕士学位论文,2008,5
[34]GB/T 3142-82,润滑剂承载能力测定法(四球法)[S]
[35]董元虎,尹兴林,冯豫川.天然气/汽油两用燃料发动机润滑油优化试验[J].长安大学学报(自然科学版),2007(2)：94－98
[2]邵昀启.可降解重负荷球磨机专用油的研制[D].广西大学,硕士学位论文,2008,5
[3]许汉立.内燃机润滑油产品与应用[M].北京：中国石化出版社,2005,1
[4]王毓民 王恒.润滑材料与润滑技术[M].北京：化学工业出版社,2005,2
[5]黄文轩.润滑剂添加剂应用指南[M].北京：中国石化出版社,2007,3
[6]刘淑芝 张红梅.汽车用油品知识300问[M].北京：化学工业出版社,2005,2
[7]刘维民 夏延秋.齿轮传动润滑材料[M].北京：化学工业出版社,2005,7
[8]刘会军.汽车齿轮油的发展与选用[J].汽车技术,2001：38-40
[9]伏喜胜.国内外车辆齿轮油发展动态[J].润滑油,1995,3：14-18
[10]GB/T7631.7-1995润滑剂和有关产品(L类)的分类第7部分：C组(齿轮)[S]
[11]赵昱东.国外大型矿用汽车研制与发展[J].有色矿山,2000,(2)：33-36
[12]蔡淑华 唐树为 宋镇廉.齿轮传动润滑及其用油[M].北京：中国石化出版社,1998,9
[13]刘瑞堂.机械零件失效分析[M].哈尔滨工业大学出版社,2003,9
[14]朱旬 秦剑秋等.润滑方式对低速重载齿轮磨损性能的影响[J].润滑与密封,1997,(1)：13-14
[15]马鸣 李光谨.柴油机齿轮失效分析[J].柴油机设计与制造,2007,(2)：35－39
[16]陈一永 张家玺.汽车变速器齿轮副磨损分析及改善措施[J].润滑与密封,2006,8(8)：181-182
[17]王成焘 姚振强 陈铭.汽车摩擦学[M].上海：上海交通大学出版社,2002
[18]林子光 徐大耐.齿轮传动的润滑[M].1980,11
[19]GB/T265-1988石油产品运动粘度测定法和动力粘度计算法[S]
[20]郎全栋 董元虎.汽车运行材料[M].北京：人民交通出版社,2002
[21]李敏 迟克彬等.润滑油基础油生产工艺现状及发展趋势[J].炼油与化工,2009.(4)：5-7
[22]S J Miller. Process for producing lube oil from solvent refined oils by isomerization over a silicoal uminophosphate catalyst: US,5413695[P].1995,5
[23]张德义.加快我国加氢工艺和技术的发展[R].加氢协作组第四届年会报告,2001：1-9
[24]Xiao J R, Winslow P, James Z N. Base stock lube oil manufacturing process:WO,9802502[P].1996,1
[25]祖德光.进一步发展我国润滑油基础油生产技术的意见[J].润滑油,1999,14(2)：4-9
[26]章文译.亚洲Ⅱ/Ⅲ类基础油需求将增长[J]石油化工要闻,2009,(1)：7-9
[27]GB/T12583－1998润滑剂极压抗磨性能测定法(四球法)[S]
[28]GB/T5096-1985石油产品铜片腐蚀试验法[S]
[29]GB/T7305-2003石油和合成液水分离性测定法[S]
[30]张景河.现代润滑油与燃料添加剂[M].北京：中国石化出版社,1991
[31]李云雁 胡传荣.试验设计与数据处理[M].北京：化学工业出版社,2005,3
[32]马成良 张海军等.现代试验设计优化方法及应用[M].河南：郑州大学出版社,2007,9
[33]王娇.甲醇汽油发动机润滑油研究[D].长安大学,硕士学位论文,2008,5
[34]GB/T 3142-82,润滑剂承载能力测定法(四球法)[S]
[35]董元虎,尹兴林,冯豫川.天然气/汽油两用燃料发动机润滑油优化试验[J].长安大学学报(自然科学版),2007(2)：94－98