1、Designation: D 5182 97 (Reapproved 2002)e1An American National StandardStandard Test Method forEvaluating the Scuffing Load Capacity of Oils (FZG VisualMethod)1This standard is issued under the fixed designation D 5182; the number immediately following the designation indicates the year oforiginal a
2、doption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.e1NOTEWarning notes were placed in the text editorially in May 2002.1. Scope1.1
3、This test method, the Forschungstelle fr Zhnrder undGetriebebau (Research Site for Gears and Transmissions)Visual Method, commonly referred to as the FZG VisualMethod, is intended to measure the scuffing load capacity ofoils used to lubricate hardened steel gears. Scoring, a form ofabrasive wear, is
4、 also included as a failure criteria in this testmethod. It is primarily used to assess the resistance to scuffingof mild additive treated oils such as industrial gear oils,transmission fluids, and hydraulic fluids. High EP type oils, forexample, those oils meeting the requirements of API GL-4 andGL
5、-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 thestandard. The values in parentheses are for information only.1.3 This standard does not purport to address all of thesafety conce
6、rns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use. For specific safetyinformation, see Section 7, Section 8, 9.2, and 9.3.1.2. Refere
7、nced Documents2.1 ASTM Standards:D 235 Specification for Mineral Spirits (Petroleum Spirits)(Hydrocarbon Dry Cleaning Solvent)2G 40 Terminology Relating to Erosion and Wear32.2 DIN Standard:4DIN 51 354 Teil 1: FZG Zahnrad Verspannungs PrfmaschineAllgemeine Arbeitsgrundlagen3. Terminology3.1 Definiti
8、ons:3.1.1 scratchesthe result of mechanical removal or dis-placement, or both, of material from a surface by the action ofabrasive particles or protuberances sliding across the surfaces.3.1.2 abrasive wearwear due to hard particles or hardprotuberances forced against and moving along a solid surface
9、.3.1.3 adhesive wear (scuffng)wear due to localized bond-ing between contacting solid surfaces leading to materialtransfer between the two surfaces or loss from either surface.3.1.4 scoringa severe form of wear characterized by theformation of extensive grooves and scratches in the direction ofslidi
10、ng.3.2 Definitions of Terms Specific to This Standard:3.2.1 polishinga mild form of abrasive wear resulting inminor loss of material and typically characterized by a smoothfinish and removal of all or part of the initial grinding marks.4. Summary of Test Method4.1 An FZG Gear Test Machine is operate
11、d at constantspeed (1450 rpm) for a fixed period (21700 revolutionsapproximately 15 min) at successively increasing loads untilthe failure criteria is reached; the initial oil temperature is 90Cbeginning at load stage four (see Table 1). The test gears areexamined initially and after the prescribed
12、duration at eachload stage for cumulative damage (scuffing) to the gear toothflanks.5. Significance and Use5.1 The transmission of power in many automotive andindustrial applications is accomplished through the use ofgeared systems. At higher operating speeds it is well knownthat the lubricant/addit
13、ive system can be a significant factor inpreventing scuffing (adhesive wear) damage to gears. This testmethod is used to screen the scuffing load capacity of oils usedto lubricate spur and helical (parallel axis) gear units.5.2 The test method is limited by the capabilities of theequipment (test rig
14、 and gears), and the performance observedmay not directly relate to scuffing performance observed withspiral bevel on hypoid gearing. It is also limited to discrimi-nating between oils with mild EP additives or less. Lubricantscontaining higher levels of additives, that is, those meeting therequirem
15、ents of API GL4 or GL5, generally exceed the1This test method is under the jurisdiction of ASTM Committee D02 onPetroleum Products and Lubricants and is the direct responsibility of SubcommitteeD02.L0.11 on Tribological Properties of Industrial Fluid Lubricants.Current edition approved Apr. 10, 1997
16、. Published October 1997. Originallypublished as D 5182 91. Last previous edition D 5182 91.2Annual Book of ASTM Standards, Vol 06.04.3Annual Book of ASTM Standards, Vol 03.02.4Available from Deutsches Institut fr Normung e. V., Beuth Verlag GmbH10772 Berlin, Federal Republic of Germany.1Copyright A
17、STM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.maximum load capacity of the test rig and, therefore, cannot bedistinguished for their scuffing capabilities by this test method.6. Apparatus6.1 FZG Gear Test Rig:6.1.1 A more complete description
18、of the test rig andoperating instructions may be found in the instruction manualsavailable from the manufacturers/suppliers identified in A2.1.2.6.1.2 The FZG gear test rig utilizes a recirculating powerloop principle, also known as a four-square configuration, toprovide a fixed torque (load) to a p
19、air of precision test gears. Aschematic of the test rig is shown in Fig. 1a and Fig. 1b. Thedrive gearbox and the test gearbox are connected through twotorsional shafts. Shaft 1 contains a load coupling used to applythe torque through the use of known weights hung on theloading arm.6.1.3 The test ge
20、arbox contains heating and cooling ele-ments to maintain and control the temperature of the oil. Atemperature sensor located in the side of the test gearbox isused to control the heating/cooling system as required by thetest operating conditions.6.1.4 The test rig is driven by an electric motor capa
21、ble ofdelivering at least 5.5 kW (7.4 HP) at 1440 rpm.6.2 Test GearsThe test gearset (pinion and gear) arecommonly referred to as type A profile and conform to theinformation supplied in Table 2. A schematic of the profile isshown in Fig. 2. Both sides of the test gear flanks can be usedfor testing
22、purposes since only one side is loaded during theevaluation. It should be noted that these gears have beendesigned with a large profile modification which increases theirsensitivity to adhesive wear modes of failure.6.3 Timer MechanismA suitable timer or revolutioncounter must be used to control the
23、 number of revolutionsduring each load stage of the test. The timer should be capableof shutting down the test rig at the appropriate time.6.4 Hot PlateA hot plate or suitable heating device isrequired to warm the gears to 60 to 80C for assembly on to theshafts.7. Reagents and Materials7.1 Mineral S
24、pirits (Stoddard Solvent).(WarningCombustible. Vapor harmful. Keep away from heat, sparks,and open flame (see Annex A1.1). Type I conforming to therequirements outlined in Specification D 235.)TABLE 1 Standard Load Stages for FZG Scuffing TestLoadStageTorqueonPinionToothNormalForceHertzianContactPre
25、ssureTotalWorkTrans-mittedLoad ClutchLoaded withA(Nm) (N) (N/mm2) (kWh)1 3.3 99 146 0.19 H12 13.7 407 295 0.97 H23 35.3 1044 474 2.96 H2+K4 60.8 1799 621 6.43 H2+K+W15 94.1 2786 773 11.8 H2+K+W1+W26 135.5 4007 929 19.5 H2+.+W37 183.4 5435 1080 29.9 H2+.+W48 239.3 7080 1232 43.5 H2+.+W59 302.0 8949 1
26、386 60.8 H2+.+W610 372.6 11029 1539 82.0 H2+.+W711 450.1 13342 1691 107.0 H2+.+W812 534.5 15826 1841 138.1 H2+.+W9AWhere:H1 = load lever H1 (light),H2 = load lever H2 (heavy),K = support rod for weights, andW1 to W9 = weights for loading (supplied with test rig).A. Diagram of a Typical FZG Test RigB
27、. Schematic Section of an FZG Test RigFIG. 1 FZG Test RigTABLE 2 Detail Data for the “A” Profile GearsParameter Value UnitsCenter Distance 91.5 mmEffective Tooth Width 20.0 mmPitch Circle Diameter:Pinion 73.2 mmGear 109.8 mmTip Diameter:Pinion 88.7 mmGear 112.5 mmModule 4.5 mmNumber of Teeth:Pinion
28、16Gear 24Profile ModificationPinion/Gear 0.8635/0.5103Pressure AngleNormal/Working 20/22.5 degreesHardnessRockwell C 60 to 62Surface RoughnessRa 0.3 to 0.7 mD 5182 97 (2002)e128. Hazards8.1 (WarningThis test method involves the use of highlyloaded gears and shafts turning at high speeds. Appropriate
29、precautions must be taken to protect personnel (see AnnexA1.2).)9. Preparation of Apparatus9.1 Test GearsThe test gears are cleaned with Stoddardsolvent to remove all of the protective coating. In some casesthis requires brushing (soft bristle brush) of the gears to removeexcess amounts of the coati
30、ng material. Each gear is to be driedand then visually inspected for any evidence of damage orcorrosion on the tooth flank surfaces. In such cases wheredamage or corrosion is found these gears should not be used fortest purposes.9.2 Test GearboxThe test gearbox and bearings shall bewashed thoroughly
31、 with Stoddard solvent to remove theprevious test oil. (This can be done at the termination of a testafter the oil has been drained from the gearbox and prior todisassembling the test gears.) It is recommended that thegearbox be flushed twice with Stoddard solvent to remove alltraces of the previous
32、 test oil. After draining the solvent fromthe test gearbox the unit should be air dried to remove all tracesof solvent. (WarningBe sure the gearbox temperature hasdecreased below 60C prior to adding the Stoddard solvent.)9.3 Assembly of Test GearsThe test gears, spacers, andbearings are heated on a
33、hot plate or other device to approxi-mately 60 to 80C. Install the test gears on the shafts with thealignment marks in the position shown in Fig. 3. Complete theassembly of the gearbox with the appropriate spacers, bearings,and front cover.9.3.1 It has been found critical for correct results that th
34、etest gears are properly aligned on their respective shafts.(WarningMisalignment can lead to erratic or lower failloads due to uneven distribution of the load on the tooth.)9.4 Test OilAdd 1.25 L of test oil to the test gearbox(approximately to the centerline of the shafts).9.5 Final AssemblySecure
35、the top of the test gear case inplace with the 6 bolts. Connect the heater to its power source.10. Procedure10.1 Prior to starting a test apply load stage 12 to the systemfor 2 to 3 min without running the motor (Table 1). This is doneto ensure all clearances are in the correct working position.Remo
36、ve all weights before proceeding to 10.2.10.2 With the test gears mounted, load clutch locking pin inplace, and load clutch bolts loose, apply load stage 1(see Table 1) to the loading clutch. Tighten the bolts of the loadclutch, (the load clutch bolts should be tightened in a star orcrosswise patter
37、n to a torque of 100 Nm) remove the weightassembly and lever arm, and remove the load clutch arrestingbolt. Start the motor (1450 rpm) and turn on the heaters. Runfor 15 min (21700 revolutions), then stop motor.10.3 Insert the locking pin and loosen the load clutch boltsso that the load is removed f
38、rom the shafts. Apply load stage 2according to Table 1. Tighten the bolts of the load clutch, (theload clutch bolts should be tightened in a star or crosswisepattern to a torque of 100 Nm) remove the weights and leverarm, and remove the load clutch locking pin. Start the motor(1450 rpm) and turn on
39、the heaters. After 15 min (21700revolutions) stop the motor. Repeat this sequence for load stage3.10.4 Beginning with load stage 4, and all subsequent loadstages, the procedure is the same as outlined in 10.2 except thatthe oil temperature must be between 90 and 93C prior tostarting the motor.10.4.1
40、 At the end of load stage 4 and each subsequent loadstage, record the final temperature and inspect the pinion gearfor damage without removing the gears from the gearbox.Record the type and amount of damage observed on the gearflank in accordance with the terminology described in Section3 and from t
41、he examples shown in Fig. 4. The inspection iscarried out without the aid of magnification. It is recommendedthat an inspection sheet such as that shown in Fig. 5 be used torecord the damage observed after each load stage.10.4.2 The failure criteria is reached when the summed totalwidth of scuffing
42、(adhesive wear) or scoring damage from all16 teeth is estimated to equal or exceed one gear tooth width,that is, 20 mm. This is then reported as the failure load stage.Examples of acceptable and unacceptable distress levels areshown in Annex A3.10.5 The test is continued until the failure load stage
43、 isreached. If the failure criteria has not been met after complet-ing load stage 12, the test is terminated at that time.11. Report11.1 Report the failure load stage according to the criteriaoutlined in 10.4.2. If the criteria was not met at the end of loadstage 12 then report the failure load stag
44、e as greater than 12.FIG. 2 Schematic of A Profile Test GearsFIG. 3 Marking and Mounting of Test GearsD 5182 97 (2002)e1312. Precision and Bias12.1 PrecisionThe precision of this test method as deter-mined by the statistical examination of the interlaboratory testresults is as follows:12.1.1 Repeata
45、bilityThe difference between successiveresults obtained by the same operator with the same apparatusunder constant operating conditions on identical test materialswould, in the long run, in the normal and correct operation ofthe test method exceed the following value in only one case intwenty.Repeat
46、ability 5 2 (1)12.1.2 ReproducibilityThe difference between two singleand independent results obtained by different operators work-ing in different laboratories on identical material would in thelong run exceed the following values only in one case intwenty.Reproducibility 5 2 (2)NOTE 1The values in
47、 the statements were determined in a cooperativeprogram conducted by the FZG Study Group and reported at the June1989 meeting of L0.11.10 of Committee D2.FIG. 4 Examples of Gear Distress in the FZG TestD 5182 97 (2002)e1412.2 BiasSince there is no accepted reference materialsuitable for determining
48、the bias for the procedure in this testmethod, bias has not been determined.13. Keywords13.1 E.P. oils; extreme pressure; FZG; gear oil; gear scuff-ing; hydraulic fluids; spur gear; transmission fluidsANNEXES(Mandatory Information)A1. PRECAUTIONARY STATEMENTSA1.1 Mineral Spirits SolventCautionCombus
49、tible.Vapor harmful.Keep away from heat, sparks and open flame.Keep container closed.Use with adequate ventilation.Avoid breathing vapor or mist.Avoid prolonged or repeated contact with skin.A1.2 General PrecautionsPersonal Injury HazardMachinery guards are suppliedwith the FZG test machine to protect personnel from hazardsassociated with rotating machinery. These guards must beproperly installed before operating the equipment.Electrical HazardThe electrical connections for the drivemotor and heater must be of approved design and constru
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