1、Designation: D5182 97 (Reapproved 2014)Standard Test Method forEvaluating the Scuffing Load Capacity of Oils (FZG VisualMethod)1This standard is issued under the fixed designation D5182; the number immediately following the designation indicates the year oforiginal adoption or, in the case of revisi
2、on, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.1. Scope1.1 This test method, the Forschungstelle fr Zhnrder undGetriebebau (Research Site for Gears and Transmiss
3、ions)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 also included as a failure criteria in this testmethod. It is primarily used to assess the resistance
4、 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, generally exceed the capacity of the test rig and,therefore, cannot be differentiated with this te
5、st method.1.2 The values stated in SI units are to be regarded asstandard. No other units of measurement are included in thisstandard.1.3 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to esta
6、blish 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, 9.3.1, and AnnexA1.2. Referenced Documents2.1 ASTM Standards:2D235 Specification for Mineral Spirits (Petroleum Spiri
7、ts)(Hydrocarbon Dry Cleaning Solvent)G40 Terminology Relating to Wear and Erosion2.2 DIN Standard:3DIN 51 354 Teil 1 FZG Zahnrad Verspannungs PrfmaschineAllgemeine Arbeitsgrundlagen3. Terminology3.1 Definitions:3.1.1 See also Terminology G40.3.1.2 abrasive wearwear due to hard particles or hardprotu
8、berances forced against and moving along a solid surface.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
9、extensive grooves and scratches in the direction ofsliding.3.1.5 scratchesthe result of mechanical removal ordisplacement, or both, of material from a surface by the actionof abrasive particles or protuberances sliding across the sur-faces.3.2 Definitions of Terms Specific to This Standard:3.2.1 pol
10、ishinga 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 operated at constantspeed (1450 rpm) for a fixed period (21700 revolut
11、ionsapproximately 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 duration at eachload stage for cumulative damage (scuffing) to
12、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 known1This test method is under the jurisdiction of ASTM Committee D02 onPetroleum Products,
13、 Liquid Fuels, and Lubricants and is the direct responsibility ofSubcommittee D02.L0.11 on Tribiological Properties of Industrial Fluids andLubricates.Current edition approved Jan. 1, 2014. Published February 2014. Originallyapproved in 1991. Last previous edition approved in 2008 as D518297(2008).D
14、OI: 10.1520/D5182-97R14.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.3Available from Beuth Verlag GmbH (DI
15、N- DIN Deutsches Institut furNormung e.V.), Burggrafenstrasse 6, 10787, Berlin, Germany.Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States1that the lubricant/additive system can be a significant factor inpreventing scuffing (adhesive wea
16、r) 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 and gears), and the performance observedmay not directly relate to scuffi
17、ng 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 therequirements of API GL4 or GL5, generally exceed themaximum load capacity of the t
18、est 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 of the test rig andoperating instructions may be found in the instruction manualsavailable from the manufacturers/suppliers identifie
19、d inA2.1.2.6.1.2 The FZG gear test rig utilizes a recirculating powerloop principle, also known as a four-square configuration, toprovide a fixed torque (load) to a pair of precision test gears. Aschematic of the test rig is shown in Fig. 1A and Fig. 1B. Thedrive gearbox and the test gearbox are con
20、nected 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 gearbox contains heating and cooling ele-ments to maintain and control the temperature of the oil. Atemperature sensor located in the si
21、de 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 capable ofdelivering at least 5.5 kW at 1440 rpm.6.2 Test GearsThe test gearset (pinion and gear) arecommonly referred to as type A profil
22、e 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 purposes since only one side is loaded during theevaluation. It should be noted that these gears have beenTABLE 1 Standard Load Stages for FZG
23、Scuffing TestLoadStageTorqueonPinionToothNormalForceHertzianContactPressureTotalWorkTrans-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 18
24、3.4 5435 1080 29.9 H2+.+W48 239.3 7080 1232 43.5 H2+.+W59 302.0 8949 1386 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
25、loading (supplied with test rig).A. Diagram of a Typical FZG Test RigB. 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 Di
26、ameter:Pinion 88.7 mmGear 112.5 mmModule 4.5 mmNumber of Teeth:Pinion 16Gear 24Profile ModificationPinion/Gear 0.8635/0.5103Pressure AngleNormal/Working 20/22.5 degreesHardnessRockwell C 60 to 62Surface RoughnessRa 0.3 to 0.7 mD5182 97 (2014)2designed with a large profile modification which increase
27、s theirsensitivity to adhesive wear modes of failure.6.3 Timer MechanismA suitable timer or revolution coun-ter must be used to control the number of revolutions duringeach load stage of the test. The timer should be capable ofshutting down the test rig at the appropriate time.6.4 Hot PlateA hot pla
28、te or suitable heating device isrequired to warm the gears to 60 to 80C for assembly on to theshafts.7. Reagents and Materials7.1 Mineral Spirits (Stoddard Solvent). (WarningCombustible. Vapor harmful. Keep away from heat, sparks,and open flame (see Annex A1.1). Type I conforming to therequirements
29、outlined in Specification D235.)8. Hazards8.1 (WarningThis test method involves the use of highlyloaded gears and shafts turning at high speeds. Appropriateprecautions must be taken to protect personnel (see AnnexA1.2).)9. Preparation of Apparatus9.1 Test GearsThe test gears are cleaned with Stoddar
30、dsolvent to remove all of the protective coating. In some casesthis requires brushing (soft bristle brush) of the gears to removeexcess amounts of the coating material. Each gear is to be driedand then visually inspected for any evidence of damage orcorrosion on the tooth flank surfaces. In such cas
31、es wheredamage or corrosion is found these gears should not be used fortest purposes.9.2 Test GearboxThe test gearbox and bearings shall bewashed thoroughly 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 gea
32、rbox and prior todisassembling the test gears.) It is recommended that thegearbox be flushed twice with Stoddard solvent to remove alltraces of the previous test oil. After draining the solvent fromthe test gearbox the unit should be air dried to remove all tracesof solvent. (WarningBe sure the gear
33、box temperature hasdecreased below 60C prior to adding the Stoddard solvent.)9.3 Assembly of Test GearsThe test gears, spacers, andbearings are heated on a 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
34、. 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 thetest gears are properly aligned on their respective shafts.(WarningMisalignment can lead to erratic or lower failloads due to uneven distributi
35、on 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 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
36、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.Remove 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 l
37、oad 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 pattern 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
38、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 from the shafts. Apply load stage 2according to Table 1. Tighten the bolts of the load clutch, (theload clutch bolts should be tightened in a sta
39、r 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 the heaters. After 15 min (21700revolutions) stop the motor. Repeat this sequence for load stage3.10.4 Beginning with load stage 4, and all subs
40、equent 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 At the end of load stage 4 and each subsequent loadstage, record the final temperature and inspect the pinion gearfor damage without removing t
41、he gears from the gearbox.FIG. 2 Schematic of A Profile Test GearsFIG. 3 Marking and Mounting of Test GearsD5182 97 (2014)3Record the type and amount of damage observed on the gearflank in accordance with the terminology described in Section3 and from the examples shown in Fig. 4. The inspection isc
42、arried 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 (adhesive wear) or scoring damage from all16 te
43、eth 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 isreached. If the failure criteria has not bee
44、n 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 stage as greater than 12.FIG. 4 Examples of Gear Di
45、stress in the FZG TestFIG. 5 Sample Inspection SheetD5182 97 (2014)412. 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 RepeatabilityThe difference between successiveresults obtain
46、ed 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.Repeatability 5 212.1.2 ReproducibilityThe difference betwe
47、en 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 2NOTE 1The values in the statements were determined in a cooperativeprogram condu
48、cted by the FZG Study Group and reported at the June1989 meeting of L0.11.10 of Committee D02.12.2 BiasSince there is no accepted reference materialsuitable for determining the bias for the procedure in this testmethod, bias has not been determined.13. Keywords13.1 E.P. oils; extreme pressure; FZG;
49、gear oil; gear scuff-ing; hydraulic fluids; spur gear; transmission fluidsANNEXES(Mandatory Information)A1. WARNING STATEMENTSA1.1 Mineral Spirits SolventA1.1.1 CautionCombustible.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 PrecautionsA1.2.1 Personal Injury Hazard Machinery guards aresupplied with the FZG test machine to protect personnel fromhazards associated with rotating machinery. Th
