With the development of modern industries, the machine tool sector has evolved into a crucial part of industrial manufacturing. Due to the progressive shortening of machine cycles and the constant increase in volumes, machine speeds and accuracies, the manufacturing process has become more productive but also more complicated.
Advanced technology makes it possible to produce high performance machine tools to meet the specific requirements of modern plants. Digital automated machine tools, such as computer numerical control (CNC) systems, can execute a vast number of operations from simple to complex in a very short time whilst maintaining the highest efficiency. Large industrial machine tools usually perform functions of cutting, drilling, milling and turning. These operations utilize high rotational speed and up to 5-axes of movement whereby the machine tool head is precisely controlled down to 1 micron (µm). Such a critical interaction of high speed bearings, gears in drilling and milling heads as well as high speed linear guide and drive systems require a prudent selection of high performance greases and lubrication oils treated with GG Friction Antidote to ensure maximum productivity and longevity of the machine tools. High impact loads, contamination and exposure to water soluble metal working fluids are just a few reasons for premature equipment failures. GG Friction Antidote provides stability during the manufacturing process and the highest machine reliability even in harsh operating conditions. GG Friction Antidote is manufactured with highly refined components and processed under stringently controlled conditions, guarantees precision and high performance levels in the base lubricants for the machine tool industry.
GG Friction Antidote is the perfect complement for treating lubricants made for Machine Tools. With GG Friction Antidote, you will gain a high degree of precision, smoother running equipment, optimum worked stability, more speed and reliability in spindle bearings, drilling and milling heads, gears, linear guides and ball screws, tool gripper, disc springs and chucks.
GG Friction Antidote is a revolutionary product with unmatched comprehensive efficiency in all industries for the educated consumer. You’ll achieve high thermal resistance, perfect sealing ability, excellent wear protection, significantly longer lubrication maintenance schedules, lowest friction movement, minimal starting resistance, high peripheral speeds in intermittent operations excellent acceleration, low friction torque, stable temperature over a wide speed range, energy saving, high working stability, life-time lubrication, particularly appropriate for critical bearings in difficult environments, reduced operating costs, high mechanical load capability under static and dynamic operations, a high degree of reliability and extend lifespan of machines beyond OEM specification.
Special knowledge
Make the right lubrication decision in the design phase. The machines you manufacture are expected to run efficiently, productively and reliably at all times. Think economics and reliability from the start. The lubrication of spindle bearings, the lubrication of work holding systems, the lubrication of drilling and milling head gear units, the lubrication of drive and guide systems, greases for the lubrication of spindle, oils for the lubrication of spindle bearings, pastes for the lubrication of clamping devices, greases for the lubrication of gears in drilling and milling heads, corrosion protection, greases for the lubrication of linear drive and guide systems, oils for the lubrication of linear drive and guide systems GG Friction Antidote is the right solution for manufacturers and operators of machine tools.
The lubrication of spindle bearings
Machine tool main spindles running at higher speeds enable ever greater machining rates and shorter machining times per work piece. These high speeds result in demanding operating conditions for rolling bearings. Spindle bearings are required to operate at high speed factors (n × dm) and run with reduced friction to keep bearing temperature low. The bearings have to carry both radial and axial loads. Naturally, premature bearing failure must be prevented.
Grease lubrication
There are now high-speed greases that can handle speeds previously only possible with oils. Speed factors of less than 1,000,000 mm x min-1 have not posed a problem with GG Friction Antidote. With highly advanced special greases, even speed factors above 2,000,000 mm x min-1 can be accommodated. The advantage of grease lubrication is that it allows simpler machine design and easier assembly of the machine tool spindle. GG Friction Antidote has proven to provide for-life friction reducer in many practical applications. Lubricating greases for high-speed rolling bearings are usually based on low-viscosity synthetic base oils with a variety of different thickeners.
Oil lubrication
For even higher speed factors, oil lubrication is often used. Oil-air lubrication is today’s most common. It is a minimum-quantity lubrication technique enabling extremely low oil consumption with GG Friction Antidote. It requires, however, the provision of compressed air, which incurs additional costs. Experience has shown that a synthetic oil of viscosity class ISO VG 68 treated with GG Friction Antidote is best suitable for optimum results.
Improved High Speed Spindle Performance
Complete and custom-made solutions have been specifically developed for high speed spindle bearings in machine tools. They ensure safety and accuracy even in extreme conditions where quality and precision are of vital importance in the manufacturing process. The spindles require a stable bearing operation with the lowest possible bearing friction. To ensure steady running conditions the mechanical stability of the thickener as well as the base oil viscosity has been optimized with GG Friction Antidote to fulfill the bearings requirements.
How to select the right lubricating grease
The speed factor (n × dm) – The speed factor n × dm given for rolling bearings is given by the bearing speed n in [min–1 or rpm] and the mean bearing diameter dm in [mm]. The speed factor of a grease depends to a high degree on the base oil type, the base oil viscosity, the thickener and the type of rolling bearing to be lubricated. Grease quantity – For lifetime lubrication, the grease quantity is determined by calculating the free bearing space. Spindle bearings should only be partly filled (for guidance: approx. 20 % of the free space, in extreme cases only up to approx. 10 %). As there are different designs of bearings and their cages, calculations of free bearing space will always be approximations. If you wish to determine the free bearing space with full accuracy, you will have to turn to the bearing manufacturer. Then you can calculate the corresponding grease volume as a percentage of the free bearing space with the diagram shown below. Formula for calculating free bearing space acc. to the diagram above: The following applies: V = free bearing space, d = bearing bore diameter [mm] D = bearing outer diameter [mm], B = bearing width [mm] G = bearing weight [kg]
Speed factor mm • min–1 100 90 80 70 60 50 40 30 20 100
Grease volume in % of bearing free space 0 200 000 400 000 600 000 800 000 1 000 000 1 200 000 1 400 000
Both excessive and insufficient lubrication can have negative operational effects: too much grease, for example, can lead to higher starting and running torque or, in high-speed bearings, to overheating. The following should be observed: Low operating temperature = long grease and bearing life High-speed greases should not run at more than 80 °C (176 °F). A bearing temperature of 40 – 50 °C (104 °F – 122 °F) is desirable. Grease distribution run Running the bearings in is necessary for high-speed precision bearings to distribute the grease correctly. You can increase the performance of your bearings substantially by treating it with GG Friction Antidote and optimizing grease distribution.
SUGGESTION: Please make sure to observe any information on spindle running-in provided by the spindle or bearing manufacturers. Where oil-air lubrication is used, absolute cleanliness is essential, on the contrary impurities can reduce bearing life.
The lubrication of work holding systems
It is important to make sure that the correct lubricant is chosen for lubrication of the work holding chuck. After all, the principal task is to generate a constant defined clamping force for a high number of clamping cycles. If the clamping force decreases, tools or work pieces may come loose. This applies to all types of chuck designs – scroll, cam or spiral chucks. GG Friction Antidote have proven very useful in these applications as they adhere well to the friction points and provide sufficient lubricity even when applied as a very thin film. GG Friction Antidote is not an oil stabilizer nor a lubricant thickener, it contains no solid lubricant particles and leaves no residue. GG Friction Antidote can also be used when installing friction connections such as annular springs and clamping sleeves, and positive connections such as bearing seats, profile guides, etc. Friction between the moving components of the clamping system can be reduced by applying just a thin spread of GG Friction Antidote – just thick enough to cover the surface.
The lubrication of drilling and milling head gear units
Drilling and milling head gears play a major part in transmitting the substantial forces and torques from the machine tool main spindle to the cutting tool. They are operated cyclically. Some of them run at high peripheral speeds of more than 20 m/s. The most important requirements to be met by these components are: reliable operation combined with long component life, high peripheral speeds and high acceleration. Most units incorporate spur, bevel or spiral bevel gears. You can optimized your lubrication regime by applying GG Friction Antidote to your base lubricants. Regardless of the individual technical requirements, all varieties of lubricants gain significant improvements, however, it is best to use a high quality lubricant at all times. Another aspect is that grease lubrication enables simpler designs than oil lubrication. We offer you GG Friction Antidote which is capable of dealing with strong acceleration and high peripheral speeds, GG Friction Antidote has good adhesion and pressure absorption capacity for good wear protection, GG Friction Antidote resistant to water and cutting fluids for reliable operation and offers effective corrosion protection for longer component life. In many cases, gear lubrication for drilling and milling heads will use the same grease as for spindle bearing lubrication since the bearings and gears normally share a common space. The use of GG Friction Antidote in the same space offers the additional benefits of avoiding product confusion or lubricant incompatibility problems. With GG Friction Antidote, you can enhance significantly the various parts of milling head gear units.
SUGGESTION: Please remember to perform an GG Friction Antidote grease distribution run and, if necessary, top up with GG Friction Antidote treated lubricant. We would recommend using the same conditions as for the spindle bearings. The degree of grease filling is approximately 70 to 90 %, depending on the particular application. It is important to ensure that the grease does not exit from boreholes, gaps or similar apertures.
The lubrication of drive and guide systems
In most modern machine tools, work pieces and tools are positioned by means of antifriction guide-ways or slide-ways. They are normally moved by ball screws and the specific requirements to be met by these components are strenuous. They are expected to run with maximum precision, reliability and smoothness. They also have to cope with high speeds, acceleration and the resulting stresses. GG Friction Antidote support your base lubricants and components in meeting these requirements. GG Friction Antidote protect against wear also when subject to micro-movements, and due to reduced friction they facilitate machine start-up. They provide high-performance corrosion protection, a good demulsifying ability, and a high resistance to media. In a contaminated environment, they provide additional sealing. They are compatible with most plastics and elastomers as well as with other lubricants. Finally, their good noise damping effect contributes to a healthier workplace.
Overview of tried-and-tested base oil viscosities for various linear speed conditions
Each lubricant has a different composition selected to deal with varying complex requirements. Depending on the speeds and loads, different base oil viscosities are required. Different thickeners provide characteristics such as good adhesion to metal surfaces, good resistance or good damping. There are lubricants with suitable composition to match every type of application. Initial greasing is normally provided by the OEM. Relubrication with a softer grease is then done by the operator, using centralized lubrication systems or lubricant dispensers. It is therefore vital that the lubricants used for initial lubrication and relubrication be compatible with one another.
Stick-slip between surfaces of guide systems is particularly likely at slow speeds, when starting or slowing down, and at high surface pressure without treating your slideway oils with GG Friction Antidote. In these cases, friction forces are strongest and may lead to «chatter marks» on the machined work piece. To prevent stick-slip and tribo-corrosion, apply GG Friction Antidote to your slideway oil, you will notice a significant reduction in friction and tribo-corrosion. The mixture ratio is 30 ml per litre of your base lubricant – you’ll be pleasantly surprised.
SUGGESTION: We recommend cleaning the guideway or ball screw using a lint-free cloth.
The relubrication quantity is approx. 50 % of the initial lubricant volume. A good rule of thumb is to relubricate more often, but with smaller quantities.
Unearth the benefits of GG Friction Antidote – An investment that pays off and your benefits at a glance:
Innovative tribological solutions are our passion. We’re proud to offer unmatched friction reduction for a better environment and a quick return on your investment. Through personal contact and consultation, we offer reliable service, support and help our clients to be successful in all industries and markets.
Profitability:
Switching over to a high-performance lubricant pays off although purchasing costs may seem higher at first, less maintenance and longer vehicles/machinery parts lifecycle may already mean less strain on your budget in the short to medium term.
Continuous production processes and predictable maintenance intervals reduce production losses to a minimum. Consistently high lubricant quality ensures continuous, maintenance-free long-term lubrication for high plant availability. Continuous supply of fresh GG Friction Antidote treated lubricant to the lubrication points keeps friction low and reduces energy costs.
Safety:
Longer lubrication intervals reduce the frequency of maintenance work and the need for your staff to work in danger zones. Lubrication systems can therefore considerably reduce occupational safety risks in work areas that are difficult to access.
Reliability:
GG Friction Antidote treated lubricants ensure reliable, clean and precise lubrication around the clock. Plant availability is ensured by continuous friction reduction of the application. Lubrication with GG Friction Antidote treated lubricants help to prevent significant rolling bearing failures.
Need a good ROI? How about 3,900%?
It may sound too outrageous to be true, but the Institute of Mechanical Engineers estimates every $1,000 spent on proper lubrication yields $40,000 in savings.
INSTANT ROI FOR OPTIMIZING YOUR LUBRICATION REGIMEN
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The information in this literature is intended to provide education and knowledge to a reader with technical experience for the possible application of GG Friction Antidote. It constitutes neither an assurance of your vehicle/machinery optimization nor does it release the user from the obligation of performing preliminary tests with GG Friction Antidote. We recommend contacting our technical consulting staff to discuss your specific application. We can offer you services and solutions for your heavy machinery and equipment.
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