Maya Ellison
Plastic gears require regular maintenance and lubrication to ensure optimal performance and longevity. While some believe that plastic components do not require lubrication or need special lubricants, this is a misconception. Lubrication is essential for reducing friction and wear and can significantly extend the lifespan of plastic gears. When choosing a lubricant for plastic gears, compatibility is crucial to prevent damage to the plastic. Various lubricants, such as silicone-based, mineral oil-based, and synthetic options, are available and suitable for different applications. This guide will explore the best practices for maintaining and lubricating plastic gears, ensuring they operate smoothly and efficiently.
| Characteristics | Values |
|---|---|
| Cleaning compound | Isopropyl alcohol |
| Cleaning tools | Hard bristle toothbrush |
| Lubricant consistency | NLGI 1 or 0 |
| Lubricant type | Synthetic, mineral-oil-based, silicone-based, PFAE, SHC or PAO |
| Lubricant brand | Lubriplate, Mobil Unirex EP1, Superlube |
| Thickener ratio | 9:1 |
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What You'll Learn
Cleaning plastic gears
First, disassemble the gear parts and lay them out on a flat surface. This will allow you to access all areas of the gears for a thorough cleaning. If you are working with an old or vintage item, proceed with caution and refer to the instruction manual before disassembling.
Next, use a toothbrush to scrub the gears with a cleaning solution. A hard-bristled toothbrush is ideal for getting into the grooves of the gears. You can use isopropyl alcohol, as it effectively breaks down substances like grime, dust, dirt, and grease. Dip the toothbrush into the alcohol and scrub the front, back, sides, and teeth of each gear.
After scrubbing, allow the gears to sit in the solution for a minute to let some of the alcohol evaporate. Then, rinse the gears with cool water. Carry out this rinsing process in a sink for about 30 seconds, or until the smell of alcohol is no longer noticeable. Ensure that each gear is thoroughly rinsed and free of any residual product.
It is important to avoid using acetone products when cleaning plastic gears, as this harsh chemical can break down or warp the plastic layers. Additionally, only clean your gears when they appear visibly dirty.
By following these steps, you can effectively clean your plastic gears, ensuring their longevity and smooth operation.
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Choosing the right lubricant
Compatibility with Plastic
The most crucial factor in choosing a lubricant is ensuring its compatibility with the specific type of plastic used in the gears. Incompatible lubricants can cause stress cracking, discolouration, and a loss of dimensional stability or structural integrity in plastic parts. Manufacturers typically determine compatibility by evaluating changes in the physical properties of the plastic, including weight, volume, hardness, strength, and elongation, under various conditions. It is recommended to select a lubricant that falls within the manufacturer's allowable change limits, typically between 7% and 10%.
Lubricant Type
Different types of lubricants are available, and the right choice depends on the specific application. Silicone-based lubricants, such as PFAE, are compatible with a wide range of plastics and can operate within a wide temperature range. They are suitable for low-load applications. Mineral-oil-based lubricants are also compatible with most plastics and offer excellent performance at a reasonable cost. However, for high operating speeds, high temperatures, or long-term operations, synthetic lubricants like hydrocarbon (PAO) types are preferred. PAOs have high aging resistance and are compatible with most plastics, providing long-term lubrication within a broad temperature range.
Viscosity
The viscosity of the lubricant is another important consideration. High-viscosity oils, such as those with an ISO VG of 100 or higher, are recommended to prevent penetration and degradation of plastic materials. Lower viscosity oils may be used for lighter loads to prevent viscous drag, while higher viscosity oils are necessary for higher loads to maintain a lubricant film.
Additives
When choosing a lubricant, it is essential to consider the additives present. Solid additives like graphite and molybdenum disulfide should be avoided as they can penetrate and weaken plastic components. On the other hand, PTFE solid additives can be beneficial by providing dry lubrication and reducing startup friction. Extreme pressure (EP) additives, commonly used in metal lubrication, are not recommended for plastic gears.
Maintenance and Re-lubrication
Regular maintenance and inspection of plastic gears are necessary to ensure optimal performance. Re-lubrication intervals will depend on the specific application, the type of machine, the frequency of use, and the level of tension the machine is under. Larger gears, for instance, may require more frequent lubrication due to higher stress and longer operating hours. It is important to refer to the manufacturer's recommendations and guidelines for specific re-lubrication schedules and procedures.
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How often to lubricate
How often you should lubricate plastic gears depends on several factors. These include the type of machine running the gears, how often the device is used, and the level of tension the machine is under daily. Larger gears, for instance, are under higher stress and work longer hours, so they will need to be lubricated more often.
It is always a good idea to lubricate plastic components whenever possible because it reduces friction and wear, lowers power consumption, and increases the life of the part. Lubricated plastic sliding bearings, for example, last up to five times longer than non-lubricated ones.
However, it is important to choose the right lubricant for your plastic gears. Manufacturers typically recommend a suitable lubricant for their products. Incompatible lubricants can cause the plastic to develop stress cracking, become discoloured, or lose dimensional stability or structural integrity.
Lubricants based on silicone, perfluorinated PFAE, mineral oils, and synthetic hydrocarbons (SHC or PAO) typically work well with plastics. However, if your application requires high operating speeds, high temperatures, or long operation, synthetic lubricants such as hydrocarbon (PAO) types are a better choice. PAOs are compatible with most plastics, have high aging resistance, and offer long-term lubrication within a temperature range of -60º to 320ºF.
Silicone-based lubricants are also highly compatible and suitable for low load applications and a wide temperature range (-90º to 425ºF). They are a good choice if your machine operates at temperatures above 100 degrees Fahrenheit.
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Lubricant compatibility
To verify compatibility, manufacturers monitor changes in the physical properties of the plastic material when exposed to the lubricant. These properties include weight, volume, hardness, strength, and elongation. The allowable change in these properties is typically within a range of 7% to 10%. It is important to conduct these tests under the worst possible conditions, such as high temperatures and adverse environments, to ensure the lubricant's compatibility.
When choosing a lubricant for plastic gears, it is recommended to use synthetic lubricants with high ageing resistance for long-term applications. Mineral-oil-based lubricants are a good choice for most plastic applications as they offer excellent performance at a reasonable cost. However, they may not be suitable for high operating speeds, high temperatures, or long operations. In such cases, synthetic lubricants like hydrocarbon (PAO) types are preferred. PAOs are compatible with most plastics and offer long-term lubrication within a wide temperature range of -60°F to 320°F.
Silicone-based lubricants are also highly compatible with plastics and are suitable for low load applications and a wide temperature range, typically from -90°F to 425°F. For extreme temperature applications, PFAE lubricants can be used, with a temperature range of up to 500°F. However, due to their high cost, PFAE lubricants should be considered only when necessary.
It is important to avoid petroleum-based lubricants, as they can damage plastic gears. This includes many greases, oils, and vaselines. Instead, opt for lubricants recommended by the manufacturer, such as white lithium grease or silicone-based grease.
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Lubricant viscosity
The viscosity of a lubricant refers to its thickness or consistency. High-viscosity oils, such as those with an ISO VG of 100 or more, are less likely to penetrate, crack, or otherwise adversely affect plastic materials. They are suitable for higher loads and help maintain a lubricant film from start to stop. On the other hand, lighter loads require lower-viscosity oils to prevent viscous drag.
The choice of lubricant viscosity depends on the specific application and operating conditions of the plastic gears. Factors such as load, speed, temperature, and environment play a crucial role in determining the appropriate viscosity. For example, silicone-based lubricants are suitable for low-load applications and offer a wide temperature range of -90°C to 225°C. In contrast, synthetic lubricants like hydrocarbon (PAO) types are preferred for high operating speeds, high temperatures, or long operation as they have excellent aging resistance and can provide long-term lubrication.
It is important to verify the compatibility of lubricants with plastics to avoid issues such as stress cracking, discolouration, or loss of dimensional stability. Manufacturers typically monitor changes in physical properties of the plastic material under different conditions to determine compatibility. Additionally, certain plastics are more reactive and prone to chemical breakdown, such as polystyrene, ABS resins, and polycarbonate, while others like nylon and polyethylene are known for their chemical stability.
When choosing a lubricant for plastic gears, it is essential to consider the viscosity and compatibility with the specific plastic material to ensure optimal performance and prolong the life of the gears.
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Frequently asked questions
You should avoid using any petroleum-based grease on plastic gears. Solid additives like graphite and molybdenum disulfide can penetrate and weaken plastic parts. Esters and polyglycols are also generally not compatible with plastic.
Synthetic lubricants are the best choice for long-term applications as they have high aging resistance. Mineral-oil-based lubricants are also a good option as they don't attack most plastics and offer excellent performance for an economical cost. Silicone-based lubricants are another great choice for low load applications and a wide temperature range.
The frequency of lubrication depends on the type of machine running the gears, how often you run the device, and the overall level of tension the machine is under daily. Larger gears under higher stress will need to be lubricated more often.
