Design of a test rig for grease endurance tests

Background The performance and endurance of lubricating greases is often assessed through model tests (like four-ball tests or SRV tests). This approach has some limitations, especially when greases with special fillers are investigated, because simplified laboratory test conditions can never replicate real operating conditions. Objective For a more reliable assessment on the performance of a lubricating grease, lubricants must be tested in close-to-actual operational conditions, e.g. through component tests. This paper presents both the design and implementation of a dedicated test rig to test lubricating greases through middle-sized thrust ball bearings. Methods The test rig design is optimized to monitor the effectiveness of lubrication and determine the useful life of grease by recording representative parameters, namely bearing temperature at different location in the bearing, vibration level, and electric contact resistance (ECR) through the bearing. Results The results of a couple of assessment tests are presented and confirm that the test rig is working as expected. Conclusions The chart of the parameters being monitored shows that the instant performance of grease lubrication can be tracked during the endurance tests, and grease failure identified. The special mechanical layout of the rig also allows the user to obtain additional information that is usually not available in other commercial greased bearing testers. This work is meant to be the first step of the development a new approach to evaluate the grease lubrication performance and a few experimental results are included as they are intended as a functional validation of the prototyped test rig.