Tribology in transition

Lubricant efficiency on a new level.

Tribology in transition

Lubricant efficiency on a new level.

The OMC₂ additive technology

Market requirements are changing due to rapid economic developments, global competition and technological progress. This challenges tribology and lubrication technology to develop ever more efficient and comprehensive lubricant solutions. A typical requirement is the further reduction of surface friction to increase energy efficiency and optimise the smooth running of motion sequences - even at extreme temperatures and under enormous loads. A further increase in power density is also required. Finally, technical designs should be as small and light as possible and extremely efficient. TUNAP offers a comprehensive solution for these different requirements: OMC₂ additive technology (OMC: Organic Molybdenum Compound).

OMC₂ technology in film

Application advantages of the OMC₂ technology

Our OMC₂ additive technology offers various advantages compared to conventional lubricants:

It enables a longer service life with lower lubricant consumption. Lower frictional heat ensures reduced energy consumption and helps to reduce the environmental impact and make a sustainable contribution to CO₂ reduction.

The lower maintenance and repair costs also increase machine availability. This in turn results in cost savings for disposal. All in all, this means significant cost and resource savings for users.

Lower lubricant consumption

Lower frictional heat

Energy saving

Reduction of CO₂ emissions

Higher machine availability

Lower material costs

Lower repair costs

Lower disposal costs

OMC₂ additive technology

The OMC₂ additive technology (organic molybdenum compound), is also known under the terms PD (Plastic Deformation) or SE (Surface Engineering). What exactly does this technology do and what are its advantages?

The active complex of the OMC₂ additive technology changes the structure of metal surfaces through a special micro-smoothing effect. This results in several advantages:

The roughness of components is not rubbed off, instead they deform under load.
The pressure absorption capacity of the surfaces increases strongly.
In the micro range, flow smoothing occurs and thus friction losses and wear are significantly reduced.

Three-phase effect of OMC₂ technology

The stronger the pressure, the more effective the OMC₂ technology: as the load increases, the OMC₂ components migrate into the metal surface and lead to the special micro-smoothing effect of the surface structure. Unevenness is smoothed out and friction and wear on the components are extremely minimised. The following three diagrams illustrate how an OMC₂ lubricant acts on a surface:

Smear film formation on the surface

Under pressure, the additive molecules of the OMC₂ technology first attach themselves to the metal surface. A shear-stable and lubricating film is formed.

Compression of the surface protection layer

With increasing pressure, the metal surfaces deform and densify on the nanoscale. The surface roughness is reduced and an effective protective layer is created. The risk of wear is already significantly reduced and the surfaces glide past each other more smoothly.

OMC2 effect develops and surface smoothens

The OMC₂ components migrate further into the metal and lead to the special smoothing effect of the surface structure. This process, also known as PD (plastic deformation) or SE (surface engineering), leads to a minimization of friction and wear of the components.

Increasing the contact surfaces with OMC₂ technology

Without OMC₂ technology, the contact area between two friction surfaces is significantly smaller due to the surface roughness. Only the rough "tips" of the surfaces touch each other (see "before", exemplary visualisation on the left).

By using OMC₂ technology, sufficient lubricating films and a protective reaction layer are formed on the surfaces. The contact surface increases and the loads are distributed evenly (see "after", example visualisation on the right).

How Does OMC₂ Differ from Conventional Lubricants?

Increase of viscosity

⦿ Effect: Increase in the thickness of the lubricating film

➕ Advantage: Simple and conventional solution

➖ Disadvantage: Behavior at low temperatures deteriorates; not applicable for high-speed applications

Solid lubricant

⦿ Effect: Solid lubricants form a physical separation layer

➕ Advantage: Simple and conventional solution

➖ Disadvantage: Not applicable for high-speed applications and circulation lubrication with filter

Conventional additives

⦿ Effect: Chemical reaction to build up robust protective layers

➕ Advantage: Nearly always applicable

➖ Disadvantage: The combination of additives is very sensitive; activation via high temperatures

OMC₂ technology

⦿ Effect: Micro flow smoothing of the rough surface

➕ Advantage: Highly effective

➖ Disadvantage: None

Examples for the Use of the OMC₂ Additive Technology

Large gear: Car

OMC₂ lubricants offer special protection in vehicle manual transmissions: they ensure smoother engine running, lower working temperatures and reduced engine oil consumption; they reduce fuel consumption and increase engine performance.

Small transmission: E-Bike

The OMC₂ technology ensures less friction between the gears in e-bike transmissions This allows energy to be saved in the battery, which enables longer ranges.

Chains: Forklift truck

OMC₂ hinges make the joints of forklift chains smooth-running again: They loosen rusted or oxidized chain joints and lead to lower repair costs and increased machine availability.

Roller bearings: Corrugated board plant

OMC₂ is also effective in the production of corrugated board: even under extreme loads, wear in the rolling bearing is reliably reduced, which reduces maintenance and repair costs.

Test results and competitor comparisons

Chain test bench

For OMC₂ technology, we rely on high-quality raw materials, carefully matched formulations and continuous quality assurance. This enables us to meet the highest demands on lubricants.

In order to measure the efficiency of various lubricants on the chain and to provide verifiable data, we test them on our two-wheel chain test rig AU 01, among other things.

In addition to cadence, torque, power, gear ratio and speed, we particularly analyze the parameters of efficiency on our chain test stand. With the data obtained from these tests, lubricants can be developed that guarantee the highest performance quality.

Bike race

We can simulate special stages or entire bike races on our chain test rig and draw conclusions as to which lubricant formulation is best suited to the distance to be covered.

Our tests show that the coefficient of friction can be reduced by up to 30% by using OMC₂ technology. What does this mean in concrete terms? In a bicycle race over 155 miles, this could result in a time advantage of one minute and 46 seconds.

The latest test by the German "BIKE" magazine confirms the quality of our OMC₂ technology: In issue 11/2020, 18 chain lubricants were tested for the criteria lubricity, creep ability, corrosion protection, dirt adhesion and handling. Conclusion: The TUNAP Sports "Chain Oil Ultimate" achieved the best result and was thus declared the test winner.

Power tool in long-term test

In this long-term test, a cordless percussion drill ran with two different greases in continuous operation: first with the reference grease, then with TUNGREASE OMC₂-2 plus. The result was clear: with the reference lubricant, the device failed after only 82 hours of operation. With TUNGREASE OMC₂-2 plus, the device ran for well over 250 hours.

TUNGREASE OMC₂-2 plus reaches a stable low level of power consumption much faster. This is due in part to the fact that this formulation is "dynamically light", i.e. it offers low resistance and facilitates movement. The OMC₂ additive technology also reduces friction and thus heat generation, energy consumption and wear.

This is proof that lubrication with TUNGREASE OMC₂-2 plus allows significantly longer operating times per battery charge.

Rolling bearing lubrication

The full potential of the OMC₂ additive technology can also be demonstrated using the example of rolling bearing lubrication on the FE8 test bench:

In a standard test procedure for the performance of lubricating greases in rolling bearings under realistic conditions, our TUNGREASE OMC₂-2 plus shows significantly lower wear values than lubricating greases from common competitors.

The average frictional torque, which is reduced by around 50 per cent both at start-up and during steady-state running, means considerable energy savings compared to conventional lubricants.

				
				DIN 51819-2-C-75/50-40
				TUNGREASE OMC₂-2 plus
				Competitors
						
Wear  on rolling elements mw50
				
≤ 2 mg
				
≥ 20 mg
				
				Cage wear mwk50
				≤ 50 mg
				≥ 50 mg
				
				Average frictional torque at 
				 
				● start Mrs
				~ 8 Nm
				~ 15 Nm
				
				● persistence Mrb
				~ 3 Nm
				~ 11 Nm

DIN 51819-2-C-75/50-40	TUNGREASE OMC₂-2 plus	Competitors
Wear on rolling elements m_w50	≤ 2 mg	≥ 20 mg
Cage wear m_wk50	≤ 50 mg	≥ 50 mg
Average frictional torque at
● start M_rs	~ 8 Nm	~ 15 Nm
● persistence M_rb	~ 3 Nm	~ 11 Nm