An Investigation into the Effects of Lubricant Type on Thermal Stability and Efficiency of Cycloidal Reducers

Modern power transmission systems are required to meet increasingly stringent demands, including a wide range of transmission ratios, compact dimensions, high precision, energy efficiency, reliability, and thermal stability under dynamic operating conditions. Among the solutions that satisfy these requirements, cycloidal reducers are particularly prominent, with their application continuously expanding in industrial robotics, computer numerical control (CNC) machines, and military and transportation systems, as well as in the satellite industry. However, as with all mechanical power transmissions, friction in the contact zones of load-carrying elements in cycloidal reducers leads to power losses and an increase in operating temperature, which in turn results in a range of adverse effects. These undesirable phenomena strongly depend on lubrication conditions, namely on the type and properties of the applied lubricant. Although manufacturers’ catalogs provide general recommendations for lubricant selection, they do not address the fundamental tribological mechanisms in the most heavily loaded contact pairs. At the same time, the available scientific literature reveals a significant lack of systematic and experimentally validated studies examining the influence of lubricant type on the energetic and thermal performance of cycloidal reducers. To address this identified research gap, this study presents an analytical and experimental investigation of the effects of different lubricant types—primarily greases and mineral oils—on the thermal stability and efficiency of cycloidal reducers. The results demonstrate that grease lubrication provides lower total power losses and a more stable thermal operating regime compared to oil lubrication, while oil film thickness analyses indicate that the most unfavorable lubrication conditions occur in the contact between the eccentric bearing rollers and the outer raceway. These findings provide valuable guidelines for engineers involved in cycloidal reducer design and lubricant selection under specific operating conditions, as well as deeper insight into the lubricant behavior mechanisms within critical contact zones.