Rod Seal Installation

Typical installation of a u-cup type rod seal. The snap fitting into non-split housings (Installation recommendation I) can essentially be made easier through suitable fitting tools. U-packings of 1 3/8" or 35 mm diameter (profile thickness 3/16" or 5 mm) up to nominal diameter 3 1/4" or 80 mm (profile thickness 3/8" or 10 mm) are snapped into non-split grooves. For this the ring is formed into a kidney shape and pushed into the rod guide. The tool is withdrawn after the seal snaps into the groove.
Fitting tool I for rod seals

A further possibility for snap-in fitting of rod seals exists in the application of a suitable plug and a rod.

Fitting tool II for rod seals

In doing this, the seal is first of all positioned by hand to one side of the groove, and then pushed with a rod until it snaps into the groove. Plug and rod should be made out of a suitable plastic material.

Fitting aid for rod seals

Before fitting sealing components, the whole system is to be cleaned to remove residues, shavings, dirt and other foreign bodies from the process. When assembling, seals may not be pulled or stretched over sharp edges, threads, spring grooves or similar. These areas are to be covered before fitting

Fitting aid for rod seals

Piston Seal Installation

Before fitting, the following points must be observed:

provide entry chamfers on the rod and the housing avoid sharp edges and cover the peaks of screw threads, etc. carefully removed dust, dirt, shavings and other foreign particles do not use any tools with sharp edges the open side of the seal must be located towards the system pressure axial play in the groove is necessary so that the seal is exposed to the medium and to pressure By using suitable fitting tools, snap-in fitting is greatly eased.

Snapping in the pressure ring.

Finished fitted seal.

Piston seals can be conveniently fitted with the help of a simple fitting aid.

Surface Finish Information

Function and working life of a seal are affected greatly by the surface finish of the sliding surfaces to be sealed. The minimum surface roughness with largest possible profile bearing length ensures optimum work life. The following table gives an overview of the permissible surface roughness and of the machining process possible. 1. Cylnder Walls Material: St 52 or better Tolerance: H 8-H 11, dependent on seal (see individual specification) Peak-to-valley-height: R max=< 2.5 m R a= < 0.05-0.3 m M r50-90 % in a cutting depth c=0.5x R zstarting from reference line of C ref=0%. Machining process: Honing and roller burnishing (rolling). Material should be removed at the concluding process stage, rather there ought to be a reshaping. Scratches, scores, machine scoring running concentrically or spirally are not permitted. 2. Rods Material: CK 45 or better Is determined by individual application and sealing component (see individual Tolerance: specification) Peak-to-valley-height: R max=< 2.5 m R a= < 0.05-0.3 m M r50-90 % in a cutting depth c=0.5x R zstarting from reference line of C ref=0%. Machining process: Non-oriented, ground or roller burnishing (rolling) Corrision protection: Hard chrome with coating thickness 30-50 m Severe true stress: Hardening (55-60 HRC) and hard chroming. Re-work (finishing, grinding among others) to required surface quality after hard chroming. In doing so, developing scratches, scores, machine scoring running concentrically or spirally are not permitted. 3. Housings Material: St, cast steel (free of cavities/blow-holes) Tolerance: Can be taken from respective groove drawings. Peak-to-valley-height: Base of groove: R max=< 6.3 m R a=< 1.6 m M r50-90 % in a cutting depth c=0.5x R zstarting from reference line of C ref=0%. Sides of groove: R max=< 15.0 m Some types allow a rougher groove base: (e.g. KI 310, KI 320: R max=< 10 m, R a= 2.0 m, see individual specification) Machining process: Turning and grinding Comment: Phospated and nitrated surfaces (bonding, chemical nickel plating) are not suitable as contact surfaces for seals without mechanical re-work.

Polyurethane Compounds Polyurethane (AU),(PU),(PUR) Polyurethane is an organic material of high molecular weight
whose chemical composition is characterised by a large number of urethane groups. Within certain temperature limits, polyurethane possesses the characteristic elastic properties of rubber. The composition of the material is determined by three components: polyol diisocyanate chain extender The type and amount of these materials used, and the reaction conditions, are decisive in determining the

properties of the resulting polyurethane material. Polyurethanes possess the following properties: high mechanical strength good abrasion resistance modulus of elasticity which can be varied within wide limits good flexibility hardness variable over a wide range whilst retaining good elasticity, (polyurethane fills the gap between soft, elastic rubber types and brittle plastics) very good resistance to ozone and oxygen Good resistance to swelling in mineral oils and greases, water, water-oil mixtures, and aliphatic hydrocarbons Temperature range for use: -30C/-22F to +80C/175F, high performance types (compounds) up to +100C/212F in mineral oils. Not resistant to polar solvents, chlorinated hydrocarbons, aromatics, brake fluids, acids and alkalis.

NBR Compounds Acrylonitrile-Butadiene-Rubber is a polymer of butadiene and acrylonitrile. The acrylonitrile (ACN)
component can be between 18 and 50% and affects the following properties of the NBR used to make seals: Swelling resistance in mineral oils, greases and fuels Elasticity Cold flexibility Gas permeability Compression set

Thus an NBR material with 18% ACN has very good cold flexibility down to ca. -38C/-36F and moderate resistance to oil and fuel, whilst a material with 50% ACN with optimum resistance to oil and fuels has in contrast a cold flexibility only down to -3C/+26F. With rising ACN content, the elasticity and the gas permeability decrease and the compression set becomes worse. Simrit materials based on these synthetic rubbers are suitable for many areas of application by virtue of their good physical properties. The proven Simmerring radial shaft seals in particular, most sealing elements for hydraulics and pneumatics, as well as O-Rings, are manufactured in large quantities from materials based on NBR. Simrit is the most experienced seal manufacturer with this elastomer base in the world. Good resistance to swelling in aliphatic hydrocarbons, eg, propane, butane, petroleum, mineral oils (lubricating oils, hydraulic oils of Groups H, H-L and H-LP) and greases, fire retardant hydraulic fluids of Groups HFA, HFB and HFC, vegetable and animal oils and greases, light heating oil and diesel fuel. A few materials are especially resistant to: hot water at temperatures up to +100C/212F (sanitary fittings), inorganic acids and bases at concentrations and temperatures which are not too high. Moderate resistance to swelling in fuels having a high content of aromatics (super grades of fuel). High swell in aromatic hydrocarbons, eg, benzene; chlorinated hydrocarbons, eg, trichloro-ethylene; flame retardant hydraulic fluids of the Group HFD; esters; polar solvents and brake fluids based on glycol, eg, ATE and Pentosin. Temperature range for use: Depending on the composition of the blend, this is between -30C/-22F and +100C/+212F and for short periods up to 130C/265F; the material hardens at higher temperatures. For special blends, the cold flexibility extends down to -55C/-67F.

FKM Compounds Fluoro-Rubber (FKM) Copolymers, terpolymers or tetrapolymers with various composition and with
fluorine contents from 65 to 71%, which thereby have varying resistance to surrounding media and varying cold flexibility, can be made by polymerisation of vinylidene fluoride (VF) and variable amounts of hexafluoropropylene (HFP), tetrafluoroethylene (TFE), 1-hydropentafluoropropylene (HFPE) and perfluoro(methylvinylether) (FMVE). Cross-linking is achieved either with diamines and bisphenols or with organic peroxides. Materials based on FKM are especially important due to their resistance to high temperatures and their chemical stability. Their permeability to gases is low. FKM elastomers display minimal weight loss in high vacuum. Resistance to ozone and the crack resistance in the presence of light are very good, as is the fire retardancy. Amines can react to destroy the material and necessitate a choice of suitable types and special blends. One particular group of materials is represented by copolymers of TFE and propylene having a relatively small fluorine content (57%). Materials based on this elastomer have excellent resistance to hot water and to steam, as well as to amines or amine-containing media, but also have reduced resistance to swelling in mineral oils. Good resistance to swelling in: mineral oils and greases (even with most additives), fuels, aliphatic and aromatic hydrocarbons, some fire retardant hydraulic fluids and synthetic aero-engine oils. In addition, newly developed materials which are cross-linked by peroxides have good resistance to media which can only be tolerated to a small extent, if at all, by conventional FKM. Such media are for instance alcohols, hot water, steam, alcohol-containing alternative fuels, and SF mineral oils. High swell in: polar solvents and ketones, fire retardant hydraulic fluids of the Skydrol type, and brake fluid, eg, ATE. Temperature range for use: ca. -20C/-4F to +200C/390F (for short periods to + 230C/445F). Special grades: -35C/-31F to +200C/390F. By suitable design, and by using material compositions developed especially for such applications, seals and mouldings can also be used at still lower temperatures.

PTFE Compounds
Polytetrafluoroethylene (PTFE) is a polymer of tetrafluoroethylene. This non-elastic material is characterized by a series of outstanding properties: The surface is slippery and repels most media. Its use is favored in all cases where the retention of residues is to be avoided. PTFE is non-toxic at working temperatures up to +200 C. The coefficient of friction is very low against most opposing surfaces made of other materials. Stiction and friction are almost the same. The electrical insulating properties are outstandingly good. They are almost independent of frequency, temperature and weathering effects. The chemical resistance exceeds that of all other thermoplastics and elastomers. Thus the resistance to swelling is good in almost all media. Liquid alkali metals and a few fluorine compounds attack PTFE at higher temperatures and pressures. The temperature tolerance is between -200 C and +260 C. Even at -200 C, PTFE still has some elasticity and therefore it can be used for seals and constructional parts, for example, with liquefied gases. When using parts of pure PTFE, the following points should be noted: Above a certain level of stress, the material continues to deform due to creep or cold flow. The abrasion resistance is low. Thermal expansion, like most plastics, is 10 times that of metals. The thermal conductivity is low so that removal of heat from bearings and from other moving seals can lead to problems. The material is not elastomeric but is hard like polyethylene. For these reasons, elastomeric seals in assemblies cannot simply be replaced by PTFE seals. With lip

seals, provision must be made for a constant additional contact pressure by use of springs or by other means. PTFE is filled with graphite, glass fibers, bronze and carbon to achieve special properties.