O-RINGS

By: MUHAMMAD SHOAIB FAREED

CONTENTS
O-Ring Standards O-Ring Sealing Principles O-Ring Applications Basic Elastomers Designing with Rubber O-Ring Gland Design Information Troubleshooting

O-RING STANDARDS
AS 568A BS 1806 DIN 3771 SMS 1586 AFNOR 47501 JIS B2401 ISO 3601-1 USA England Germany Sweden France Japan International

O-RING SEALING PRINCIPLES

O-Rings are bidirectional seals, circular in shape and cross-section. An O-Ring seals through the deformation of the seal material by installation and media pressure to close off the gap between mating components. Higher system pressure can cause deformation through the gap, known as extrusion, resulting in seal failure. Choosing a harder seal material or installing back-up rings to support the O-Ring may alleviate this problem.

O-RING SEALING PRINCIPLE

The tendency of an O-Ring to return to its original shape when the cross section is deflected is the basic reason why O-Rings make excellent seals. Elastomers may take up the stack-up of tolerances of the unit and its memory maintains a sealed condition.

O-RING SEALING PRINCIPLES

PRESSION
O-Rings with smaller cross-sections are squeezed by a higher percentage, normally 20% In Static applications, the recommended squeeze is between 15 to 30%. In vacuum, squeezing can even be higher. In dynamic applications the recommended squeeze is between 8-16%.

O-RING SEALING PRINCIPLES

SEALING TIPS
Larger the cross-section, more effective the seal. Avoid sealing axially and radially at the same time with the same O-Ring. Do not use the O-Ring (seal) as a bearing to support a load or center a shaft. Always look for the O-Ring installation and assembly instructions, if provided by OEM.

O-RING APPLICATIONS TYPE

SEALING APPLICATION TYPES

STATIC

DYNAMIC

FACE

AXIAL

SLOW ROTATION

OSCILLATING

RECIPROCATING

ROTARY

O-RING APPLICATIONS
STATIC
1. AXIAL
The O-Ring cross section is squeezed axially in the groove similar to a flat gasket.

O-RING APPLICATIONS
STATIC
2. RADIAL
The O-Ring cross section is squeezed radially in the groove between the inside diameter (ID) and outside diameter (OD).

O-RING APPLICATIONS
STATIC
3. DOVETAIL
The O-Ring squeezed in groove. is axially a dovetail

O-RING APPLICATIONS
STATIC
4. BOSS SEAL
O-Ring is used for sealing straight thread tube fittings in a boss.

O-RING APPLICATIONS
DYNAMIC
1. RECIPROCATING
Seals used in applications that slide back and forth The O-Ring may either be housed in a groove for Rod Seal or in the cylinder wall for piston seal without any changes in design limitations or seal performance.

O-RING APPLICATIONS
DYNAMIC
2. OSCILLATING
Oscillating applications are those seeing both rotary and reciprocating movement. A valve spindle is an example of an oscillating application

O-RING APPLICATIONS
DYNAMIC
3. ROTARY
Rotary seals refer to seals used in applications that rotate.

O-RING APPLICATIONS
MISCELLANEOUS APPLICATIONS
The O-rings are used in a variety of applications. Wipers, buffers, and drive belt applications are just some of the examples.

BASIC ELASTOMERS
Elastomer is synonymous with rubber Polymer that can be modified to a state
Exhibiting little plastic flow Nearly complete recovery from an extending force, and upon immediate release of stress, will return to approximately its own shape.

BASIC ELASTOMERS
SELECTION BASED ON RESISTANCE TO THE MEDIA
Chemical effect of the media on the O-ring. Excessive deterioration of the O-ring must be avoided. A significant amount of volume shrinkage usually results in premature leakage of O-ring seal. First step: select an elastomer that is compatible with the chemical environment.

BASIC ELASTOMERS
COMPOUND
Mixture of base polymer(s) and other chemicals which form a finished rubber. Basic of compound design is selection of the polymer type. Compounder may add reinforcing agents e.g. carbon black, color pigments, curing or vulcanizing agents, activators, plasticizers, accelerators, antioxidants or anti radiation additives.

BASIC ELASTOMERS
Acrylonitrile Butadiene, Nitrile or Buna N (NBR)
Co-polymer of butadiene and Acrylonitrile Acrylonitrile varies between 18% to 50% Nitrile contents increases, resistance to petroleum base oils and hydrocarbon fuels increases Good in compression set, tear and abrasion resistance. Weak against ozone, sunlight or weather. NBR is standard material for hydraulics and pneumatics.

BASIC ELASTOMERS
Acrylonitrile Butadiene, Nitrile or Buna N (NBR)

BASIC ELASTOMERS
Fluorocarbon Rubber (FKM)
Highly Fluorinated Carbon-Based polymers Wide range of chemical compatibility, Low compression set and excellent aging characteristics. Temperature working range: -26C to 205C Increase in Fluorine content increases resistance to chemical attack Resist mineral oils and greases, aliphatic, aromatic and also special chlorinated hydrocarbons, petrol, diesel fuels, silicone oils and greases

BASIC ELASTOMERS
EPM / EPDM
Ethylene and propylene monomers Temperature range is -50C to 120C/150C Excellent resistance to Heat, Water, Steam, Alkali, Mild Acidic and Oxygenated Solvents, Ozone and Sunlight. Can also be used with Brake Fluids and Phosphate Ester-Based Hydraulic Fluids Not recommended for Gasoline, Petroleum Oil and Grease, and Hydrocarbon Environments. Inexpensive Material for normal use.

DESIGNING WITH RUBBER

COMPRESSION SET AND SQUEEZE
Compression set is the percentage of deflection that the elastomer fails to recover after a fixed period of time under a specific squeeze and temperature. It is a measure of the expected loss of resilience or memory of a compound. Compression set is generally determined in air and measured as a percentage of original deflection.

DESIGNING WITH RUBBER

COMPRESSION SET AND SQUEEZE
Compression set is calculated as follows;
C t0 t1 100 % t0 t s

DESIGNING WITH RUBBER

COMPRESSION SET AND SQUEEZE
Lower compression set vales indicates improved remaining seal capacity Generally increases with increased temperature and time Minimum squeeze should be about 0.175 mm

DESIGNING WITH RUBBER

O-RING HARDNESS
Softer the elastomer, the better the seal material conforms to the surfaces to be sealed and lower pressure is required to create the seal. Softer the elastomer, higher the coefficient of friction. The softer the elastomer the more risk of being extruded into the clearance gap between the mating surfaces. Harder materials offer greater resistance to flow. Hardness is indicated by Durometer Reading Shore A

DESIGNING WITH RUBBER

DESIGNING WITH RUBBER

TENSILE STRENGTH AND ELONGATION
Tensile strength is a measurement of the amount of force required to rupture an elastomeric specimen. Elongation is an increase in length expressed numerically as a percentage of initial length at the point of rupture.

DESIGNING WITH RUBBER

VOLUME CHANGE
Volume change is the increase or decrease of the volume of an elastomer after it has been in contact with a medium. Usually measured in percentage. Almost always accompanied by a change in hardness. Volume swell is caused by absorption of medium. In dynamic applications, volume swell up to 15 or 20 % is usually acceptable. More than 3 to 4% shrinkage can be a serious problem.

DESIGNING WITH RUBBER

MODULUS
Modulus refers to stress at a predetermined elongation, usually 100% Comparison for good extrusion resistance Increases with increase in hardness

DESIGNING WITH RUBBER

O-RING CROSS SECTION DIAMETER (CSD)
Static Application
No rapid high pressure cycling, larger CSD Less susceptible to compression set, swell and incidental surface damage Large CSD, more stable & tend not to rotate on assembly Rapid high pressure cycling, smaller CSD Less susceptible to decompression problems

DESIGNING WITH RUBBER

O-RING CROSS SECTION DIAMETER (CSD)
Dynamic Application
Normally governed by surface contact speed Higher the speed, smaller the CSD Better to choose smaller CSD to avoid friction
O-Ring CSD (mm)
1.76 2.62 3.53

Max. Surface Speed (m/s)

7.62 3.04 2.03

O-Ring CSD is not critical for speed less than 2.03 m/sec

DESIGNING WITH RUBBER

O-RING CROSS SECTION DIAMETER (CSD)
CHARACTERISTICS OF CSD CHOICE
LARGE CROSS SECTION
More Stable More Friction Needs More Space Better Compression Set

SMALL CROSS SECTION

Less Stable Less Friction Needs Less Space Poor Compression Set

Less Swell
Worse Decompression Larger Tolerances Less Sensitive to Damage

Possibly More Swell

Better Decompression Closer Tolerances Sensitive to Damage

DESIGNING WITH RUBBER

O-RING CROSS SECTION DIAMETER (CSD)
GENERAL RULES FOR CSD CHOICE ON O-RING ID BASIS
O-RING ID RANGE (mm)
0 < ID < 20
20 < ID < 100 100 < ID < 200 200 < ID < 300

O-RING CSD (mm)

1.78 or larger
2.62 or larger 3.53 or larger 5.33 or larger

DESIGNING WITH RUBBER

SELECTION OF O-RING OD AND ID
Consider the initial stretch of the O-Ring on assembly
SEAL TYPE
Flange Flange Trapezoidal Flange Groove Crush

PRESSURE DIRECTION
Internal External

COMMON SEAL/ GROOVE DIMENSION

OD ID Centroid ID

Piston Rod/Housing

ID

In any case, initial stretch on assembly should not exceed 3%

O-RING GLAND DESIGN

STATIC APPLICATIONS
Flange Seal (Axial)
Flanges are assembled in metal to metal contact No remarkable gap No risk for extrusion of O-Ring

TROUBLESHOOTING
Extrusion and Nibbling
Failure Pattern:
Typical of high pressure system Can be identified by small bites (nibbles) taken from the O-ring on the downstream (low pressure) side.

TROUBLESHOOTING
Extrusion and Nibbling
Problem Source:
Excessive clearances Excessive system pressures O-Ring material too soft Degradation of the O-ring by system fluid Irregular clearance gaps caused by eccentricity Improper machining Sharp edges O-ring size too large for the gland

TROUBLESHOOTING
Extrusion and Nibbling
Suggested Solution:
Decrease gland clearances by machining Use back-up rings to prevent extrusion Employ harder O-Rings Re-check elastomer compatibility Improve concentricity Break sharp edges Install proper size O-Ring

TROUBLESHOOTING
Spiral Failure
Failure Pattern:
Generally found on long stroke hydraulic piston seal with low pressure differential O-Ring surface exhibits a series of deep, spiral, 45 angle cuts

TROUBLESHOOTING
Spiral Failure
Problem Source:
Caused when certain segment of O-ring slide while other segments simultaneously roll O-Ring gets caught on an eccentric component or against the cylinder wall, causing twisting and development of 45 angle surface cuts.

TROUBLESHOOTING
Spiral Failure
Suggested Solution:
Check for out of round cylinder bore Decrease clearance gap Machine metal surfaces to 10 to 20 micro inch finish Improve lubrication Use internally-lubricated O-Rings Employee Quad Rings

TROUBLESHOOTING
Abrasion
Failure Pattern:
Can be identified by a flattened surface on one side of the O-Ring or wear-lines on the cross section parallel to motion Occurring primarily in dynamic seals

TROUBLESHOOTING
Abrasion
Problem Source:
Metal surfaces too rough Metal surfaces too smooth Poor lubrication Excessive temperatures System contaminated by abrasive

TROUBLESHOOTING
Abrasion
Suggested Solution:
Use recommended metal finishes Provide adequate lubrication Check material compatibility with system temperature Eliminate abrasive contamination with filters

TROUBLESHOOTING
Compression Set
Failure Pattern:
Compression set failure produces flat surfaces on both sides of the O-ring cross section being squeezed

TROUBLESHOOTING
Compression Set
Problem Source:
Elastomer with poor compression set properties System pressure too high Excessive swelling of O-Ring material in system fluid Too much squeeze Incomplete curing of O-ring material during vulcanization Excessive system temperature

TROUBLESHOOTING
Compression Set
Suggested Solution:
Employ low compression set elastomer Use material that resists operating or frictionally generated heat Re-check O-ring compatibility with system chemicals Reduce O-ring squeeze if possible Inspect O-rings for correct physical dimensions

TROUBLESHOOTING
Weather or Ozone Cracking
Failure Pattern:
Failure mode marked by the appearance of many small surface cracks perpendicular to the direction of stress Seals exposed to atmospheres containing ozone and air pollutants

TROUBLESHOOTING
Weather or Ozone Cracking
Problem Source:
Ozone attacks unsaturated or double bond points in some polymer chains, causing chain scission Cracking of the O-Ring

Suggested Solution
Use O-ring elastomers that are resistant to ozone attack

TROUBLESHOOTING
Heat Hardening and Oxidation
Failure Pattern:
O-Ring surface appears pitted and/or cracked Often accompanied by the flatness of high compression set

TROUBLESHOOTING
Heat Hardening and Oxidation
Problem Source:
Excessive environmental temperature
Excessive elastomer hardening Evaporation of Plasticizer Cracking from oxidation

Suggested Solution
Lower operating temperature Use high temperature and oxidation resistant O-Ring materials

TROUBLESHOOTING
Installation Damage
Failure Pattern:
Failure mode marked by short cuts, notches or a skinned or peripherally peeled surface on the O-ring.

TROUBLESHOOTING
Installation Damage
Problem Source:
Sharp edges on mating metal components or Gland Sharp threads over which O-Ring must pass during assembly Insufficient lead-in chamfer Blind grooves in multi-port valves Oversize O-Ring ID on piston Undersize O-Ring ID on rod Twisting or pinching of O-Ring during installation No O-Ring lubrication during installation

TROUBLESHOOTING
Installation Damage
Suggested Solution:
Break sharp edges on mating metal components Cover threads during O-Ring installation Provide 20 lead-in chamfer Break sharp corners of chamfer and O-Ring groove edges Install correctly sized O-Rings Use lubrication during assembly

TROUBLESHOOTING
Explosive Decompression
Failure Pattern:
Failure mode marked by short splits or ruptures going deep into the O-Ring cross section O-Ring surface covered with small blisters

TROUBLESHOOTING
Explosive Decompression
Problem Source:
Absorption of gas by the O-Ring while operating in high pressure conditions Subsequent rapid decrease in system pressure traps within the O-Ring micropores This causes surface blisters and ruptures as the gas seek an avenue of escape

TROUBLESHOOTING
Explosive Decompression
Suggested Solution:
Increase time for decompression Increase material hardness to 80-95 shore A Reduce O-Ring cross sectional size Specify a decompression resistant material

TROUBLESHOOTING
Explosive Decompression
Failure Pattern:
Failure mode marked by small cracks in O-ring stress area Accompanied by loss of physical volume

TROUBLESHOOTING
Explosive Decompression
Problem Source:
Extraction of O-ring material plasticizer component by system chemicals or fluid in dry-out situation

Suggested Solution:
Employee chemically compatible O-ring material with low-to-no extractable plasticizer content