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Mechanical Face Seals

Mechanical face Seals are designed to be employed in
most abusing working conditions, accepted worldwide
to use in extremely harsh environments under enormous
stresses, sand, dirt, mud, dust and earth material.

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Mechanical Face Seals

  1. 1. Mechanical Face Seals
  2. 2. Why SAP PARTS Seals  Corrosion Resistant.  Higher operational life.  Precision Lapped seals.  No micro-fine scratches.  Wear Re-countering Design.  Minimum face load variations.  Self-renewing sealing surfaces.  Special Seal and O - Ring materials.  Suitable for Heavy Duty Applications.
  3. 3. PageContent 1 Mechanical Face Seals............................................................................................ 2 2 Application Requirement ...................................................................................... 3 3 Sealing Function ........................................................................................................... 4 4 Lubrication ....................................................................................................................... 5 5 Seal Design ..................................................................................................................... 6 6 Special Seal Design................................................................................................... 10 7 Innovations....................................................................................................................... 11 8 Sealing System Clearance..................................................................................... 13 9 Materials ............................................................................................................................ 15 11 Mechanical Face Seal Design Input Data.................................................. 18 10 Mechanical Face Seals © SAP PARTS India. 1 O ring ................................................................................................................................... 16
  4. 4. Mechanical Face Seals Mechanical face Seals are designed to be employed in most abusing working conditions, accepted worldwide to use in extremely harsh environments under enormous stresses, sand, dirt, mud, dust and earth material. Sealing technology for Static and Dynamic Applications is mainly concerned with providing sealing solutions for machinery and applications in which conventional seals fail or lack the necessary durability. For Years together, SAP PARTS™ branded Mechanical Face Seals have been used by OEMs and Users of Seals with outstanding success in Construction Equipments, Transmission Drives, axles, Rollers and Argo machineries. The Special Alloy Cast iron materials Provided by SAP PARTS ™ are having extraordinary capacity for wear resistance, for a verity of demanding applications, such as mining machinery, agriculture equipments, undercarriage vehicles, track rollers and many other applications. Continuous technological research in SAP PARTS™ sealing solutions guarantee our esteemed customers a long lasting, highly durable service life and maximum productivity of equipments using SAP PARTS™ Seals. © SAP PARTS India.2
  5. 5. Application Requirements © SAP PARTS India. Machines operating in abrasive media like dirt, dust,sand, mud and stone demands extreme wear resistance of the sealing system. A high quality comopnet sets like Bearing, wet brake discs, gears, spindles, axles need to be perfectly protected against contamination of destructive media. Must withstand to a Circumferencial Speed of up to 10 m/sec The Sealing faces must continuously lubricated as to prevent any cold welding due to excessive heat generated in rubbing. Wear rate of Sealing Surfaces must be proportional to the face load within the sealing system. The static as well as dynamic leakage prevention must be guaranteed. The heat generated at sealing faces due to friction must be despised with adequate oil flow in the sealing system. The pressures pipe in the application must be handled by the sealing system. 3 Mechanical Face Seals
  6. 6. Sealing Function The alloy cast iron seal rings are preloaded by Torric rings or O - Rings. As a result, the axial load closes the gap between the seal faces, which leads to the sealing function. The relative movement in circumferential direction is only taken place between the seal faces. Axial load experienced by the metal sealing faces. Transmission of the friction torque to the housing components. Static sealing between each seal ring and its housing. The seal faces of the metallic rings are precision lapped. The Load distribution by O rings is combinition of various Load vectors as below - The Seals are designed in such a way that they open out from the seal faces towards the centre axis, forming a cone-shaped gap which has the following benefits: Due to capillary action in the Gap and centrifugal force , lubricant admits easily in to the seal faces. Potential cold welding of the seal faces is avoided since Adequate lubrication and cooling are assured. As wear goes on , sealing band increases and it can virtually only end when the seal collar will completely worn out. This sealing system retains a continuous oil film on the sealing surfaces. © SAP PARTS India.4
  7. 7. © SAP PARTS India. Lubrication Absolute Lubrication is Most necessary for the function of the mechanical face seal. The use of oil lubrication considerably increases with the field of applications and with respect to peripheral speed. This is because of the heat description properties of the oils. As a standard Transmission oils, grade SAE 80 and SAE 90, found to be quite suitable for typical face seal operation. The oil level after flling should be between the axis center line and 2/3 of the seal diameter................................................. When filled to the correct level, the oil will generally is sufficient for the lifetime of the seal. The face seal requires no additional maintenance. Oil lubrication When the applications are with low sliding speeds al low as 1m/sec, grease is the right consideration as a permanent lubrication. Seal Face Gap is vital consideration however in this selection. The maintenance care needs to be taken while filling grease, is that if the gun pressures is increased chances of dislodging of O - rings can result. Grease lubrication 5 Mechanical Face Seals
  8. 8. Seal Design Mechanical Face Seal DO- Type The DO type Mechanical Face Seal consists of two identical metal face seals and two rubber O - rings placed on the Ramp profile of the metal seal. The SAP PARTS ™ Seals comes in two material versions - Alloy cast iron and Alloy Forged Steel grades. The O- ring material s however are of 4 types based on the application requirements At Seal assembly the o-rings are compressed between the tapered contact surfaces of the seal ring and housing. The o-rings undergo a calculated compression as per SAP PARTS ™ standards it is around 25% volumetric compression, which is critical for proper operation of the sealing system Also the overall system Cleanliness of the o-rings and housing free of oil and dirt is of primary importance. Lubrication of the o-rings with oil or grease is not permitted during the installation process There are most comman Two Types of Mechanical Faces Seals. That is with O Ring ( DO Type) and with Trapezoidal Torric Rings (DF Type) . © SAP PARTS India.6
  9. 9.                                    Design - DO Type © SAP PARTS India. Installed condition retaining lip seal face Housing Bore gripping taper shoulder seal ring deformed o-ring O-RING A B SEAL RINGS WITH O-RING TI seal face land land surface gripping taper seal face taper throat radius retaining lip HOUSING BORE A R3 T1 T2 T3 R1 R2 T4 0D5 0D3 0D4 0D1 0D2 7 Mechanical Face Seals
  10. 10. Seal Design Mechanical Face Seal DF- Type The Mechanical Face Seal of DF Type consists of two metallic angular seal rings with identical geometrical profiles. The seal rings are assembled with trapezoid rubber rings which are placed in the particular housing bore. The geometry of the housing profile is comparatively easier to produce and the seal installation does not require an installation tool. As compared to the DO type Mechanical face seals, the resilience of the trapezoid rubber ring is normally stiffer. This limits the permitted axial movement and tolerance. Historically a numerous mechanical face seal designs were developed based the verity of application needs. SAP has few unique designs extremely suitable for demanding applications and adverse operating condition. The Design of one of the seal in the group is Inverted wrt to the other seal. This provides considerable advantage of manufacturing process of the sealing system mating components. © SAP PARTS India.8
  11. 11. Housing bore A Rz 25-40 t2 t1 t3 RS Řd Řdf β Installed condition seal face bore Ø shoulder deformed belleville washer seal ring Trapezoid ring bŘd1 h Seal rings with trapezoid ring seal face land land surface seal face taper ŘDa ŘDi H Designs - DF Type © SAP PARTS India. 9 Mechanical Face Seals
  12. 12. Special Seal Design SAP PARTS not only offers “off-the-shelf” designs – its engineering team is also available to work with your engineers to design ‘non-standard’ metal face seals. Whether developing a new seal size or type to fit your application, or utilizing a new metal seal or O-Ring material, SAP PARTS engineers have the experience necessary to design, procure and test these concepts and follow them to production. © SAP PARTS India.10
  13. 13. © SAP PARTS India. Innovations At SAP Parts, we continuously effort to pioneer developments that create competitive advantage with our parts. Our innovation plan and actions are in close collaboration with our suppliers, customers and human resources in order to meet the variable needs of customers, from time to time. Innovation is the USP of SAP Parts. Moreover it is our core value and we intend to proactively employee innovative thinking culture in all our opertions. The Sealing Solutions Delivered by SAP Parts Involves ahigh end research and patented technology warranting the highest performance and application sustainability of Mechanical Face Seals at - Max 10 M/s Surface speed. Most Severe Environmental Situations. 11 Mechanical Face Seals
  14. 14. BEARING CAVITY PRESSURE SAP Parts Seals Come with most advance and innovative anti corrosive surface treatment called CED. CED is an Extremely high corrosion protection. A 20 micron dry film of coating thickness can withstand as much as 1000 hours salt spray test ASTM B117.Able to coat complex shapes with a very high degree of accuracy and repeatability. This is an environment friendly, Water - based technology eliminates risk of fire and reduces air and water pollution. © SAP PARTS India.12 Technological Developments  Seal Design for Differential Load applications. Model for Contact Surface Wear Life Prediction. Elastomeric Variable Load Stress Relaxation Modeling. Innovative Surface Treatments for Demanding Applications.  Functional Conformance of Metallurgical Properties of Ni-Hard Cast Alloys & Sealing Surface Asperities in Abrasive Environment. Finite Element Model Details Axial constraint (Y-direction) Representative Insertion tool Innovations TIME = 5 UX (AVG) RSYS = 0 PowerGraphics EFACET = 1 AVRES = Mat DMX = 10. 406 SMN = 3. 3936 SMX = 2. 72519 -3. 3936 -2. 71374 -2. 03387 -1. 354 - .674138 . 005728 . 685595 1. 36546 2. 04533 2. 72519
  15. 15. © SAP PARTS India. O - Ring Cross Section d1 d1 < 8.0 8 < d1 < 12.7 d1 > 12.7 Gap 'S' 4 5 6 Ra < 6.5 μm Rz < 10.0 μm Rmax < 16.0 μm The axial gap "S"in the housing is vital, and is such that it meets the demands of the construction equipments and off highway Vehicle industry. For high sliding speeds it may be necessary to reduce the axial compression, thus reducing the load of the seal faces and the heat generation in the seal face. This is achieved by increasing the axial gap ''S". The following gaps are possible, depending on the O-Ring cross section. SAP Parts recommend that tests be carried out to find the most appropriate setting. Since the O-Ring is always oversized to the housing, the edges of the housing must be rounded. Surfaces Under pressure, elastomers adapt themselves to irregular surfaces. However, for liquid-tight conditions, certain minimum requirements have to be made on the surface finish of the faces to be sealed. Scores, scratches, pores and concentric or spiral machining scores are not permissible. For the surface of the seal installation chamber we recommend a machining quality of Mechanical Face Seals. Installed condition retaining lip seal face Housing Bore gripping taper shoulder seal ring deformed o-ring TM 13 Sealing System Clearance Mechanical Face Seals
  16. 16. X Y Z Contact Forces, Contact Surface & Torque Capability Load v/s Circumferential Speed Characteristics Linear Speed [ m/s] 0 0 50 100 150 200 250 300 1) 350 400 450 500 25 50 75 100 125 N=150 N=200 N=300 N=400 N=500 N=750 N=1000 N=2000 N=4000 1 2 3 4 5 6 7 8 9 10 11 12 SealOutsideDiam[mm] Ask for Seal Housing Gap “S’’ N is RPM © SAP PARTS India.14
  17. 17. © SAP PARTS India. Materials Material Chemical Composition c Si Ni Cr Mo Co V W P s Microstructure Hardness SAE-52100 Forged Steel 0.93 - 1.05 0.15 - 0.35 0.25 Max 1.35 - 1.60 0.10 Max - - - 0.025 Max 0.015 Max Fine Tempered Martensite 59 - 65 HRc FC15CR3MO ( ASTM-A 531-ll Class B) Cast Iron 3.2 - 3.6 1.1 - 1.6 1 - 2.0 14 - 16 2.0 - 4.0 0.2 max 0.2 Max 0.2 max - - Cementite Microstructure 64 - 75 HRc Ni-Hard Cast Iron 3.0 - 3.6 0.4 - 0.7 3.5 -4.3 1.2 - 1.7 0.4 Max - 0.3 -0.6 - 0.3 Max 0.1 Max Eutectic Carbide M7C3 in the Matrix of Martensite 57 - 64 HRc SAE-52100 FC15CR3MO Ni-Hard Magnification To address the main potential failure threats of a sealing system it is needed, the Wear and corrosion resistance to be adequate in the material of a seal ring. Specifically for mining machines, agriculture machinery. SAP Seals uses Alloy Steels of various Grades, following various Manufacturing Processes like Forging, and Investment Casting etc. Most preferably used are the forged Alloy Steel of Grade SAE:52100 also called as Bearing steel and Special Alloy Steel Castings, detail Specifications of these Seal Ring materials are as below:" Seal Ring Materials SAP PARTS ™ offers different coatings which provide a considerable good sealing solutions for harsh environmental conditions, and enhanced corrosion resistance for demanding environments and applications.If any special requirements SAP PARTS™ provides customized solutions on coating for which a contact to the SAP PARTS™ Engineering is needed 15 Mechanical Face Seals
  18. 18. Nitrile -25 100 Excellent Good Excellent Excellent Low LT Nitrile -50 105 Excellent Good Excellent Excellent Low Viton -10 190 Good Good Fair Excellent High HNBR -40 135 Excellent Good Excellent Excellent High Silicone -60 165 Poor Poor Excellent Poor Medium Service Temp (-) C Service Temp (+) C Abrasion Resistance Tear Resistance Water Resistance Oil Resistance Cost O Rings SAP PARTS ™ uses several materials for its Torric rings are available to meet a variety of application requirements. The most common materials are nitrile (NBR) and silicone. Viton and highly saturated nitrile (HNBR) are available for more specialized applications. The table listed below gives a brief comparison between available O- ring options The elastomers of various hardness are served depending upon the application requirements. Below is the comman materials and their applicability wrt service temperature conditions for reference. Elastomer properties for O/T -Ring selection © SAP PARTS India.16
  19. 19. O-Ring Deformation NODAL SOLUTION STEP = 5 SUB = 20 TIME = 5 CONTPRES (AVG ) DMX = 5.08001 SMX = 1.89639 0 .21071 .421419 .632129 .842838 1.05355 1.26426 1.47497 1.68568 1.89639 X Y Z NODAL SOLUTION STEP = 5 SUB = 20 TIME = 5 UY RSYS = 0 DMX = 5.08001 SMN = -.533E-05 SMX = 5.08001 -.56444 1.12889 1. 69333 2.25778 2.82222 3.38667 3.95111 4.51556 5.08001X Y Z © SAP PARTS India. 17 Mechanical Face Seals
  20. 20. Mechanical Face Seal Design Input Data Form Contact Information Seal Housing Groove Parameters Company Name :........................................................................... Date: .............................................................................................. Contact Person's Name: ............................................................... Email ID: ........................................................................................ Phone No.1: .................................................................................... Phone No.2: ................................................................................... S Housing Flange Gap D Groove Diameter - Max D1 Groove Corner Diameter D2 Housing Inside Diameter a Ramp Angle r Groove Radius L4 Distance of Groove from Face h Seal Group Width Do Outer Diameter of Seal DI Inner Diameter of Seal Horizontal VerticalHousing Position Material / grade Hardness Surface Finish Dynamic Run Out Offset Motion - Direction of Rotation Clockwise Counter- Clockwise Both Normal RPM Max RPM Assembly Removal Frequency Rare Offten Space Restrictionss Yes No If Yes - Extenet of Ristriction Operating Temperature Oil Sump Environment Max Min Contamination Partical Type % Exposed % Submerged Application Load Extent in Kg/Cm2 Fluid / Lubrication Grade Viscosity Sump Level Application Description Type Axial Radial Oil Grease © SAP PARTS India.
  21. 21. Disclaimer. SAP PARTS (TM) is the Registered trademark of SAP PARTS. The content included in this Catalouge has been compiled from a variety of sources and is subject to change without notice as are any products, programs, offerings, or technical information described in this Catalouge. The Company makes no representation or warranty whatsoever regarding the completeness, or adequacy of the Catalouge or content, or the suitability, functionality, or operation of references , images displayed in this Catalouge or its content. The Company specifically disclaims all , express or implied, including without limitation the warranties of merchantability, fitness for a particular purpose, and non-infringement with respect to this Catalouge. In no event will the Company be liable for any special, indirect, incidental or consequential damages even if company has been advised of the possibility of such damages. All the content is for user reference and any resemblance of the displayed images with any known product is at all not intentional. All the technological Data,Lists, Images, Drawings,Catalogues,Downloadable Content,etc.is However Owned by SPA Parts (TM) and unauthorised modification by user is Prohibited. Wherever any trade Sign ,Logo, or Image is used in specific, it may owe to the respective owner and not of SAP PARTS. For all updated know-how and queries kindly contact on info@sapparts.com SAP Parts Works: Plot No.85. B.U.Bhandari Indl. Estate, Off Nagar Road, Sanaswadi, Tal - Shirur, Dist. PUNE –412208, Maharashtra. INDIA Phone: +91 2137-619269 / 619271 / 619272 E-mail: sales@sapparts.com Cell: +91 9225546956 , +91 9561562957 www.sapparts.com

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