Lip Seal

RADIAL LIP SEALS OVERVIEW AND FUNCTION
Dr. Dr Frank Bauer Institute of Machine Components (IMA) Universitt Stuttgart / Germany
Basics F Function of PTFE and El t ti f PTFE- d Elastomeric- Li seals i Lip l Shaft surface A l i Analysismethods and T t Ri th d d Test Rigs Simulation of Lip seals
Institute of Machine Components
UNI STUTTGART Sealing Technology
STLE 2010 Annual Meeting
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Content
air conditioner gears servo steering valve cap tail pipe
sunroof
door and window seal lamp housing differential gear g wheal bearing
Demands and trends engine: crankshaft, crankshaft camshaft, valve steam, pistons, pistons cylinder head
brake hydraulics
Higher velocities Higher Hi h temperatures Aggressive fluids Cheaper production of the shaft!
STLE 2010 Annual Meeting Hrl
Sealing applications 2
ambient conditions - d t dust - dirt - water - t temperature t
operating conditions s a t pos t o - shaft position - rotation speed - start & stop - concentricity - vibrations - temperature

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Sealing System 3

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Contacting Sealing Systems for rotating applications 4
Criteria
Seal Type Elastomeric Elastomeric PTFE Lip seal Lip seal Lip seal Seal edge Sealing Aid plain PTFE Lip seal spiral groove ++ ++ ++ + ++ ++ ++ -++
Reverse Pumping Static Tightness Thermal Resistance Chemical Resistance Direction of Rotation Needs perfect Shaft
+ + -++ --
++ + ----
With and without Sealing Aids

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Function - Pro/ Con 5
housing
different design / geometries sealing of oil and grease zero / low pressure
rotary shaft lip seal oil side sealed fluid shaft width of contact spring air side
DIN 3760 / 3761, ISO 6194 materials: NBR FPM ACM NBR, FPM,
contact area

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Function - Elastomeric-Lip Seal 6
oil side shaft

K
air side seal edge
seal edge oil

K
shaft
Fluid fill d Fl id filled sealing area. li Why is the fluid prevented from leacking out of the seal? g
Lip surface is displaced from the shaft due to hydrodynamic effects.
Reverse Pump Effect

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Function - Elastomeric-Lip Seal Hydrodynamic Lubrication 7
Hydrodynamic pumping due to micro asperities on the seal lip.

rotary shaft lip seal housing figurative distribution of the contact pressure
oil side oil
air side
undistorted micro asperities rotation: distorted wavy micro asperities due to friction
distribution of the frictional shear stress
shaft

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Function - Elastomeric-Lip Seal Pump Effect 8
Lip seal
- sealing mechanism - lubrication - wear

fluid pumping in the sealing area
Sealing system - friction - temperature

- oil aging - elastomer aging
- wear - leak tightness - life time
- leakage g - dry running

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Influence Shaft Surface 9
Pump Effect System = P P Eff t S t Pump Effect Seal Lip + P Eff t S l Li Pump Eff t Shaft Effect Sh ft
Possible cases pumping direction: inside inside seal: inside shaft:
inside outside
dry running
ideal
leakage

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Pump Effect Sealing System 10
DIN 3760 / 3761: average roughness Ra = 0,2 0,8 m medium roughness Rz = 1 5 m max. roughness Rmax 6,3 m no machinig lead (twist-textures) well moistening surface no damage / scratches, porousity, grooves hardness at least 55 HRC, depth of hardening 0 3 mm 0,3 diameter tolerance ISO h11 roundness t l d tolerance IT 8
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Shaft Specifications 11
Textures (twist of shaft) hydrodynamic fluid pumping

aligned textures (scrolling)
fine
coarse undirected texture (no machining lead)
superposed
lead length
circumfe ference
angle period length depth cross section

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Pump Effect of Shaft 12
Chemical Attack Expansion (Quellen) or shrinking Blisters in the area of the seal edge Thermal Attack High t Hi h temperatures at th seal edge t t the l d High velocity of the counterface Thermal Attack of the oil and the additives, oilcoal formation
Abrasive Wear of the Shaft and the Seal edge Lubrication in the contacting area (mixed lubrication) Rough Shaft surface (Wear on the seal edge) Dust and particles (Wear at the shaft )

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Failure Modes of Elastomeric- Lip seals 13
genau waagrecht
Suspended Weight Method

dnnes l
Carmen Method (Daimler AG)

Rauheitstaster
Wischeffekt
n = 20 min-1
Parallele Tastschnitte
Welle
Bleistiftstrich
Rohaar
Schappseide S303 Fishing Line 0,22 mm m = 30 g
Analysis of Roughness-measurements
Shows twist on the shaft due to movement of the hairline

80
Microstructure-Analysis (IMA)
Schwellwert 0.8 - Pixelfilter 10
ci ircumferen ntial
70 60
Hufigkeit
0 - 0.1 0.1 - 0.2 0.2 - 0.5 0.5 - 1
y 0 -90 90
50 40 30 20 10 0
-90 -80 -70 -60 -50 -40 -30 -20 -10 0
10 20 30 40 50 60 70 80 90
Winkel [Grad]
Scratch-analysis of topography measurements

Pumping Rate Analysis Next slide

Analysismethods Shaft Lead Detection 14
Pumping Rate
Lip seal mounted backwards
Pump rate (measured leakage) is used to compare different sealing systems
Shaft Lead Detection
Rotation of the shaft in both direction The difference of the Pumping Rate is the R t i th pumping amount of i t f the shaft!
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Pumping Rate Analysis 15
Oilchamber Spindle S i dl Temperaturesensor Heatingelement Coolingwater

Sealingmount
EMotor Base Bearinghousing Belt

Speeds up to 15.000 rpm Temperature from 20C up to 150 C Shaftdiameter up to 150 mm At atmospheric pressure or pressurized
RSS Shaft
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Long Time Test Rig 16
6000
Full film lubrication/ High speed + Temp.
90 80 70
5000
52 Test Rigs!
temperature [C]
4000
60 50
rpm [min.-1]
3000 40 2000 rpm temperature 30 20 10 0 0 5 10 15 20
1000
Mixed lubrication Heavy Wear
time [h]
Test program: Temperature and rotational speed profile with different conditions of lubrication different failure modes
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Long Time Test Rig 17
7 Test Rigs! Mounting plate l t Loadcell Shaft Belt driven spindle Aerostatic bearing Oil chamber
Lip Seal with housing

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Friction test rig 18
1) Dryrun with tempered shaft
2) Wetted with tempered shaft
3) Sealing with tempered oil
4) Pumping with tempered oil

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Friction Torque test conditions 19

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Flow Analysis Test Rig 20

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Flow Analysis Test Rig 21
t = 6s
1 2 3
Edge of 1st groove .
t = 12s
t = 18s
t = 24s
t = 30s
Air filled groove Penetrated fluid Stopper

t = 36s
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Visual Analysis Glass hollow shaft 22
Plain brass particles Pl i b ti l which do not influence the flow

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Visualizing Particles 23
Airside Airside
Oilmenism Staticsealing St ti li point
reversepumped oil

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Dynamic function: Pumping 24

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Dynamic function: Pumping 25
CFD-Multiphase Oil and air with free surfaces
FEM Structural optimizations

LengthTop Extension LengthFront L th F t Extension HightTop Extension Widthof thelip
HPC-Cluster HPC Cluster 32 Processors / 96 Gb RAM
CFD Heat Transfer
Institute Instit te
Connection to High Performance Computing Center Uni Stuttgart CFD Velocity and Pressure Fields FEM Material- and Wearmodels Bwgrid 5600 Processors Legend: Connection 10 Gbit
Filler in PTFE-matrix
Simulation Examples

Simulation - Overview 26
LengthTop Extension E i LengthFront Extension HightTop Extension Extension

Knoten nRadialkraft R[N] tF
10,00 8,00 8 00 6,00 4,00 2,00 0,00
Widthof thelip
Radialkraftverteilung 43N 43 N 42N 42 N 7N 7N

Ring/ 1. Damm
2. Damm
3. Damm
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Simulation FEA; Geometry optimization 27
oilside lseite

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Prototype 28
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Maximalgeschwindigkeit der Welle
Drei Gewindegnge mit Durchmesser 80 mm
Geschwindigkeitsfeld im Kanal Unterschiedliche Frderung in Abhngigkeit von der Spiralrillengeometrie

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Simulation CFD; Flow in spiral groove 29
Kont taktnormalspannung [N/mm ]
6,0 5,0 4,0 3,0 2,0 1,0 , 0,0
= 45 ; = 25 45; 25
Geometry for The CFD-Analysis
Berhrbreite [mm]
Contact A l i C t t -Analysis of the Seal edge Asymmetric distribution On the oil and the airside! oilVerzerrungsstruktur unter der Dichtkante
Untersuchung des hydrodynamischen Druckaufbaus unter der Dichkante
Bewegte Wand (Welle)

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Simulation CFD; Flow in Seal edge of Elastomeric Lip seal 30
Berechnung des Geschwindigkeits- und Temperaturfeldes Asymmetrisches Temperaturfeld Berechnung der Wrmebergangskoeffizienten 136 Gehuse l RWDR Welle Welle Luft Luft 200 2 RWDR l

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Simulation Heat transfer 31

Lip Seal

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RADIAL LIP SEALS OVERVIEW AND FUNCTION

STLE 2010 Annual Meeting

air conditioner gears servo steering valve cap tail pipe

ambient conditions - d t dust - dirt - water - t temperature t

Institute of Machine Components

STLE 2010 Annual Meeting

Institute of Machine Components

STLE 2010 Annual Meeting

Contacting Sealing Systems for rotating applications 4

With and without Sealing Aids

Institute of Machine Components

STLE 2010 Annual Meeting

Function - Pro/ Con 5

Institute of Machine Components

STLE 2010 Annual Meeting

Function - Elastomeric-Lip Seal 6

oil side shaft

air side seal edge

seal edge oil

Lip surface is displaced from the shaft due to hydrodynamic effects.

Reverse Pump Effect

Institute of Machine Components

STLE 2010 Annual Meeting

Function - Elastomeric-Lip Seal Hydrodynamic Lubrication 7

Hydrodynamic pumping due to micro asperities on the seal lip.

oil side oil

distribution of the frictional shear stress

Institute of Machine Components

STLE 2010 Annual Meeting

Function - Elastomeric-Lip Seal Pump Effect 8

- sealing mechanism - lubrication - wear

Sealing system - friction - temperature

- wear - leak tightness - life time

- leakage g - dry running

Institute of Machine Components

STLE 2010 Annual Meeting

Influence Shaft Surface 9

Possible cases pumping direction: inside inside seal: inside shaft:

Institute of Machine Components

STLE 2010 Annual Meeting

Pump Effect Sealing System 10

STLE 2010 Annual Meeting

Textures (twist of shaft) hydrodynamic fluid pumping

coarse undirected texture (no machining lead)

angle period length depth cross section

Institute of Machine Components

STLE 2010 Annual Meeting

Pump Effect of Shaft 12

Institute of Machine Components

STLE 2010 Annual Meeting

Failure Modes of Elastomeric- Lip seals 13

Suspended Weight Method

Carmen Method (Daimler AG)

Shows twist on the shaft due to movement of the hairline

0 - 0.1 0.1 - 0.2 0.2 - 0.5 0.5 - 1

-90 -80 -70 -60 -50 -40 -30 -20 -10 0

Scratch-analysis of topography measurements

Pumping Rate Analysis Next slide

Analysismethods Shaft Lead Detection 14

Lip seal mounted backwards

Pump rate (measured leakage) is used to compare different sealing systems

Shaft Lead Detection

STLE 2010 Annual Meeting