Technology Document

SAP PARTS

SAP Parts - Floating Seal Features

Innovative Sealing Solutions for haul

Truck Breaking application.
Date: 21 s t October 2016

SAP PARTS Pvt.Ltd. Plot No.85,B.U.Bhandari Indl.Estate,Off Nagar Road,Sanaswadi, Dist.PUNE- 412208 (M.S.) INDIA www.sapparts.com

Technology Document

Introduction:
A Mechanical Face
Floating Seal essentially
consists of Two Metal
Faces
of
superior
metallurgical properties,
machined by such an art
as to form a sealing
surface while the faces
are retained in rotary
sliding contact by two
elastomeric
energizers
from opposite sides. This
system seals entry of
media from either side all
the time, both while inrun and in-static conditions, thus forms a Mechanical Seal. The
actual sealing happens between the metal rings which are
virtually floating in between the compressed energizer system.

SAP-Seal Design Considerations:

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.

This sealing system retains a continuous oil film on

the sealing surfaces.

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.
Material-Metal Face Seal:
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. Specically for mining machines,
Haul truck wet break applications, SAP Seals uses Alloy Steels
of various Grades, following various Manufacturing Processes
like Forging SAE 52100 Grade, Investment Casting- High
Chrome Moly Alloy Cast Iron and Centrifugal Casting - Special
Alloy Steel Castings Ni-Hard Grade containing Graphite for
low friction and higher abrasion resistance.
Metallurgical Specifications:

The Load distribution by O rings is combination of various

Load vectors as below

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 Seals are designed in such a way that they open out from
the seal faces towards the center axis, forming a cone-shaped
gap which has the following benets:

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.

SAP PARTS Pvt.Ltd. Plot No.85,B.U.Bhandari Indl.Estate,Off Nagar Road,Sanaswadi, Dist.PUNE- 412208 (M.S.) INDIA www.sapparts.com

Technology Document
Metal seal ramp, by employing FEA modeling techniques for
Floating seal and O ring assembly.

Materials- Performance Matrix:

Material

SAE52100
Forged
Steel

Performance

FC15C43MO

Ni-Hard
Alloy Cast
Iron

Abrasion
Resistance
Toughness

Good

(ASTM-A 532II Class B)

Cast Iron
Best

Good

Best

Better

Heat
Resistance
PV Results

Good

Better

Best

Better

Good

Best

Good

Better

Best

Spalling
Galling

&

Better

Materials- Rubber O-Ring:

O Ring Deformation :

SAP PARTS uses several materials for its Torric rings 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. Apart from these , HNBR Cold Formula, FP &
Silicone material O rings are suggested for highly customized
end applications.
Nitrile

Service
Temp(-) C
Service
Temp(+) C
Abrasion
Resistance
Tear
Resistance
Water
Resistance

-25

LT
Nitri
le
-50

100

105

190

135

165

Excelle
nt
Good

Excel
lent
Good

Good

Excellent

Poor

Good

Good

Poor

Excelle
nt

Excel
lent

Fair

Excellent

Excellent

Oil Resistance

Excelle
nt
Low

Excel
lent
Low

Excell
ent
High

Excellent

Poor

High

Medium

Cost

Viton

HNBR

Silicone

-10

-40

-60

Initial distance A

Axial constraint (Y-direction)

SAP Parts Rubber seals are made by special processes with

control on specifications like, Hardness, compression set,
elongation, specific gravity, tensile strength, Oil and Air aging
Volume swelling, Change in hardness, Low temperature
compatibility, TR values (TR10/TR13), at specifications in line
with international standards for Rubber products viz-ASTM D2000 & ASTM -1414.In addition to these material properties
performance tests capabilities are developed to validate the
product like LoadV/s Deflection analysis, Stress Relaxation
modeling and FEA analysis of O rings.
O-Ring Contact Geometry: SAP Parts can estimate the
contact pressure, O-ring deformation, and Force at O-Ring to

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SAP Parts- Floating Seal Features

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Technology Document
Load Vs/Circumferential Speed

Innovations:
Innovation is the USP of SAP Parts. The Sealing Solutions
delivered by SAP Parts Involves a high end research and
patented technology, warranting the highest performance and
application sustainability of Mechanical Face Seals at
- Max 5 M/s Surface speed.
- Most Severe Environmental Situations.
Technological Developments

Load V/s Deflection Charecterstics:

Surface Coating:

250

GAP BETWEEN TWO

HOUSING (mm)

200

PEAK LOAD(kg)

FACE LOAD (KG)

Min.face load (kg)

150

100

50

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.

SAP Parts Seals Come with most

advance and innovative anti
corrosive surface treatment
called CED. Cathodic Electro
Deposition is an extremely high
corrosion protection. A 20 micron dry lm 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 re and reduces air
and water pollution.

0
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10

Gap Between Two Housing (Deflection) mm

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Technology Document
Testing:

Report: Torque V/s Time

A multilateral Quality Assurance approach is employed. This

includes Comparative analysis of vigorous performance tests
carried out on Seals on Test bench simulating accelerated field
condition in the Laboratory. The known standards parts are
tested against Sap Parts products in the same environment to
get the comparable data. The known standards may be any of
known / competitor product that is tested against same
specification SAP Parts Product for analysis purpose. Test may
be intentional by Customer Requirement or Voluntary by SAP
Parts Design Verification Process. Being continuous up
gradation process, the results of such test are used to improve
ongoing developments. Several such performance tests are
carried out yielded benchmarking of

Seal Specifications:
PARAMETER

DESCRIPTION

SPECIFICATION

Material

Metal Seals - Forged by

Ring Rolling Process Cast
Alloy By Centrifugal,
Investment Castings.

Steel-100Cr6

Rubber Rings O Rings

NBR/HNBR/Silic
on/Viton

Through Hardened and

Tempered in controlled
atmosphere. Fine tempered
Marten site
Microstructure.

60-63 HRc
Forged Steel

Sealing
Surface
Flatness

Within 3 light Bands of

Optical Interference of
Monochromatic Light.

1~3 Micron Max

Sealing
Surface
Roughness

Polishing Attained By
Lapping Process.

< 0.5Rt

The Dual Cone

Especially Designed Ramp

angle profile with Higher
Grip texture to hold the O
rings firmly.

8-15-20 Degree

With Oil

5 Meter/Sec Max

With Grease

3 Meter/Sec Max

Hardness

Alloy Cast Iron

Ni-Hard

65- 70 Hrc Cast

Iron

Seal life & Endurance Test Set-Up:

1.

Mud Packing Test:

2.

4.

and

Leakage

with

Heat Generation Test :

3.

Mud Submerged Wear

Contamination Test.

Time v/s Pressure v/s Surface Speed in

Lubrication to study amount of Heat Generated.

Elastomeric Test :

Angle

Oil Compatibility Test

Face load variation v/s Time/Temperature.

O- Ring Squeezing Test.

O- Ring Contraction Test.

P-V Test

Pressure v/s Velocity(Linear Speed)

Wear, Galling and Spilling Test

2016/10

Operating
Speed

Pressure/Load
Bearing
Capacity

SAP Parts- Floating Seal Features

3 Bars Max

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