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ADVANTAGE SAP PARTS

Mechanical Face – Duo Cone Seals

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INDEX

1. INTRODUCTION.

2. SAP SEAL DESIGN PRINCIPLE.

3. MECHANICAL FACE, DUO CONE SEALS FEATURES.

4. DEVELOPMENT.

5. APPLICATION ENGINEERING.

6. NEW DEVELOPMENT – TECHNOLOGY SOLUTION.

7. PRODUCT DESIGN CONSIDERATIONS.

8. SEAL RING MATERIALS.

9. TORIC RING ( O RING) MATERIALS.

10. DUO-CONE SEAL RAMP ANGLES.

11. DESIGN INFORMATION.

12. LOAD DEFLECTION.

13. PRESSURE VELOCITY.

14. SIGNIFICANT FACTORS INFLUENCING THE DESIGN SELECTION.

15. SEAL WEAR MEASUREMENT.

16. LUBRICANT REQUIREMENTS.

17. SPECIALTY SEALS.

18. SAP PARTS’ UNIQUE SEAL LIFE TESTING.

19. CUSTOMER SPECIFIC SEAL DESIGN & DEVELOPMENT.

20. FUNCTIONAL TEST LAB CAPABILITIES.

21. QUALITY ASSURANCE.

22. SOLUTIONS TO SEAL FAILURE MODES.

23. SAP PARTS’ MECHANICAL FACE SEALS MANUFACTURING PROCESS CONTROL.



ADVANTAGE SAP PARTS

Mechanical Face – Duo Cone

Seals

IIIIntroductionntroductionntroductionntroduction:

SAP Parts is ISO 9001: 2008 CertifiedISO 9001: 2008 CertifiedISO 9001: 2008 CertifiedISO 9001: 2008 Certified leading manufacturer of Precision Mechanical

face-Duo Cone Seals.

Based in PUNE – INDIA, it is the most advance facility catering the innovative Design-Development and technology

Solutions for your Sealing Requirements.

SAP Parts Duo Cone Seals are accepted and used by most of the leadingSAP Parts Duo Cone Seals are accepted and used by most of the leadingSAP Parts Duo Cone Seals are accepted and used by most of the leadingSAP Parts Duo Cone Seals are accepted and used by most of the leading Construction Equipments Construction Equipments Construction Equipments Construction Equipments OEM based in OEM based in OEM based in OEM based in

Europe, USA & Asia.Europe, USA & Asia.Europe, USA & Asia.Europe, USA & Asia.

SAP Parts’ Seals are technologically developed for

protection of equipment working in the extreme and

most adverse conditions like mud, rock-dust, sand,

and water, desert heat and sever cold. These Seals

provide very effective lubricant retention and exclude

contaminates in all applications across all types of

conditions have proven a long service life with low

maintenance.

SAP Parts seal designs use elastomeric O-Rings to

provide loading for the metal component. The design

uses the contact area between the metal sealing rings

to create a static and dynamic seal.

These Seals serves under most of the drastic and hostile service conditions and applications where all other radial-

lip type elastomeric seals do not withstand.

SAP SEAL SAP SEAL SAP SEAL SAP SEAL DESIGNDESIGNDESIGNDESIGN::::

These Seals are fitted in Groove of a retaining Housing

to form the sealing at the adjoining faces. Metal faces

are precision Lapped to Rt < 0.5. The seals having faces

profiled to spherical shape of R 2032 mm. This face is

further lapped to form a flat band at the outer side The

ramp angle of Seal and Housings are slightly different

and form a wedge for the rubber ring to slide into and

form a compressed profile giving load on the seals and

making it intact.

In the application, one of the metal seal is always

stationery while other is rotating with respect to the

roller.

The friction in the lapped faces transmit the load and

sealing caused retains the oil filled in small cavity formed

12 3

4

1− SEAL RING, STATIC 3. SEAL RING,ROTATING2.O−RING 4.O−RING

F

FG

FL

COMPRESSED O-RING

FACE LOAD



by the faces. The Flat Portion of seal 2 mm wide will start wear from the end i.e. from OD and will go on towards

ID. Till it reaches to the area where spherical radius starts.

Mechanical faceMechanical faceMechanical faceMechanical face, Duo Cone Seals, Duo Cone Seals, Duo Cone Seals, Duo Cone Seals FeaturesFeaturesFeaturesFeatures::::

- Corrosion-resistant seal rings

- Precision lapped, self-renewing sealing surfaces

- Minimum face load variations

- Special seal and O-Ring materials to match application requirements

Rotating speed, lubrication, temperature, and differential pressure are factors to consider when determining seal

face loads. Mechanical face, Duo Cone Seals provide good performance across a wide range of face loads,

therefore, compensating for considerable assembly tolerance buildup, misalignment, and wear.

DEVELOPMENTDEVELOPMENTDEVELOPMENTDEVELOPMENT::::

To avoid the high cost of equipment downtime it needs the best available seal. The SAP Parts Mechanical face Seals

provides superior performance in extreme applications where positive lubricant retention and the ability to keep out

damaging and/or abrasive materials are essential.

Application EngineeringApplication EngineeringApplication EngineeringApplication Engineering::::

At SAP PARTS, its engineers can analyze your sealing requirements, recommend the metal face seal that would

best meet your needs, work with your engineers to design the installation and even provide drawing to aid in your

design.

PARAMETERS DESCRIPTION SPECIFICATIONS

Material Forged by Ring Rolling Process

Loss Wax Investment Casting

SAE 52100 /100Cr6

Special Alloy Steel

FC15Cr3MO

Hardness Through Hardened and Tempered in

controlled atmosphere. Fine tempered

Marten site Microstructure

60-63 HRc

The Flatness guarantee

on the surface

Within 3 light Bands of Optical

interference

1~3 Micron Max

The surface roughness

on the Lapped surface

Flatness Attained By Diamond Lapping

Process

< 0.5Rt

The Dual cone angle

range

Conforming to OEM Specifications.

Specially Designed Ramp angle

profile with Higher Grip texture

to hold the O rings firmly.

8-15-20 Degree

Operating Speed With Oil 10 Meter/Sec Max

Operating Speed With Grease 3 Meter/Sec Max

Pressure / Load Bearing

Capacity

3 Bars Max

12 3

4 5

1. SEAL STATIC2. O−RING3.SEAL ROTATING4.O−RING

5.HOUSING



NEW DEVELOPMENT NEW DEVELOPMENT NEW DEVELOPMENT NEW DEVELOPMENT –––– TECHTECHTECHTECHNOLOGY SOLUTIONNOLOGY SOLUTIONNOLOGY SOLUTIONNOLOGY SOLUTION

* DUAL FACE UNITIZED, SILICONE GEL FILLED MECHANICAL CASSETTE SEAL ASSEMBLY. *Under Patent Registration

Customer INPUT Conditions For DevelopmentCustomer INPUT Conditions For DevelopmentCustomer INPUT Conditions For DevelopmentCustomer INPUT Conditions For Development SAP PARTS Development SolutionSAP PARTS Development SolutionSAP PARTS Development SolutionSAP PARTS Development Solution

Purpose:

The Seal Assembly is designed to protect the spindle from dust, dirt, mud in the

environment of application and prevent the Oil filled in, from leakage, while in function

and to provide a stable sealing for higher life.

Design Solution :

It is comprised of two mechanical face seals - Sealing Discs, duly hardened - tempered to

60 HRc and Precision lapped, achieving the surface finish level Ra<0.08, retained by 4

Torric Rings i.e. O- Rings out of NBR60SH and the cavity formed by the Sealing Discs, filled in with Special Silicone Gel to

dissipate the frictional heat generated in working.

The entire assembly is enclosed by two formed Seal Casings (Plasma Nitrided and Corrosion Protected), the inside and outside

dia. of which is in contact with the Spindle OD & housing ID, is bounded by rubber. Thus forming a *dual face unitized, silicone

gel filled mechanical cassette seal assembly.

Function:

The cover fixed on the spindle is stationery and so do the mechanical seal associated with it, however the cover & seal at

Housing side will undergo the wheel dynamics and cause the high pressure at the opening of the seal lead to pump out the dust

particles. The seal case is formed inverted on outer face. It will arrest the environmental debris to come and in case they travel

through the space between two covers will get arrested at O – rings (Big Dia.) In non-moving condition the dirt will settle by

gravity in the gap at the outside periphery of the cover track and hence it will not ideally cross the barrier formed by mechanical

seals’ lapped faces in contact. Similar is the case for the oil filled in the spindle, it will be arrested to come out by the virtue of

inner O-Ring (Small Dia.) Thus the Seal assembly can perfectly serve the purpose it is intended to be used for.

Special Features & Advantages:

1. Balanced face load - on the sealing discs by virtue of 4 Torric rings placed inside the case.

2. Nick provided on Sealing Discs - leads to spring action for stability. This gives proper sealing even after wear.

3. Rubberized casing - protects spindle & Housing from wear due to metal contact.

4. Silicone Gel - dissipates the frictional heat generated in working and arrests dirt to move any further.



Product Design Product Design Product Design Product Design ConsiderationsConsiderationsConsiderationsConsiderations

Seal Ring Materials Seal Ring Materials Seal Ring Materials Seal Ring Materials ::::

SAP Seals uses Alloy Steels of various Grades, following various Manufacturing Processes like Forging, Sheet Metal

Forming 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:

SEAMLESS ROLLED BARS, TUBES, FORGED &

TURNED RINGS, CRCA Sheet - Formed Seals

SPECIAL ALLOY IRON CASTINGS - FCCrMo

(FOR FLOATING SEALS)

Grade SAE 52100

FC5Cr6Mo× FC9Cr6Mo× FC15Cr3Mo× FC15Cr6MoNiV× G-Cr Mo V 17.3.1

Chemical

Composition % Min. Max. % Min Max Min Max Min Max Min Max Min Max

C 0.93 1. 05 C 3.60 4.00 3.50 3.90 3.20 3.60 3.20 3.60 3.40 3.80

Si 0.15 0. 35 Si 1.50 2.00 1.20 1.70 1.10 1.60 1.10 1.60 0.70 1.20

Mn 0.25 0.45 Mn 0.50 1.00 0.50 1.00 0.50 1.00 0.50 1.00 0.70 1.00

Cr 1.35 1 .60 Cr 4.50 6.00 8.30 10.50 14.00 16.00 14.00 16.00 15.00 18.00

P - 0.025 - - - - - - - - - - -

S - 0.015 - - - - - - - - - - -

Mo - 0. 10 Mo 5.00 8.00 5.00 8.00 2.00 4.00 2.00 4.00 2.00 3.00

Cu - 0. 30 Co 0.20 MAX 2.50 3.50 0.20 MAX 0.20 MAX - -

Ni - 0. 25 Ni 1.70 2.10 1.70 4.30 1.00 2.00 1.00 2.00 - -

Al - 0.05 - - - - - - - - - - -

Sb - 0.005 - - - - - - - - - - -

Sn - 0.03 V 0.20 MAX 1.70 2.40 0.20 MAX 1.30 2.00 0.50 1.00

As - 0.04 W 3.50 4.50 3.50 4.50 0..2 MAX 0..2 MAX - -

Manufacturing Made by Electric Arc

Furnace, Ladle Refining

Furnace & Vacuum De -

Gassing.

By Investment Casting Loss of Wax Process

Surface Free from surface defects

such as Cracks, Seams,

Laps, Pit- marks, Rust &

Scale etc

Free from surface defects such as Blow Holes, Cracks, Seams, Laps, Pit- marks, Rust & Scale etc

Heat Treatment Through Hardening,

Quenched in Oil &

Tempering.

Shall be used as casting state Air cooled after maintaining 500 ~

550˚C for 1.5 Hr & maintaining for 2 Hr

Air cooled after maintaining

850~900˚C For 20~40 min

Hardness 62 ± 3 HRC62 ± 3 HRC62 ± 3 HRC62 ± 3 HRC HRC 65HRC 65HRC 65HRC 65----72727272

Microstructure Uniformly distributed

small carbides in

tempered martensite

matrix

Uniformly distributed small carbides in tempered martensite matrix

Retain Austenite RA < 4% RA < 4%



Torric Torric Torric Torric RingRingRingRing ( O Ring) ( O Ring) ( O Ring) ( O Ring) Materials Materials Materials Materials ::::

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.

Nitrile LT Nitrile Viton HNBR Silicone

Service Temp(-)�C -25 -50 -10 -40 -60

Service Temp(+)�C 100 105 190 135 165

Abrasion Resistance Excellent Excellent Good Excellent Poor

Tear Resistance Good Good Good Good Poor

Water Resistance Excellent Excellent Fair Excellent Excellent

Oil Resistance Excellent Excellent Excellent Excellent Poor

Cost Low Low High High Medium

DuoDuoDuoDuo----Cone Seal Ramp Angles Cone Seal Ramp Angles Cone Seal Ramp Angles Cone Seal Ramp Angles

Seal Ramp Angle ∝ This design of Ramp angle offers a more uniform load profile over its operational face gap

range. In the application due to external pressure, debris packing, or vibration the torics can

force down the ring and can cause sudden decay of the face load and sealing integrity to

avoid this specified Ramp angle is provided which forms a wedge in between housing and

retains the Torric more firmly.

8� ∝ By this extent it offers increased toric retention and a more uniform face load profile.

15� ∝ By this extent , the sealing design offers resistance to internal operating pressure and an

ability to achieve higher sealing face loads than those available with the 8� seals. This design

is most commonly used in final drive, axle, and wheel applications.

20� ∝ This is similar to the 15� seal design in that it resists internal pressures. The 20� design

produces higher face loads than either the 8� design. It is most commonly used in

undercarriage applications.

Seal RSeal RSeal RSeal Ring Sizesing Sizesing Sizesing Sizes

SIZES(mm) Min Max

AAAA 50 395

BBBB 39 365

CCCC 14 38

DDDD 52.2 400



Design Information Design Information Design Information Design Information

Seal Housing: The installation dimensions of the seal housing are

shown in the Figure. .

The axial gap S in the housing is such that it meets

the demands of the construction machinery 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

Load Deflection Load Deflection Load Deflection Load Deflection ::::

The typical load/deflection chart for a Duo-

Cone Seal illustrates the flat curve

developed by its design. These seals work

satisfactorily over a wide range of the curve.

Load deflection characteristics vary by

Mechanical face, Duo Cone Seals type, O-

Ring material and seal group size. SAP

PARTS engineering should be consulted for

design assistance concerning proper

loading of Mechanical face, Duo Cone

Seals.

DEFLECTION IS USED FOR APPROPRIATION OF CONTACT PROFILE

Pressure Velocity Pressure Velocity Pressure Velocity Pressure Velocity

Mechanical face, Duo Cone Seals performance capability can be described by its Pressure-Velocity (PV) or load

speed

O - Ring Cross Section

d1 Gap 'S'

d1 < 8.0 4

8� d1 �12.7 5

d1 > 12.7 6

Ra < 3.2 µm

Rz < 10.0 µm

Rmax < 16.0 µm

GAP

COMPRESSEDO−RING

RAMP ANGLE

12 3

4

1. SEAL STATIC2. O−RING

3.SEAL ROTATING

4.O−RING

5.HOUSING



533 mm

457 mm

146 mm

Face Load

Rotational Speed

rating. The face load required to keep the metal seal rings in contact is related to the allowable speed, as described

by the following chart. Many factors influence this relationship, including seal ring material, seal ring diameter,

operating temperature, lubricant viscosity, differential pressure across the load rings and action of centrifugal force

on the load ring.

In low speed applications or with light lubricants,

face pressures are generally increased to insure

sealability. The same is true when seals are

exposed to high differential pressures and/or

large endplay or deflections. Lower face loads

are

specified for applications producing high

peripheral speeds or high ambient temperatures.

High speeds tend to centrifuge lubricant away

from the seal face, and centrifugal forces tend to

roll the torics up the seal ramp, increasing the

face load. Both conditions contribute to scoring

failures. Mechanical face, Duo Cone Seals have

been used successfully to 456 mpm (1500 fpm).

Consult SAP Parts Precision Seals when selecting

face load to insure appropriate design target.

Significant Factors Influencing the design SelectionSignificant Factors Influencing the design SelectionSignificant Factors Influencing the design SelectionSignificant Factors Influencing the design Selection

The selection of the proper Mechanical face, Duo Cone Seals is contingent on a thorough application review.

Differences in operating conditions have a significant impact on the optimum Mechanical face, Duo Cone Seals

for your product. Shown in the table below are significant application variables and the component

of the Mechanical face, Duo Cone Seals product they affect.

Variable Variable Variable Variable Design ConsiderationDesign ConsiderationDesign ConsiderationDesign Consideration

Speed Metal Seal Ring Material

Internal/External Pressure Metal Seal Ring Material and Ramp Angle

External Operating Environment Metal Seal Ring and Torric Ring Material

Temperature Torric Ring Material

Available Space Mechanical face Seal Type

End Play Metal Seal Type and Seal Ramp Angle



Seal Wear MeasurementSeal Wear MeasurementSeal Wear MeasurementSeal Wear Measurement

SAP Duo Cone Seals automatically compensate for wear.

SAP PARTS has developed technology for Wear Re – countering Profile,

enables lapped metal seal faces automatically and continually renewed.

The mating faces form a contact band

around 0.5 to 1.0 mm wide that retains

the oil lubricant and seals out all foreign

material. As wear occurs, the contact

band will widen slightly and migrate

inward until the inside diameter is

reached. As shown in the figure, the seals

wear down the spherical radius.

Remaining life can be easily estimated by visual inspection of the seal band location. Remaining wear life can be

estimated based on a linear relationship of service hours and contact band position.

Physical measurement of wear can be determined by measuring the distance between the sealing contact band

and the inner diameter of the sealing ring. To calculate the wear life remaining on the seal, measure the distance

between the seal inner diameter and the sealing contact band. If this distance is greater than 50% of the distance

between the seal inner diameter and outer diameter, there is adequate seal life for this seal to be reused.

Formed seals are more flexible than the cast rings they replace and, as a result, produce a wear pattern different

than cast ring designs. Typically, formed seals wear in an axial rather than radial direction, as depicted below, due to

their increased flexibility.

The total thickness of the flange is usable wear material on the formed seal rings, and good seal performance can

generally be expected until the flange is completely worn away. Measuring the ring flange thickness and using the

chart below can estimate remaining service life. Minimum flange thickness required for usability is 1.27mm

With formed seal rings, the measured parameter used to check the remaining seal life is flange thickness at the

outer edge. The measurement must be made carefully since the shoulder is only 1.52 mm from the edge of the

flange. Estimates of expected seal life are difficult because there are many differences in machine applications,

job conditions, maintenance and other factors that affect seal service life.

Formed Seal Wear Chart

Flange Thickness Seal Wear

mm % Worn

1.91 0

1.59 25

1.27 50

0.95 75

0.64 100

0.32 125

0.00 150



Lubricant Requirements Lubricant Requirements Lubricant Requirements Lubricant Requirements

Because the dynamic sealing surfaces are metal, lubricant is always required on the inside diameter of the seals. Oil

lubricant should be used with all Mechanical face, Duo Cone Seals. A detergent type SAE 10W-40 is the

recommended lubricant type. However, other mineral base oils ranging from 10WT to 90WT are commonly used,

depending on ambient temperature requirements. EP gear lubricants should be used with caution, as some EP

additive packages are incompatible with silicone torics.

In some slow rotating or oscillating applications, certain types of grease may be used, but mineral base oils are

always preferred. Grease is not recommended in applications where the seal face surface speed exceeds 30.5 mpm

Oil not only provides lubrication to the sealing faces, but also serves to cool the seal rings. Lubricant must cover a

minimum of one third of the sealing surface to properly lubricate and cool the rings. Mechanical face, Duo Cone

Seals work best in clean, closed systems. To allow adequate volume for thermal expansion, closed cavities should

not be filled more than 90% full. Maximum care should be taken to insure lube cavities are clean at assembly – free

from dirt, scale and other foreign materials. Cleanliness levels of 500mg mass per square meter of surface area and

a maximum particle size of 1.0mm should be maintained at assembly to provide maximum life.

Specialty Seals Specialty Seals Specialty Seals Specialty Seals

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’ UNIQUE SEAL LIFE SAP PARTS’ UNIQUE SEAL LIFE SAP PARTS’ UNIQUE SEAL LIFE SAP PARTS’ UNIQUE SEAL LIFE TESTINGTESTINGTESTINGTESTING

The Seal Life , Leakage & Endurance Test Rig is designed to

1. Test the Possible Oil Leakage from the seals in

assembled condition inside the housing.

2. Test the seal wear pattern and face load experienced by

the seal while on run.

3. Test the life of the seal to an extent of maximum wear

causing failure

For this testing, there is an arrangement made in the Test

Rig, to hold the housings or similar grooved flanges in which the seals fits. There are two halves of Housing flanges

holding the seals in as like actual assembled conditions which are posted on two axial spindles in front of each

other.

One being stationary which has the load cell in linear axis that can record the desired load applied when seal

surfaces meet each other. Another flange is mounted on the moving spindle of which the RPM can be controlled by

a frequency drive. The cavity formed by the seals in

assembled condition contains the Oil, the pressure

and temperature of it can be controlled by the

hydraulic system and heaters and thermocouples.

There are various controls of each constituent system

on the Control panel which can indicate and record

the intervals of test and the parameters associated.

Collectively the seal in assembled condition is put for

test for various test with a set force and the respective

face load is monitored. The test is taken at various

intervals of 100 Hrs altering the Load, RPM, Oil

Pressure, Temperature , ambient conditions , and in

presence of Mud ( Kantalome:i7 Grade) for 500,

1000,2000 Hrs respectively, based on the test plan for

the particular seal.

Customer Specific SEAL Design & Development:Customer Specific SEAL Design & Development:Customer Specific SEAL Design & Development:Customer Specific SEAL Design & Development:

SAP PARTS have set Design Guidelines for Duo Cone Seals. SAP PARTS furnish Design Input Data Sheet to

Customers and get maximum application and service condition inputs from them. Its Design Team study and

analyze this data with its existing database and considering application suggest a proto design marching to the

requirement . SAP PARTS categorically focus on the Rubber Ring Compression Set and set Force needed to fit the

Seals in Assembly. For this SAP PARTS have Seal Face Load Determination Test Rig as a part of its Design Validation

Process from which SAP PARTS collect information to Plot set Force against the Gap distance between the housings

likely to be in actual operations at the customer end. In the design Data input sheet you can identify SAP PARTS ask

your Housing Groove Profile . If it is not given SAP PARTS determine it based on its knowledge bank and suggest

you .

Functional Test LabFunctional Test LabFunctional Test LabFunctional Test Lab Capabilities Capabilities Capabilities Capabilities

SAP Parts Precision Seals has a fully operational functional test laboratory located at its facility in PUNE ,INDIA.

SAP PARTS utilizes this lab for customer support and the development and validation of new seal designs. The lab

equipment is designed to effectively simulate the operating variables that impact the performance of metal face

seals. A number of different tests are available.



Seal abilitySeal abilitySeal abilitySeal ability and Scoring Resistance and Scoring Resistance and Scoring Resistance and Scoring Resistance

(Pressure vs. Velocity Testing) (Pressure vs. Velocity Testing) (Pressure vs. Velocity Testing) (Pressure vs. Velocity Testing)

Sealability tests evaluate the seal’s ability to operate under certain conditions. Scoring resistance tests are run to

determine a metal seal ring material’s resistance to scoring/galling of the seal faces. The seal is assembled to match

the operating conditions found in the application. This includes seal face loads, internal operating temperatures,

internal operating pressures, rotational speeds, etc.

Load (Load vs. Deflection) Testing Load (Load vs. Deflection) Testing Load (Load vs. Deflection) Testing Load (Load vs. Deflection) Testing

Load deflection tests evaluate the loading characteristics of the

elastomeric ring for a given size. This information is used to effectively

determine the O-Ring compression required to obtain optimal loading on

the metal seal faces.

Wear (Mud Box) Tests Wear (Mud Box) Tests Wear (Mud Box) Tests Wear (Mud Box) Tests

Wear testing utilizes mud box equipment to evaluate a metal seal ring

material’s resistance to abrasive wear. Seals are assembled, the seal cavity

is filled with oil, and the seal exterior is exposed to mud slurry. Test cycles

are run to accelerate the wear process. Wear is quantified by the amount

of movement of the sealing band during the test.

Oil Compatibility TeOil Compatibility TeOil Compatibility TeOil Compatibility Testing (sting (sting (sting (Compression SetCompression SetCompression SetCompression Set, Heat Resistance, etc.) , Heat Resistance, etc.) , Heat Resistance, etc.) , Heat Resistance, etc.)

Oil compatibility tests can be run to evaluate the elastomeric O-Ring

material’s compatibility with oils or greases that may be used in your

application. A compression set test is the most common test run to

evaluate these characteristics.

O-Ring specimens are compressed and held at a specific amount of

compression while exposed to the oil and high temperatures for long periods of time. At the conclusion of the test,

the amount of permanent set of the O-Ring materials is recorded.

Quality Assurance Quality Assurance Quality Assurance Quality Assurance

SAP PARTS has a fully functional Quality Assurance laboratory. Equipment includes two Exclusive and unique test

Rigs for Life Testing, Validation and Face load estimation of the duo cone seals and state-of-the-art surface finish

analyzer, Monochromatic Optical Prism to identify flatness accuracy at light bands level.

Solutions To SEAL Solutions To SEAL Solutions To SEAL Solutions To SEAL Failure Modes Failure Modes Failure Modes Failure Modes

While Mechanical face, Duo Cone Seals generally perform very satisfactorily, premature failure can occur for a

number of reasons but can be avoided or minimized through proper seal design and/or installation.

Uneven or Excessive Face Load Uneven or Excessive Face Load Uneven or Excessive Face Load Uneven or Excessive Face Load

This results from improper seal assembly. Either the seal ring is tilted in the assembly or the toric is twisted. Both

result in uneven face loads circumferentially around the seal face. This can cause the seal rings to either separate,

allowing oil

to flow outward, or gall from localized high face load.

Mishandling of Seals Mishandling of Seals Mishandling of Seals Mishandling of Seals

Mishandling of seals during assembly can cause immediate leaks or premature failure. Failure can occur due to

cutting or tearing of the elastomeric load ring, breakage of the sealing ring, contamination of the seal face with dirt

or lint, etc.

When assembling Mechanical face, Duo Cone Seals, please carefully observe assembly instructions provided by SAP

PARTS.

Internal Pressure Spikes Internal Pressure Spikes Internal Pressure Spikes Internal Pressure Spikes

Mechanical face, Duo Cone Seals can withstand a varying amount of internal pressure, depending on the design.

Generally, internal pressure should be maintained below 1.0-1.7 Bar to guarantee satisfactory sealing performance.

If your application exceeds these requirements, please consult SAP PARTS’ engineering staff for further information.

Improper Housing Design Improper Housing Design Improper Housing Design Improper Housing Design

EVEN

PRESSURE

12

3

1. SEAL2. O−RING3.SEAL HOUSING.



It is critical that the application seal housing conform to the design information provided by SAP PARTS. The

relationship between the seal assembly and its mating component is critical to the acceptable performance of the

sealing system.

Improper Use of Oil Improper Use of Oil Improper Use of Oil Improper Use of Oil

Selection of improper oil can cause premature failure due to degradation of both the elastomeric O-Ring and metal

sealing ring. Some oils are incompatible with elastomers and cause long-term degradation with exposure, especially

when combined with heat. Improper oil usage can cause metal seal failure due to scoring from inadequate

lubrication flow.

Mud Packing Mud Packing Mud Packing Mud Packing

Mud packing can be a problem in environments where the Mechanical face, Duo Cone Seals is continually exposed

to

dirt and mud. Mud can pack the cavity between the seal housing, seal ring and load ring. Over time, this can cause

the O-Ring to be pushed out of position, resulting improper face loads or mud being pumped past the load ring.

Guarding arrangements are not highly recommended as they trap mud in. However, some are used for severe

applications such as landfills. In this case, it is recommended that a slotted design be utilized.

OOOO----RingRingRingRing Abrasion Abrasion Abrasion Abrasion

Abrasion of the O-Ring can occur in applications where it is exposed to abrasives such as dirt, sand and rocks.

Abrasion of the O-Ring causes deterioration and tearing of the elastomer, leading to failure. This can be minimized

through proper O-Ring material selection.



SAP PARTS’ Mechanical Face Seals Manufacturing SAP PARTS’ Mechanical Face Seals Manufacturing SAP PARTS’ Mechanical Face Seals Manufacturing SAP PARTS’ Mechanical Face Seals Manufacturing Process Process Process Process Control:Control:Control:Control:

Q C D Units OD < 100 OD: 100 -200 OD: 200 - 300 300 < OD

OUTSIDE DIAMETER mm ±0.300 ±0.500 ±0.500 ±0.8

INSIDE DIAMTER mm ±0.300 ±0.500 ±0.500 ±0.8

TOTAL WIDTH mm ±0.300 ±0.300 ±0.300 ±0.500



TOTAL WIDTH mm ±0.100 ±0.200 ±0.200 ±0.300



TOTAL WIDTH mm ±0.100 0.200 0.300 0.300

O-RING GRROVE DIAMETER mm ±0.3 ±0.3 ±0.5 ±0.5

SMALL DIAMTER mm ±0.3 ±0.4 ±0.4 ±0.5

TRACK DIAMETER mm ±0.3 ±0.25 ±0.5 ±0.5

RAMP ANGLE DEG � Min ' ±30' ±30' ±30' ±30'

SURFACE ROUGHNESS OF TRACK Ra

FACE DISTORTION Max mm 0.150 0.200 0.250 0.300

OVALITY Max mm 0.300 0.400 0.800 1.000

HARDNESS HRC- 62

MICROSTRUCTURE

SPHERE RADIUS mm

SURFACE FINISH Ra

6 FLAT LAPPING48" Flat Bed Lapping

Machine3 3 2 FLATNESS mm 0.01 0.02 0.03 0.04

FLATNESS mm 0.005 0.01 0.015 0.02

SURFACE FINISH Ra

1 2 3 Q C D

LOW MEDIUMHIGH QUALITY COST OUTPUT

MACHINE

COMPETITIVE

ADVANTAGE OF

PROCESSCRITICAL PARAMETER/S

SEAL OD RANGE : Tolerances

Duo Cone Seal Manufacturing - Quality Control of Critical Process Flow

SR NO PROCESS

3

2

1 FORGINGRing Rolling Forging

Setup3 2 3

2 PRE-TURNING Centre Lathe Machine 2 1

3 2

2.500 ~ 6.300

4 HEAT TREATMENT

Contineuous Mesh

belt furnace with

Atmosphere Control &

Cryogenic treatment

3 2 3±3

Fine Tempered Martensite

3 CNC MACHINING CNC Turning Centre 3 2

INDEX

±100

0.400

7 DIAMOND LAPPING

Flat bed Diamond

Lapping Polishing

Machine

3 3 10.030 ~ 0.080

5 SPHERICAL LAPPING

48" Spherical Bed R

2032 mm Lapping

Machine

3

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