Project-I

GUJARAT TECHNOLOGICAL UNIVERSITY, AHMEDABAD

Project- I
Presentation
On
“Study related to the problems in the
Cylinder Assembly of Hydraulic Jaw
By

1. MAKANI BHARGAV H. (159680319530)

2. MAHESHWARI PRATIK K. (159680319528)
3. JADEJA JAYPALSINH B. (169680319525)
4. SAMA SALMAN A. (159680319547)

Guided by:-
Gorasiya Mansukh Vishrambhai
HJD INST. OF TECH. EDUCATION AND RESEARCH, KUTCH.
Contents
1. Abstract

2. Introduction

3. Literature Review

4. Problem definition

5. References
 ABSTRACT
In this project the main focusing part is hydraulic cylinder and its handling components.
The hydraulic system can be formed by piston, cylinder, hydraulic fluid and hydraulic ‘O’
ring sealing.

The hydraulic cylinder and the hydraulic ‘O’ ring seal damages due to heat dissipation,
(upper surface forms dents) causes loosening and cracking occurs due to stress corrosion
cracking. The dispersion of Contaminants makes oil properties flubbed.

Hence the life decreases as there is failure for the parts frequently. Although many others seal
will perform the same function, the popularity of the “o” ring is greatly infused by commercial
considerations. Therefore in this project focus is on improvement in the life of O-ring seal of
hydraulic cylinder and cost reduction for the same.
2. INTRODUCTION
 Introduction of Hydraulic seal

Hydraulic seals and guides :- Hydraulic cylinder seals are used to seal the opening between
various components in the hydraulic cylinder.

Dynamic seals :- They seal between components in relative motion. In a hydraulic cylinder the
rod sealing system seals dynamic reciprocating motion between the piston rod and head, while
the piston sealing system seals dynamic reciprocating motion between the piston and cylinder
bore.

Static seals :- They seal between components fixed together without relative motion. Hydraulic
cylinders use static seals in various locations depending on the design and construction. The
most common are static seals between the piston and piston rod and between the head and
cylinder bore tube.
Hydraulic Cylinder Assembly
 BASIC PARTS HYDRAULIC CYLINDER

1. Piston seal functions :- Act as pressure barrier and prevent fluid passing the piston – important for
controlling the cylinder motion or maintaining the position when at rest
2. Rod seal functions :- Act as pressure barrier and keep the operating fluid inside the cylinder regulate
the fluid film which extends with the surface of the piston rod – important to inhibit rod corrosion and to
lubricate the wiper seal and the rod seal itself. Accept the lubrication film back into the cylinder when the
rod retracts

3. Buffer seal functions :- Protect the rod seal from fluid pressure peaks in excess of system pressure
attenuate the fluctuations in system pressure, thereby improving rod seal performance by allowing the rod
seal to deal with more constant or gradually changing pressure . Act as an internal excluder to keep
system contaminants, such as metal particles, from damaging the rod sea.
 BASIC PARTS HYDRAULIC CYLINDER

4. Wiper seal functions :- Exclude external contaminants from entering the cylinder assembly and the
hydraulic system. Accept the lubrication film back into the cylinder when the rod retracts

5. Guide rings (rod and piston) functions :- Prevent metal-to-metal contact between components. React
the radial load caused by side loads on the cylinder assembly. Keep the piston rod and piston accurately
centered in the cylinder assembly – important for performance of the rod sealing system and piston
sealing system.
BASIC PARTS HYDRAULIC CYLINDER

Fig.2 Detailed assembly for rings in single unit

3.Literature Review
Manufacturing:-

• O-rings can be produced by “injection moulding” and “transfer moulding”.

History

• The first patent for the O-ring, is dated May 12, 1896 as a Swedish patent “J O LUISBERG”, the inventor of the O-

ring, received the patent. The US patent for the O-ring was filed in 1937 by a then 72-year-old denies born machinist

Neil Christman.Soon after migrating to the USA in 1891, he patented an air brake system for street cars(trams).

Despite his legal efforts, his intellectual properties rights were passed from company to company until they ended up

at warehouse.During World War II the US government commandeered the O-ring patient as a critical war-related

item and gave the right to manufacture to other organizations.

Typical applications :-

High temperature applications

Vacuum applications etc.

Successful O-ring joint design requires a rigid mechanical mounting that applies a predictable deformation to the O-

ring. This introduces a calculated mechanical stress at the O-ring contacting surfaces. As long as the pressure of

the.Fluid being contained does not exceed the contact stress of the O-ring, leaking cannot occur. Fortunately, the

pressure of the contained fluid transfers through the essentially incompressible O-ring material, and the contact stress

rises with increasing pressure. For this reason, an O-ring can easily seal high pressure as long as it does not fail

mechanically. The most common failure is extrusion through the mating parts.
Typical applications :-

In vacuum applications, the permeability of the material makes point contacts quite useless. Instead, higher mounting

forces are used and the ring fills the whole groove. Also, round back-up-rings are used to save the ring from excessive

deformation. Because the ring feels the ambient pressure and the partial pressure of gases only at the seal, their

gradients will be steep near the seal and shallow in the bulk (opposite to the gradient of the contact stress [See: High-

vacuum systems below 10−9 Torre use copper or nickel O-rings. Also, vacuum systems that have to be immersed in

liquid nitrogen use indium O-rings, because rubber becomes hard and brittle at low temperatures.
Sizes :-

O-rings come in a variety of sizes British Standard (BS) which are imperial sizes or metric sizes. Typical dimensions of

an O-ring are internal dimension (ID), outer dimension (OD) and thickness / cross section (CS)
Material :-
O-ring selection is based on chemical compatibility, application temperature, sealing pressure, lubrication requirements,
udometers,synthetic rubber.

Butadiene rubber (BR)

Butyl rubber (IIR)
Chloro-sulfonated polyethylene (CSM)
Epi-chlorohydrin rubber(ECH, ECO ) etc.

Thermoplastics:
Thermoplastic elastomer (TPE) styrene
Thermoplastic polyolefin (TPO) LDPE, HDPE, LLDPE, ULDPE
Thermoplastic polyurethane (TPU) polyether, polyester

Chemical Compatibility:
Air, 200 - 300 °F – Silicone
Beer - EPDM
Chlorine Water – Viton (FKM)
 Types of seals
1. WIPER SEAL
2. ROD SEAL
3. PISTON SEAL
4. O-RING SEAL
WIPER SEAL

5. The function of a wiper scraper seal is that of an axial seal, in creating a tight fit whilst still allowing a reciprocating
ram rod to pass through the inner bore of the seal. Also commonly known as Wiper Seals, Scraper Seals, or Dust
Seal products, the primary use of a wiper scraper seal is to prevent dust, debris and moisture entering the gland
housing of sealing system and damaging the pressure seals of a fluid system as reciprocating or rotating parts move,
with expensive or even dangerous results.

Fig. 4 Wiper seal

 Types of seals
ROD SEALS

1. The rod seal is the most critical seal on any type of fluid power equipment preventing leakage of fluid from within
the cylinder to the outside. Leakage through the rod seal can reduce equipment performance, and also in extreme
cases can cause environmental issues.

Fig. 5 Rod seal

 Types of seals
PISTON SEALS

1. Piston seals maintain sealing contact between the piston and the cylinder bore. Differential pressures acting on the
piston to extend or retract the piston rod can be in excess of 400 bar (5800 psi). The pressure acting on the piston
seal increases contact forces between the piston seal and cylinder surface. Therefore, the surface properties of the
sealing surfaces are critical to proper seal performance.(Counter surface seal properties)

Fig. 6 Piston seal

 Types of seals
O-RING SEALS

1. An O-ring, also known as a packing, or a torrid joint, is a mechanical gasket in the shape of a torus it is a loop of
elastomer with a round cross-section, designed to be seated in a groove and compressed during assembly between
two or more parts, creating a seal the interface.

Fig. 7 O-RING SEAL

 O-ring and Seal Failure
In the semiconductor industry, the failure of a single O-ring or seal can result in millions of dollars in damaged
production, downtime and maintenance costs. In many environments, an O-ring or seal failure can result in the
complete evacuation of a facility-or worse, the exposure of personnel to toxic chemicals.

Prevention of O-ring and seal failures through proper design, material selection and maintenance certainly minimizes
the risk of failure. Attention to the condition of replaced O-rings and seals, as well as the equipment performance over
time, will result in improved process reliability, reduced operating costs and a safer work environment.

O-rings and seals often fail prematurely in applications because of improper design or compound selection. This section
is designed to provide the viewer with examples of common failure modes. By correctly identifying the failure mode,
changes in the design or sealing material can lead to improved O-ring and seal performance.

From the end-user's point of view, an O-ring or seal can fail in three (3) general ways:
• Leaking
• Contamination
• Chang`e in Appearance

It is useful to analyze the environment, O-ring or seal design and elastomer when there is an O-ring or seal failure.
 O-ring and Seal Failure
Seal failure in Leaking

Fig. 8 Seal failure in Leaking Fig. 9 Seal failure in Contamination

Fig. 10 Seal failure in Appearance Change

 EXTRUSION, OVER-COMPRESSION AND SPIRAL FAILURE

Extrusion
Description: The O-ring or seal develops ragged edges (generally on the low-pressure side) which appear tattered.

Contributing Factors: Excessive clearances. Excessive pressure. Low-modulus/hardness elastomer. Excessive gland fill.
Irregular clearance gaps. Sharp gland edges. Improper sizing.

Suggested Solutions: Decrease clearances. Higher-modulus/hardness elastomer. Proper gland design. Use of
polymer backup rings.

Fig. 11 Extrusion failure of Seal

 EXTRUSION, OVER-COMPRESSION AND SPIRAL FAILURE

Over-Compression
Description: The O-ring or seal exhibits parallel flat surfaces (corresponding to the contact areas) and may
develop circumferential splits within the flattened surfaces.

Contributing Factors: Improper design-failure to account for thermal or chemical volume changes, or excessive
compression.

Suggested Solutions: Gland design should take into account material responses to chemical and thermal
environments.

Fig. 12 Over Compression failure

 EXTRUSION, OVER-COMPRESSION AND SPIRAL FAILURE

Spiral Failure
Description: The O-ring or seal exhibits cuts or marks which spiral around its circumference.

Contributing Factors: Difficult or tight installation (static). Slow reciprocating speed. Low-modulus/hardness
elastomer. Irregular O-ring surface finish (including excessive parting line). Excessive gland width. Irregular or
rough gland surface finish. Inadequate lubrication.

Suggested Solutions: Correct installation procedures. Higher modulus elastomer. Internally lubed elastomers.
Proper gland design. Gland surface finish of 8-16 micro-inch RMS. And possible use of polymer backup rings.

Fig. 13 Spiral Seal Failure

 CHEMICAL DEGRADATION, THERMAL DEGRADATION AND EXPLOSIVE DECOMPRESSION

 Chemical Degradation

Description: The O-ring or seal may exhibit many signs of degradation including blisters, cracks, voids or discoloration.
In some cases, the degradation is observable only by measurement of physical properties.
Contributing Factors: Incompatibility with the chemical and/or thermal environment.

Suggested Solutions: Selection of more chemically resistant elastomer .

Fig. 14 Chemical Degradation failure

 CHEMICAL DEGRADATION, THERMAL DEGRADATION AND EXPLOSIVE DECOMPRESSION

 Thermal Degradation

Description: The O-ring or seal may exhibit radial cracks located on the highest temperature surfaces. In addition, certain
elastomers may exhibit signs of softening-a shiny surface as a result of excessive temperatures.

Contributing Factors: Elastomer thermal properties. Excessive temperature excursions or cycling.

Suggested Solutions: Selection of an elastomer with improved thermal stability. Evaluation of the possibility of cooling
sealing surfaces.

Fig. 15 Thermal Degradation failure

 CHEMICAL DEGRADATION, THERMAL DEGRADATION AND EXPLOSIVE DECOMPRESSION

 Explosive Decompression

Description: The O-ring or seal exhibits blisters, pits or pocks on its surface. Absorption of gas at high pressure and the
subsequent rapid decrease in pressure. The absorbed gas blisters and ruptures the elastomer surface as the pressure is
rapidly removed.
Contributing Factors: Rapid pressure changes. Low-modulus/ hardness elastomer.
Suggested Solutions: Higher-modulus/hardness elastomer. Slower decompression (release of pressure).

Fig. 16 Explosive failure of seal

4. Problem
definition
 Objectives of Present work

Fig. 20 Oil leakage from the assembly due to O-ring failure

 Objectives of Present work

Damaged
Oil Seal

Fig. 21 Damaged Oil seal

 FUTURE WORK PLAN

Work to be done in the upcoming semester

 Suggestion about Material improveme

 Cost evaluation of overall design

 Investigate pressure of system and its efficiency

 Life of the components

 Different improvement techniques

5. Reference
 REFERENCES

1. P. K. Chandrashekara, R. B. Mali, C and Pneumatics, Tech-Max publications, Pune, First edition 2016.

2. Richard C. Dorf, Robert H. Bishop, Modern Control Systems, Pearson Education International.

3. S. R. Majumdar, McGraw-Hill, Oil Hydraulics Systems, Principles and Maintenance

4. K. ShanmugaSundaram, S. Chand, Hydraulics and Pneumatic control, Co. book Publisher, New Delhi, 2009.

5. http://www.globalspec.com/learnmore/mechanical_components/seals/hydraulic_pneumatic_seals

6. https://www.tss.trelleborg.com/global/en/products_2/hydraulicseals/hydraulic-seals.html?gclid=EAIaIQobCh

MItKeplq_y1wIVgjUrCh2sWg_REAAYASAAEgJjZvD_BwE

7. https://www.tss.trelleborg.com/e-learning/en/Hydraulic_Seals_Basics/story_html5.html

8. http://www.eisinserts.com/?gclid=EAIaIQobChMItKeplq_y1wIVgjUrCh2sWg_REAAYAiAAEgLN_fD_BwE

9. http://www.martins-rubber.co.uk/blog/an-o-ring-material-selection-guide/