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SAP Parts - Floating Seal Features

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

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SAP Parts - Floating Seal Features

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  1. Technology Document SAP Parts - Floating Seal Features Innovative Sealing Solutions for haul Truck Breaking application. Date: 21st 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

  2. Technology Document • Introduction: This sealing system retains a continuous oil film on the sealing surfaces. A Mechanical Face – Floating Seal essentially consists of Two Metal Faces of 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 from opposite sides. This system seals entry of media from either side all the time, both while in- 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. superior energizers 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. Specifically 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. run 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. 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 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. 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

  3. Technology Document Materials- Performance Matrix: Metal seal ramp, by employing FEA modeling techniques for Floating seal and O ring assembly. Material SAE- 52100 Forged Steel FC15C43MO Ni-Hard Performance (ASTM-A 532- II Class B) Cast Iron Best Alloy Cast Iron Abrasion Resistance Toughness Good Better Good Best Better Heat Resistance PV Results Good Better Best Better Good Best Spalling Galling & Good Better Best 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. Initial distance “A” Axial constraint (Y-direction) Nitrile LT Nitri le -50 Viton HNBR Silicone Service Temp(-) C Service Temp(+) C Abrasion Resistance Tear Resistance Water Resistance -25 -10 -40 -60 100 105 190 135 165 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 Cost High Medium 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 D- 2000 & 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. ing Contact Geometry: SAP Parts can estimate the contact pressure, O-ring deformation, and Force at O-Ring to 2016/10 SAP Parts- Floating Seal Features Pg. 2 of 7

  4. 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 • • • Seal Design for Differential Load applications. Model for Contact Surface Wear Life Prediction. Elastomeric Variable Modeling. Innovative Surface Treatments for Demanding Applications. Functional Conformance of Metallurgical Properties of Ni-Hard Cast Alloys & Sealing Surface Asperities in Abrasive Environment. Load Stress Relaxation • • Load V/s Deflection Charecterstics: Surface Coating: SAP Parts Seals Come with most advance and innovative anti corrosive surface called CED. Cathodic Electro Deposition 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. 250 treatment GAP BETWEEN TWO HOUSING (mm) 200 PEAK LOAD(kg) Min.face load (kg) 150 FACE LOAD (KG) 100 50 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 2016/10 SAP Parts- Floating Seal Features Pg. 3 of 7

  5. Technology Document Report: Torque V/s Time Testing: 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 Alloy Cast Iron Ni-Hard Rubber Rings – O Rings NBR/HNBR/Silic on/Viton 60-63 HRc Forged Steel Hardness Through Hardened and Tempered in controlled atmosphere. Fine tempered Marten site Microstructure. 65- 70 Hrc Cast Iron Seal life & Endurance Test Set-Up: Sealing Surface Flatness Within 3 light Bands of Optical Interference of Monochromatic Light. 1~3 Micron Max 1. Mud Packing Test: • Mud Contamination Test. Submerged Wear and Leakage with Sealing Surface Roughness Polishing Attained By Lapping Process. < 0.5Rt 2. Heat Generation Test : • Time Lubrication to study amount of Heat Generated. v/s Pressure v/s Surface Speed in The Dual Cone Especially Designed Ramp angle profile with Higher Grip texture to hold the O rings firmly. 8-15-20 Degree 3. Elastomeric Test : Angle • Oil Compatibility Test • Face load variation v/s Time/Temperature. Operating Speed With Oil 5 Meter/Sec Max 3 • O- Ring Squeezing Test. With Grease Meter/Sec Max • O- Ring Contraction Test. 4. P-V Test Pressure/Load Bearing Capacity 3 Bars Max • Pressure v/s Velocity(Linear Speed) • Wear, Galling and Spilling Test 2016/10 SAP Parts- Floating Seal Features Pg. 4 of 7

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