O-Rings

TECHNICAL GUIDE

1
© Copyright by Angst + Pfister 2022 Subject to alteration
All specifications for information only.

O-Rings Technical Guide 2

 Table of Contents
1. Introduction 6
General remarks 7
Function 8
Determination of dimensions 10
Determination of material 10
Resilience 11
Acetone test 11
Fire response 11
Compression set 13
Hardness 14
2. Design Notes 16
Elastomer O-Rings 18
Static applications 19
Axial seals for static applications 21
Radial seals for static applications 25
Special applications 27
Dynamic applications 29
Dynamic applications hydraulic 31
Dynamic applications pneumatic 34
Special applications 38
General Design notes 41
Back-up Rings 57
Virgin PTFE O-Rings 59
Metallic O-Rings/C-Rings 60
3. Manufacturing Tolerances 62
Manufacturing tolerance for elastomer O-Rings 64
Defect limits 65
4. Mounting instructions and accidental damage to the O-Rings 68
Mounting instructions 70
Accidental damage to the O-Rings 73
5. Groove Dimensions 76
Introduction 78
Availability from stock at Angst+Pfister 78
Groove dimensions for O-Rings 79

3 O-Rings Technical Guide

Introduction

General remarks • Design

• Function

Identification of elastomer O-Rings • Identification of elastomer O-Rings

• Determination of dimensions
• Determination of material
• Resilience
• Acetone test
• Fire response
• Compression set
• Hardness

O-Rings Technical Guide 4

 1

5 O-Rings Technical Guide

GENERAL REMARKS

Introduction

O-Ring seals are already more than 100 years

old and were first registered as gas sealing rings
in a water-cock patent by Thomas A. Edison in
1882. Other patents for the use of O-Rings were
granted in North America in 1930. It was only
with the discovery and development of synthetic
rubber around 1930 that O-Rings began their
successful growth.

Continuous development in the materials sector,

in particular the creation of new groups of
elastomers, has supported growth in the number
of applications for O-Rings. Nowadays this is the
most common type of seal, with millions in use
in all sectors of industry.

In addition to their excellent sealing properties,

O-Rings are simple to mould, easy to mount and
maintain and do not require large housings.
They can be used both statically and dynamically.
The correct choice of material for the fluid and
temperatures concerned is also critical. The
O-Ring continues to be the sealing element with
the best price/performance ratio.

O-Rings Technical Guide 6

General remarks
on O-Rings

An O-Ring is an endless ring with a circular cross-

d2
section. It is manufactured to close tolerances,
with a high surface finish and can provide an
axial or radial seal. Its dimensions are quoted in Ød1
terms of the inside diameter d1 and the diameter
of the cross-section d2.

The simple symmetrical shape of the O-Ring

makes it the ideal type of dual-action seal for
many applications. It is available in a large
number of sizes and in a wide range of mater-
ials and is used for many several sealing
applications.

7 O-Rings Technical Guide

GENERAL REMARKS

Function

Elastomers behave like highly viscous fluids. The maximum sealing force z and the O-Ring
Pressure exerted on them is propagated to seating Z1 are functions of the O-Ring cross-
practically the same degree in all directions sectional diameter d2, its hardness, the compres-
(basic law of hydrostatics, Blaise Pascal). The sion selected (d2 – D) and the pressure differential
radial and axial forces generated by the O-Ring (P1 – P2).
housing are reinforced by the pressure - use of
the fluid to be retained. The total sealing force Where O-Rings and housings are defined in
thus created increases as the pressure of the accordance with the data in our catalogues,
fluid rises. «mechanical tightness» can be assumed, pro-
vided that the following criteria are satisfied:
Polymers and metals do not react to
pressurization, in other words, it is only – Seal between stationary parts:
compression that creates the seal. This means assume loss-free tightness with liquids
that virgin PTFE O-Rings are designed to be and diffusion losses with gases
compressed once only and require an enclosed
mounting. With metal O-Rings it is possible to – Seal between moving parts:
provide holes so that the pressure of the fluid is with liquids, a film can build up at the slide
added to the compressive force. face and lead to leakage losses in the long
term. With gases there will be a loss at the
slide face.

Practical experience has shown that this

definition is generally valid. Variable operating
conditions, such as temperature and pressure
cycles, can lead to leakage under certain
Propagation of pressure circumstances.

Z1 Z1

Z
Z

P1 P2 P1 P2
D d2

P1 = P2 P1 > P2

O-Rings Technical Guide 8

Designation of the elastomer O-Rings

Material Brief description Brief description

Trade name
name ISO 1629 ASTM D-1418

Acrylate elastomer Europrene AR® ACM ACM

Hytemp®

Acrylonitrile butadiene elastomer Europrene® NBR NBR

Krynac ®

Nipol®

Perbunan®

Butyl elastomer Esso Butyl® IIR IIR

Polysar Butyl ®

Chloroprene elastomer Baypren® CR CR

Butador®

Neoprene®

Ethylene acrylate elastomer VAMAC® AEM AEM

Ethylene propylene diene elastomer Dutral®

EPDM EPDM

Keltan ®

Vistalon®

Fluoroelastomer Fluorel® FKM FPM

Tecnoflon®

Viton®

Fluorosilicone elastomer Silastic® FVMQ MFQ

Hydrogenated acrylonitrile elastomer Therban ®

HNBR HSN

Tornac®

Zetpol®

Natural rubber Natsyn® NR NR

Perfluorelastomer Kalrez ®
FFKM FFKM

Polyesther urethane elastomer Vulcollan ®

AU AU

Urepan®

Polyether urethane elastomer ARCOL® EU EU

Silicone elastomer Elastosil® VMQ MVQ

Rhodorsil ®

Silastic®

Silopren®

Styrene-butadiene elastomer Buna S® SBR SBR

Europrene®

Polysar S®

Tetra Fluorethylene Propylene AFLAS® FEPM FEPM

9 O-Rings Technical Guide

GENERAL REMARKS

Dimensions Determination
of materials
The internal diameter (d1) is best measured
with a graduated plug gauge or, for larger
O-Rings, a measuring tape. It is also possible,
in emergencies, to determine the developed It is only possible to determine the exact com-
length by cutting the O-Ring, but this method is position of materials in the laboratory and this
susceptible to error. is relatively expensive. TGA thermal analysis
to ASTM E-1131 enables groups of materials to
The cross-sectional diameter (d2) is measured be precisely identified. It is a relatively simple
radially and axially with feeler gauges without matter to establish the broad definition of the
any spring force. Contactless measurement with material group using the density, and this can be
a profile projector is also possible. undertaken with the aid of the table below.

Determination of the material group

Material Density*
groups g/cm3
ACM Acrylate Elastomer 1.30 – 1.40

AEM Ethylene Acrylate Elastomer 1.30 – 1.41

AU Polyester Urethane Elastomer 1.20 – 1.40

CR Chloroprene Elastomer 1.30 – 1.50

EPDM Ethylene-Propylene Elastomer 1.10 – 1.20

EU Polyeter Urethane Elastomer 1.20 – 1.40

FEPM Tetra Fluorethylene Propylene 1.90 – 2.00

FFKM Perfluorelastomer 1.90 – 2.00

FKM Fluoroelastomer 1.80 – 2.00

FVMQ Fluorosilicone Elastomer 1.40 – 1.50

HNBR Hydrogenated Acrylonitrile Elastomer 1.20 – 1.30

IIR Butyl Elastomer 1.10 – 1.40

NBR Acrylonitrile Butadiene Elastomer 1.20 – 1.30

NR Natural Rubber 1.10 – 1.40

SBR Styrene-Butadiene Elastomer 1.10 – 1.30

VMQ Silicone Elastomer 1.30 – 1.40

* The exact densities of specific elastomer compounds are available on request.

O-Rings Technical Guide 10

 Resilience

The NBR, FPM and EPDM elastomer groups

all have different resilience properties and
can therefore be reliably identified using non-
destructive tests. They can be used in hardness
ranges from 60 Shore A/IRHD to 90 Shore A/
IRHD.

Acetone test

The acetone test differentiates between

fluoroelastomers and perfluoroelastomers
very easily. Perfluoroelastomers show virtually
no swelling in acetone, whereas a significant
degree of swelling occurs relatively quickly in
fluoroelastomers.

Fire response

Given the fire response characteristics and the

type of residues, the elastomer group can be
determined.

11 O-Rings Technical Guide

GENERAL REMARKS

Determination of the elastomer group

Elastomer Fire response Type of residues Characteristics

- burns well in its own flame,

NBR - friable, very slightly greasy - flickering, shooting flame
but very unevenly

- does not burn in its own flame - very strong pungent odour,
FKM/FFKM - only very slight residues
- light-coloured smoke as intense as e.g. ammonia

- does not burn in its own flame

VMQ/FVMQ - burning area becomes white - solid, white - yellow-white flame, white smoke
- smell not intense

- burns very well in its own flame

EPDM - very fine-grained, very slightly greasy - pungent odour
- smoking

- does not burn in its own flame,

(flame-resistant), i.e. the specimen
CR - solid particles, not greasy - rather pungent odour
is extinguished when the flame
is removed

- burns well with its own flame - slightly greasy but not as much as
IIR - slightly intensive odour
- yellow smoky flames natural rubber

- does not burn in its own flame - soft and fluid, the specimen drips - immediately fluid at the point
AU/EU
- strong characteristic odour after an extended burning test of burning, a kind of melt

- burns very well in its own flame

NR - uniform fire response - sticky, greasy, white - characteristic odour
- smoky flames

O-Rings Technical Guide 12

 Compression set

The compression set of an elastomer is a simple which changed its shape has been removed. It
method of determining the quality and curing is tested to DIN 53517 or ASTM D395 method B,
degree of a vulcanised material. An O-Ring is after 25% compression by storing in air in a hot
defined by the resilience of its material, which cabinet, usually for 24 h at +100° C.
guarantees its sealing function, and this test is
therefore very practical. The following is generally valid: the lower the
compression set, i.e. the lower the residual
Compression set is defined as the permanent deformation, the higher the grade of the
deformation of an elastomer after the force compound.

The compression set data shown in our physical

data sheet refers to tests with specimen sheets
d 2 -d 2*
% compression set = . 100 6 mm thick. Tests on O-Rings, particularly
d 2 -D those with a cross-section of less than 6 mm,
give slightly inferior results. Compression set
* O-Ring in compressed state
values measured on the O-Ring are available on
request. The compression set is used as evidence
to evaluate the vulcanization degree of a rubber
O-Ring and this test procedure is often applied
to indicate the proper production process of
O-Rings.

Compression/resilience/residual compression set

Compression Resilience Residual

compression set

I II III

d2 D d2*

d2 Nominal cross-section of O-Ring

D O-Ring in compressed state
d21 O-Ring after removal of stress

13 O-Rings Technical Guide

GENERAL REMARKS

Hardness

The hardness of the material is defined as The hardness data given in our physical data
follows: Resistance of an elastomer material to sheet refers to tests with 6 mm thick specimens.
penetration of a specimen with a defined force Hardness tests on O-Rings give different values.
for a defined time. It is measured as Shore A The round cross-section means that the results
or IRHD (International Rubber Hardness are up to 10 points lower, particularly with
Degree). smaller cross-sections. Correction values for
measurements on O-Rings are available on
Hardness is tested to: request.
– Shore A to DIN 53505
– IRHD to DIN 53519/1 or DIN 53519/2

PTFE-FEP
covered O-Rings

These seals provide an ideal combination of coating makes it easy to determine the core
the elastic properties of elastomer O-Rings material; red means silicon (VMQ) and black is
and the chemical resistance of PTFE or FEP. fluoroelastomer (FKM). The hardness cannot be
Their function is the same as that of elastomer reliably determined because it is affected by the
O-Rings. They are identified by the same FEP cover.
sizes as other O-Rings. The transparent FEP

O-Rings Technical Guide 14

Virgin PTFE
O-Rings

The outstanding property of solid O-Rings made

from virgin PTFE is their universal chemical
resistance. The disadvantage of non-elastic be-
havior requires special housing grooves.
Tightness is achieved solely by deformation of
the cross-section and is not dependent on the
properties shown by elastomeric materials.

Metal O-Rings
and C-Rings

These are designed for high-temperature and

high-pressure use. They require specially desig-
ned open housing grooves. Their tightness
function is achieved by deforming the cross-
section or is improved by adding pressure-
reinforcing holes or gas pressure filling, as
appropriate.

15 O-Rings Technical Guide

Design notes

Elastomer O-Rings Definition of the type of mounting

Compression
Static applications Compression of cord diameter

Rugosity
Axial seals for static applications Special groove profiles

Radial seals for static applications Surface roughness

Special applications Use of O-Rings in vacuum applications

Dynamic applications Compression

Dynamic applications hydraulic Profiles and surface finish of grooves

Determination of O-Ring compression and depth of groove

Dynamic applications pneumatic Examples of O-Ring compression for pneumatic operation
Profile and rugosity of grooves

Immersed mounting
Special applications O-Rings in rotary applications
Use as drive belts

O-Ring in rotary applications

Force required for cross-sectional deformation
Extension and compression
Slide face material and surfaces
Pressure
General Design notes Material hardness
Lubrification
Friction
Wear
Running speed
Contamination at the seal

General
Back-up Rings Back-up Ring types
Design notes
Mounting cavities
Virgin PTFE O-Rings Limitations
Surface finish
Designs
Metallic O-Rings/C-Rings Surface finish

O-Rings Technical Guide 16

 2

17 O-Rings Technical Guide

DESIGN NOTES

Elastomer O-Rings

Definition of the
type of mounting

O-Rings are used in static or dynamic applications. Flange seal, axial compression, static application
In static applications the O-Ring can be used as
a flange or cover seal to provide axial tightness
or as a rod or piston packing to provide radial
tightness. In dynamic applications the O-Ring
is used as a rod or piston packing, mainly on
reciprocating parts, to provide radial tightness.
In exceptional cases it may be used for tilting
movements, in which case special mounting
conditions must be taken.

Rod packing, radial compression,

static or dynamic applications

Piston packing, radial compression,

static or dynamic applications

O-Rings Technical Guide 18

 Static applications

In static conditions the O-Ring compression

is higher than in dynamic applications. The
requirements at the sealing surfaces are dif-
ferent, i.e. coarser machining can be accepted.
In general, a seal with the largest possible cross-
section should be chosen. Larger cross-sectional
diameters are subject to greater compression
[mm] and in percentage terms their tolerance
deviations are smaller.

Compression force

The mounted O-Ring must be deformed and Calculation of compression

this is associated with a change in the cross-
section. This compression must initiate the
D
sealing load against the counter surfaces. When d2

pressure is applied the compressive force

automatically increases. The minimum com-
pression necessary depends on the application,
the maximum compression is governed by
the requirement for long service life. If the
compression is too high this has a negative effect d 2- D
Compression (%) = . 100
on the compression set. d2

In static applications a higher compression

can be selected because there is no friction or
wear. If the surfaces are coarse or slightly worn
the compression must be increased (to the
maximum permissible) and if possible O-Rings
made from softer materials used.

19 O-Rings Technical Guide

DESIGN NOTES

The table of mounting dimensions for static

applications that is given in the chapter 5
«Groove Dimensions» applies to O-Rings with
a hardness of 70 IRHD/Shore A. It fully utilizes
the permissible range for compression that
is given in the diagram below. Where O-Rings
with a hardness of 90 IRHD/Shore A are used,
the percentage compression should be reduced
somewhat if possible (lower spring resistance
means easier mounting).

Compression of cord diameter

O-Rings Technical Guide 20

Design and surface finish of grooves

The profile of the groove is largely determined by the type of O-Ring mounting and the most efficient
way of manufacturing the groove. The volume of the groove is normally approximately 25% larger
than the cross-sectional area of the O-Ring. This is necessary because of the high degree of thermal
expansion of the elastomer and the possibility that it might swell. Other rules apply to vacuum.

Axial seals for

static applications

Pressure exerted from inside The groove is located in the flange or in the cover.
The direction of deformation (elongated by the
interference to the groove diameter of the inner
grove side wall or pressed by the interference
to the outer grove side wall diameter) is critical
when determining the dimensions of the groove
as the O-Ring carries out relative movement
under compressive stress and changes its
position inside the groove. It is therefore an
advantage if it is supported on the side away
from the pressure. When the pressure is applied
from inside it is beneficial for the O-Ring to be
slightly compressed on its outer diameter. A
compression of 1 to 3% is ideal; this also enables
tighetly compressed.
C ±0. 1 ØA h1 1

If the pressure is applied from outside, the

b

O-Ring must press against the internal diameter

b

of the groove. Up to 6% elongation of the O-Ring

P internal diameter is permitted.

a
a
R1
R2

21 O-Rings Technical Guide

DESIGN NOTES

Locating groove

Locating grooves should be basically rectangular

in design. However, for production engineering
reasons, the walls of the groove may slope by up
to 5°.

Roughness

Surface Pressure Roughness Roughness class

Ra Rt Rz

µm µm µm

not pulsating 1.60 16.00 6.30 N7

Contact surface
pulsating 0.80 6.30 3.15 N6

Side of groove not pulsating 3.20 22.00 12.50 N8

The surface finish shown here applies to O-Rings

with a hardness of 70 to 90 IRHD/Shore A. If
the contact surfaces are less finely machined
for reasons of economy, softer O-Rings must be
used and the cross-section must be more tightly
compressed.

O-Rings Technical Guide 22

Special groove profiles

Dovetail groove

In certain types of assembly, the O-Ring must

be held firmly in the groove (e.g. valve seats)
and dovetail grooves should be provided. It is
then permissible to apply only slight dynamic
stresses to the O-Ring.

Single-sided dovetail groove Two sided dovetail groove

23 O-Rings Technical Guide

DESIGN NOTES

Dovetail groove dimension

Diameter of
Depth Width Radius
O-Ring +0.05
D+0 C+/- 0.05 Radius
cross-section
of groove of groove max.
d2 D C R1 R2
mm mm mm mm mm
3.00 2.40 2.60 0.10 – 0.20 0.75
3.50 2.90 3.00 0.10 – 0.20 0.75
3.53 2.90 3.00 0.10 – 0.20 0.75
3.55 2.90 3.00 0.10 – 0.20 0.75
3.60 3.00 3.10 0.10 – 0.20 0.75
4.00 3.30 3.40 0.10 – 0.20 0.75
5.00 4.10 4.20 0.10 – 0.20 0.75
5.30 4.50 4.50 0.10 – 0.20 0.75
5.34 4.50 4.50 0.10 – 0.20 0.75
5.70 4.85 5.00 0.10 – 0.20 0.75
6.99 6.00 6.20 0.10 – 0.20 1.50
7.00 6.00 6.20 0.10 – 0.20 1.50
8.40 7.50 7.80 0.10 – 0.20 1.50

Where the hardness of the O-Rings > 80 IRHD/Shore A a groove

with C approximately 3% larger must be selected

Triangular
groove

Triangular groove dimensions

It is very difficult to check the dimension of the
contact surface that is at an angle of < 45%. This Diameter of
type of mounting should not be considered for O-Ring cross Chamfer
section
O-Rings with a cross-sectional diameter d2 < 3
d2 w
mm. The O-Ring is subjected to considerable
mm mm
permanent deformation which shortens its
3.00 4.10 +0.20/0
service life. Rectangular grooves are preferable. 3.50 4.70 +0.20/0

ØA 3.53 4.70 +0.20/0

Triangular groove 4 5°
wØ h11
3.55 4.70 +0.20/0
3.60 4.90 +0.20/0
4.00 5.50 +0.20/0
5.00 6.80 +0.20/0
5.30 7.30 +0.25/0
5.34 7.30 +0.25/0
5.70 7.80 +0.25/0
6.99 9.50 +0.30/0
7.00 9.50 +0.30/0
8.40 11.50 +0.30/0

O-Rings Technical Guide 24

 Radial seals for
static applications

The groove is in a shaft or piston (cylinder

packing) or in the cylinder liner (rod packing). In
static cylinder and rod packing applications the
O-Rings are sprung radially and are subjected to
the same percentage compression.

Rod packing, groove in cylinder wall Cylinder packing, groove in piston or shaft

C ±0. 1
C ±0. 1

b rounded and free from bur rs

b

0°
2
–
15 °

a D
R2

R2
a
R1

A
c
R1

Ø F H8 /1 7
Ø E h1 1
Ø B H9
Ø A H8/f

a
rounded and free a
from burr s c
°0

5° 5°
–2

z 0° – 0° – z
5°

Clearance A from 100 bar and Ø 50 mm = H7/g 6

Tolerance C from cross-sectional Ø > 3 mm = ±0.2

Slope z: see table on page 37

25 O-Rings Technical Guide

DESIGN NOTES

Roughness

The surface finish shown here applies to O-Rings

with a hardness of 70 to 90 IRHD/Shore A. If
the contact surfaces are less finely machined
for reasons of economy, softer O-Rings must be
used and the cross-section must be more tightly
compressed.

Roughness

Surface Pressure Roughness Roughness class

Ra Rt Rz
pulsating µm µm µm
not pulsating 1.60 16.00 6.30 N7
Contact surface
pulsating 0.80 6.30 3.15 N6
not pulsating 3.20 22.00 12.50 N8
Side of groove
pulsating 1.60 16.00 6.30 N7

Sides of groov e b

Sealing su rfaces a

O-Rings Technical Guide 26

Special Use of O-Rings
applications in vacuum
applications

Special guidelines must be observed for the

design of O-Rings and their seating grooves
when they are used for vacuum applications.
The following general design notes apply:

• Extremely clean and finely machined contact

surfaces and groove sides

• The degree to which the O-Ring fills the

groove is between 90% and 100% (normal
mountings have a filling ratio of 75%).

• The O-Ring compression is 30% and therefore

higher than in compression mountings.

• For high vacuum from 10 -6 mbar only FPM,

CR and FFKM can be used.

• In the ultra-high vacuum range only FPM

Requirements and FFKM can be used.

for O-Rings

• High-performance elastomer grades with Boxed O-Ring

very low compression set guaranteeing a
virtually uniform sealing force over a long
service life.
Atmosphere

• Tight manufacturing tolerance to guarantee

precisely designed sealing load
Va cuum
• Clean sealing faces; the smallest fault or
contamination causes leakage

• No impact offset and clean deburring in the

radial
27 O-Rings Technical Guide
DESIGN NOTES

Groove dimensions: Rectangular groove, radial compression

O-Ring cross- Compressione

Filling ratio
sectional Depth of groove Width of groove Radius O-Ring O-Ring
of the groove
diameter compression
d2 D 0/-0.05 C±0.05 R1 R2
mm mm mm mm % %
1.78 1.25 2.10 0.10 0.25 29.70 95.00
2.00 1.40 2.15 0.10 0.25 30.00 95.00
2.50 1.75 2.65 0.10 0.25 30.00 95.00
2.62 1.85 3.10 0.10 0.25 29.40 94.00
3.00 2.10 3.20 0.10 0.25 30.00 95.00
3.50 2.45 3.70 0.10 0.25 30.00 95.00
3.53 2.50 4.15 0.10 0.25 29.20 94.00
4.00 2.80 4.25 0.20 0.50 30.00 95.00
5.00 3.50 5.30 0.20 0.50 30.00 95.00
5.34 3.70 6.30 0.20 0.50 30.70 96.00
6.99 4.90 8.20 0.20 0.50 29.90 95.00

Roughness

Surface Vacuum Roughness Roughness class

Ra Rt Rz
µm µm µm
Normal 0.80 6.30 3.15 N6
Contact surface up to 10 h mbar
-8
0.40 3.00 1.60 N5
up to 10 h -11 mbar 0.10 0.80 0.40 N3
Sides of groove generally 1.60 16.00 6.30 N7

Material to For normal vacuums up to 10–5 mbar all our

standard materials can be used. In the high

be used
vacuum area from 10–6 to 10–9 mbar FPM, CR
and FFKM can be used. In the ultra high vacuum
area FPM and FFKM must be used.

O-Rings Technical Guide 28

Dynamic
applications

In dynamic applications the compression of the O-Ring is lower than in static applications. The contact
surface must have a smoother finish in order to keep abrasion resistance and wear within limits. In
general, the largest possible cross-section should be selected for the seal. The reasons are two-fold:
compression and tolerance. Larger cross-sectional diameters are subject to higher compression (in
mm) and in percentage terms their tolerance deviations are smaller.

In contrast with static applications, the

deformation of the O-Ring cross-section is kept
lower in order to minimize friction, wear and
temperature rise. The minimum compression
necessary depends on the application (hydraulics
or pneumatics). The maximum compression is
governed by the requirement for durability.

Determination of compression

d 2 -D D
Compression (%) = . 100 d2

d2

29 O-Rings Technical Guide

DESIGN NOTES

General notes on the use of O-Rings

in dynamic applications

• The larger clearances required for dynamic

applications mean that at high pressures
provision must be made for back-up rings.
(see section «Back-up rings», page 57)

• Good lubrication conditions should always

prevail in dynamic operation. Where this is
not the case, e.g. in pneumatics, the O-Ring
compression must be modified. (see section
«Dynamic applications, pneumatics» on
page 31)

• The resistance to contact fluids, including

hydraulic fluids, must be checked. The
compatibility of the lubricating greases used
must also be checked.

• The temperatures of the fluids to be retained

may rise as a result of friction heat. The
material used should therefore never be
subjected to temperatures at its upper
service limit.

• Contaminated fluids and external soiling

should be avoided. They damage the seal
and this causes leaks.

• It must be kept in mind that peak pressures

may be considerably higher than the system
pressure (provide back-up rings).

• The relatively high friction that is present,

particularly when lubrication conditions
are less than ideal, can be partly reduced by
reducing the compression. Take care not to
go below the minimum compression as this
is necessary to initiate the sealing process.

O-Rings Technical Guide 30

Dynamic applications,
hydraulics

The table of groove dimensions in the section «Sets of dimensions» applies to O-Rings with a hardness
of 70 IRHD/Shore A. Softer materials are unsuitable for dynamic applications. Where O-Rings with
a hardness of 90 IRHD/Shore A are used, slightly higher compressive force and friction must be
assumed. In this case the percentage compression can be slightly reduced.

The following diagram shows the permissible bandwidth for compression

Compression of cross-section diameter

31 O-Rings Technical Guide

DESIGN NOTES

Profiles and surface

finish of grooves

Where O-Rings are used in dynamic service When used as rod packings, O-Rings can be
the compression must be precisely defined compressed by 1% to 3% at the outer diameter.
and the lowest possible coefficient of friction If mounted in a piston groove, the internal
is essential. This affects the dimensions and diameter may be extended by up to 6%. This
surface finish of the groove. In normal cases feature is principally used when O-Rings in
the volume of the groove is designed to be inch sizes are inserted into metric cavities. With
25% larger than the volume of the O-Ring. The higher pressures and large clearances there is
radial change in cross-section must be taken up the danger of extrusion of the O-Ring (migration
by the axial excess width of the groove. Fully into the gap). Back-up rings are therefore
enclosed O-Rings must be avoided because they necessary. If one or two back-up rings are used,
have a considerably higher compression force. the width of the groove (dimension C) must be
Thermal expansion or possible swelling of the enlarged to the full width of the back-up rings.
material can lead to failure.
(see section on Back-up rings, page 57).

Rod packing, groove in cylinder wall Cylinder packing, groove in piston or shaft

O-Rings Technical Guide 32

 Surface finish

Strict compliance with the surface finishes

shown here is an important factor for the service
life of the O-Ring. A better finish reduces wear
and prolongs the life of the O-Ring.

Roughness

Surface Pressure Roughness Roughness class

Ra Rt Rz
µm µm µm
Slide face 0.40 3.00 1.60 N5
Contact surface a
Base of groove 0.80 6.30 3.15 N6
Sides of groove b 0.80 6.30 3.15 N6

33 O-Rings Technical Guide

DESIGN NOTES

Dynamic applications, pneumatics

The section «Sets of dimensions» does not (short or long) and service (heavy or light)
give any mounting dimensions for dynamic greatly affect the spring characteristic of the
applications in pneumatics because the O-Ring O-Ring and therefore its sealing capacity and
compression is very heavily influenced by the service life.
conditions of use.
In general, it can be said that O-Ring compression
Factors such as the fluid (oil-free or oiled air), can be between 4% and 14%.
running speed (slow or fast), length of stroke

Compression of cross-section diameter

O-Rings Technical Guide 34

Determination of O-Ring compression
and depth of groove

The following criteria must be clarified before

determining the O-Ring compression:

• Compressed air: oil-free or oiled

• Stroke speed: fast (≥ 0,5 m/s) or slow (Shall

be: <0,5m/s)

• Stroke length: long (≥ 0,1 m) or short (s 0,1 m)

• Service: heavy, continuous service, pulsation

frequency shall be: pulsation frequnecy >=
30/min. or light, intermittent stroke, shall be:
pulsation frequency <30/min.

Determination of O-Ring compression and depth of groove

Ø Cross Basic
Oil-free Fast Slow Long Short Heavy Light
sectional compres- Oiled air
air speed speed stroke stroke service service
diameter sion
mm % ≥ 0.5 m/s < 0.5 m/s ≥ 0.1 mm < 0.1 mm
1.50 - 3.00 14 * o * o * o * o
3.01 - 5.00 12 * o * o * o * o
5.01 - 7.00 10 * o * o * o * o

* Basic pressure is reduced 1.5 %

o Basic pressure remains the same, no reduction Depth of groove = Ø x (100% – actual compression): 100

35 O-Rings Technical Guide

DESIGN NOTES

Examples of O-Ring compression

Example 1 Example 2
Diameter of O-Ring cross-section 4 mm Cross-sectional 0 of O-Ring 6,99mm
Basic compression 12% Basic compression 10%

Operating conditions: Conditions of service:

• Oil-free air: reduction –1.5% • Oiled air: no reduction 0.0%

• Slow speed: no reduction 0.0% • Speed 0.7m/s: reduction –1.5%

• Long stroke: reduction –1.5% • Stroke length 0.5m: reduction –1.5%

• Light service: no reduction 0.0% • Heavy service: reduction –1.5%

Total reduction –3.0% Total reduction –4.5%

Basic pressure 12% minus 3% Basic compression 10% minus 4.5%

gives an effective compression of 9%. gives an effective compression of 5.5%
Determination of groove depth D: Determination of groove depth D:

O-Ring cross-sectional O-Ring cross-sectional

Ø 4.0mm x 0.91 = 3.64mm Ø 6.9mm x 0.945 = 6.60mm

Profiles and rugosity of grooves

The use of the O-Ring in dynamic pneumatic When used as rod packings, O-Rings can be
applications requires minimum friction. As there compressed 1% to 3% at the outer diameter. If
is no lubrication, or at best faulty lubrication, mounted in a piston groove, the inner diameter
wear can be reduced by precisely defining the may be extended by up to 6%. This feature is
compression values. The groove width C should mainly used when O-Rings in inch sizes are
be slightly modified since the compression is inserted into metric cavities.
less than in hydraulic applications i.e. it should
be reduced.

O-Rings Technical Guide 36

Profiles of The groove is in a rod instead of rod or piston
(cylinder packing) or in the cylinder wall (rod
packing). For dynamic cylinder or rod seals the
grooves O-Rings are sprung radially. The compression
values are between 4% and 14%, depending on
the cross-sectional diameter.

Rod packing, groove in cylinder wall Cylinder packing, groove in piston or shaft

Slope z, radius R1 / R2

Cross-
sectional Radius Chamfer
diameter
d2 R1 R2 z
mm mm mm mm
1.50 0.10 0.25 2.00
1.60 0.10 0.25 2.00
1.78 0.10 0.25 2.00
2.00 0.10 0.25 2.00
2.40 0.10 0.25 2.00
2.50 0.10 0.25 2.00
2.62 0.10 0.25 2.00
3.00 0.10 0.25 2.00
3.53 0.20 0.75 3.00
4.00 0.20 0.75 3.00
5.00 0.20 0.75 3.00
5.35 0.20 0.75 3.00
5.70 0.20 0.75 4.00
6.99 0.20 0.75 4.00
7.00 0.20 0.75 4.00

37 O-Rings Technical Guide

DESIGN NOTES

Roughness

Surface Pressure Roughness Roughness class

Ra Rt Rz
µm µm µm
Slide face 0.40 3.00 1.60 N5
Contact surface
Base of groove 0.80 6.30 3.15 N6
Sides of groove 0.80 6.30 3.15 N6

Special applications

Immersed An O-Ring that is mounted below the surface of

a liquid is suitable for sealing pneumatic pistons
and has the advantage of lower abrasion and
mounting thus lower wear. To initiate the sealing process,
it requires a pulsed pressure difference of 1 to
Cylinder seal, groove in piston 2 bar.

The outer diameter of the O-Ring must be slightly

greater than the cylinder diameter (2% to 5%) in
order to ensure the sealing function. The inner
diameter of the O-Ring d1 must not touch the
bottom of the groove. The groove depth must be
greater than the O-Ring cord diameter d2.

O-Rings Technical Guide 38

Groove dimensions: Rectangular groove, radial compression

O-Ring cross- Depth Width

Radius Chamfer
sectional diameter of groove of groove
d2 D C R1 R2 z
mm mm mm mm mm mm
3.00 3.30 3.50 0.10 0.25 2.00
3.50 3.80 4.00 0.20 0.75 3.00
3.53 3.80 4.00 0.20 0.75 3.00
3.55 3.80 4.00 0.20 0.75 3.00
3.60 3.90 4.10 0.20 0.75 3.00
4.00 4.30 4.50 0.20 0.75 3.00
5.00 5.30 5.60 0.20 0.75 3.00
5.30 5.60 6.00 0.20 0.75 3.00
5.34 5.60 6.00 0.20 0.75 3.00
5.70 6.00 6.50 0.20 0.75 4.00
6.99 7.30 8.00 0.20 0.75 4.00
7.00 7.30 8.00 0.20 0.75 4.00
8.40 8.70 9.50 0.20 0.75 4.00

Roughness

Surface Pressure Roughness Roughness class

Ra Rt Rz
µm µm µm
Slide face 0.40 3.00 1.60 N5
Contact surface
Base of groove 0.80 6.30 3.15 N6
Sides of groove 0.80 6.30 3.15 N6

Rod seal
O-Rings in rotary
applications
O-Rings can only be used for slow rotary or
tilting movements. The O-Ring should always
be used as a rod packing in the housing. It must
never be stretched over the shaft but should
preferably be compressed by 5%. The sliding
surface must be hardened (min. 50HRC).
39 O-Rings Technical Guide
DESIGN NOTES

Basis of calculations

Groove depth D = O-Ring cross-sectional Ø: D = d2 x 0.94

O-Ring internal diameter d1 = shaft Ø A + 5%: d1 = A x 1.05
Groove width C = O-Ring cross-section diameter d2 plus10% C = d2 x 1.10

Roughness

Surface Roughness Roughness class

Ra Rt Rz
µm µm µm
Contact surface 0.40 3.00 1.60 N5
Mounting Chamfer 0.80 6.30 3.15 N8

Use as drive belts

O-Rings can be used as drive elements for low- Limitations:
torque such as those in tape recorders. O-Rings
• Contact with liquids should be avoided as
manufactured using a special process must be
this increases slip
used for these applications. As a rule an EPDM
grade with good ozone resistance and 70 to 80 • The smallest bending radius is 3 x cross-
IRHD/Shore A hardness is used. The extension sectional diameter d2
of the O-Ring at the internal diameter should be
• The thickness d2 at the cross-section should
between 8% and 12% and the peripheral speed
not be less than 3,00 mm
should not exceed 20 m/s.
• The maximum extension is 15% of internal
diameter d1 (preferably an extension from
8% to 2%)

• Tensile strength when mounted is approx.

0,5 to 1,5 N/mm2

• After extended service times residual tensile

deformation is to be expected

• If considerable heat is evolved the O-Ring

can be expected to shrink (Joule effect)

O-Rings Technical Guide 40

General design notes

Compression table for the most com-

mon O-Ring cross-sectional diameters
The following table shows the groove depth D [mm] to be selected, depending on the O-Ring cross-
sectional diameter d2 and the compression [%].

Compression

D d 2 -D
d2 Compression (%) = . 100
d2

Depth of groove D

Com-
O-Ring cross-sectional diameter d2 [mm]
pression
% 1.50 1.60 1.78 2.00 2.40 2.50 2.62 3.00 3.53 4.00 5.00 5.34 5.70 6.99 8.40
28 1.08 1.15 1.28 1.44
27 1.10 1.17 1.30 1.46 1.75 1.83 1.91 2.19
26 1.11 1.18 1.32 1.48 1.78 1.85 1.94 2.22 2.61 2.96
25 1.13 1.20 1.34 1.50 1.80 1.88 1.97 2.25 2.65 3.00 3.75 4.00 4.28
24 1.14 1.21 1.35 1.52 1.82 1.90 1.99 2.28 2.68 3.04 3.80 4.06 4.33
23 1.16 1.23 1.37 1.54 1.85 1.93 2.02 2.31 2.71 3.08 3.85 4.11 4.39 5.39 6.47
22 1.17 1.25 1.39 1.56 1.87 1.95 2.04 2.34 2.75 3.12 3.90 4.17 4.45 5.46 6.55
21 1.19 1.26 1.41 1.58 1.90 1.98 2.07 2.37 2.79 3.16 3.95 4.22 4.50 5.53 6.64
20 1.20 1.28 1.42 1.60 1.92 2.00 2.10 2.40 2.82 3.20 4.00 4.27 4.56 5.60 6.72
19 1.22 1.30 1.44 1.62 1.94 2.03 2.12 2.43 2.86 3.24 4.05 4.33 4.61 5.67 6.80
18 1.23 1.31 1.46 1.64 1.97 2.05 2.15 2.46 2.89 3.28 4.10 4.38 4.67 5.74 6.89
17 1.25 1.33 1.48 1.66 1.99 2.08 2.17 2.49 2.93 3.32 4.15 4.43 4.73 5.81 6.97
16 1.26 1.34 1.50 1.68 2.02 2.10 2.20 2.52 2.97 3.36 4.20 4.49 4.79 5.88 7.06
15 1.28 1.36 1.51 1.70 2.04 2.13 2.23 2.55 3.00 3.40 4.25 4.54 4.85 5.95 7.14
14 1.29 1.38 1.53 1.72 2.06 2.15 2.25 2.58 3.04 3.44 4.30 4.60 4.90 6.02 7.22
13 1.30 1.39 1.55 1.74 2.09 2.18 2.28 2.61 3.07 3.48 4.35 4.65 4.96 6.09 7.31
12 1.32 1.41 1.57 1.76 2.11 2.20 2.30 2.64 3.11 3.52 4.40 4.70 5.02 6.16 7.39
11 1.34 1.42 1.58 1.78 2.13 2.23 2.33 2.67 3.14 3.56 4.45 4.75 5.07 6.23 7.48
10 1.35 1.44 1.60 1.80 2.16 2.25 2.36 2.70 3.18 3.60 4.50 4.81 5.13 6.30 7.56
9 1.37 1.46 1.62 1.82 2.18 2.28 2.38 2.73 3.21 3.64 4.55 4.86 5.19 6.37 7.64
8 1.38 1.47 1.64 1.84 2.20 2.30 2.41 2.76 3.25 3.62 4.60 4.91 5.24 6.44 7.73
7 1.40 1.49 1.66 1.86 2.23 2.33 2.44 2.79 3.28 3.72 4.65 4.97 5.30 6.51 7.81
6 1.41 1.50 1.67 1.88 2.26 2.35 2.46 2.82 3.32 3.76 4.70 5.02 5.36 6.58 7.90
5 1.43 1.52 1.69 1.90 2.28 2.38 2.49 2.85 3.35 3.80 4.75 5.07 5.42 6.65 7.98
4 1.71 1.92 2.30 2.40 2.52 2.88 3.39 3.84 4.80 5.13 5.47 6.72 8.06
3 2.33 2.43 2.54 2.91 3.42 3.88 4.85 5.18 5.53 6.79 8.15
2 3.46 3.92 4.90 5.23 5.59 6.86 8.23

41 O-Rings Technical Guide

DESIGN NOTES

Force required
for cross-sectional deformation

This graph gives the required compressive force

for 10%, 15% and 20% compression of an O-Ring.
These are specific guideline values at +20°C.
The value found (in N/mm) then only needs to
be multiplied by the internal diameter d1 of the
O-Ring.

Compression of cross-sectional diameter

Example for O-Ring OR6300, NBR 90

• Internal diameter: d1 = 75.57 mm
• Cross-sectional diameter: d2 = 5.34 mm
• Hardness: 90 IRHD/Shore A
• Compression: 15%
• Force (N/mm) x internal diameter d1 (mm)
= compressive force (N): 27 N/mm x 75.57 mm
= 2040 N
O-Rings Technical Guide 42
 Extension and
compression

The internal diameter d1 of O-Rings should

not be extended more than 6% or compressed
more than 3% when they have been mounted.
The tolerances of the O-Ring cord diameter d2
are not to be considered. During extension the
cross-section, originally circular, becomes oval.
In order to achieve the desired compression,
this flattening must be taken into account when
designing the groove depth.
Elastic expansion

d2

d2 *

d 1 * -d 1
Elastic expansion: . 100
Ød 1 Ød 1 *
d1

d1 * = internal diameter extended or compressed

d2* = cross section flattened

43 O-Rings Technical Guide

DESIGN NOTES

Slide face materials

and surfaces
It is only possible to guarantee fault free The rugosity of the contact surface is significant
operation and long service life for a seal if the for wear and durability of a seal. The maximum
metal contact surfaces fulfill certain values for values for Ra, Rt and Rz are given for each sealing
rugosity and enable the fluid to wet them. The element.
wettability of a surface is a critical factor in
The center roughness value Ra is the arithmetic
building up a lubricating film. Wettability of the
mean value of the absolute of all distances y of
slide face is promoted by, in descending order:
the roughness profile from the mean line within
• Soft C steel the total measuring distance lm.

• Hardened steel

• Hard chrome-plated surface

• Stainless steel

• Cast iron Y
Ra
• Bronze, brass

• Aluminium / alloys

• Plastics
lm

The maximum depth of roughness Rt is the In both tests only the roughness of the surface is
vertical distance between the highest and lowest taken into account, not its waviness.
point of the roughness profile within the total
measured length lm.
Z1 Z2 Z3 Z4 Z5
Rt

lm
le
lm=5xle

Rz = 1/5 (Z1 + Z2 + Z3 + Z4 + Z5)

Average depth of roughness Rz is calculated
from 5 consecutive individual measured lengths.

O-Rings Technical Guide 44

 Contact area
ratio tp
Depth of surface smoothness The contact area ratio tp (%) of a surface is also
highly significant when seals are being used.
Rp Rt
This is the percentage ratio of the bear - in
length to the measured length lm at a certain
cut depth (recommended 0,5 Rt). For dynamic
contact surfaces a contact area ratio of ³ >50% is
recommended for 0,5 Rt (the depth of smoothing
lm is less than 0,5 Rp).

The smoothing depth Rp is the vertical distance

between the highest point and the mean line of
a roughness profile.

Idealised profile sections for assessment of surface

45 O-Rings Technical Guide

DESIGN NOTES

Peaks can be removed from the surface by honing,

rolling, drawing or rollering; nevertheless the
valleys remain as lubricating pockets.

with non-cutting process with cutting process

Pressure activated
seal load
In static applications where structural parts
are sufficiently strong the pressure can rise
considerably. It is important that the components
to be sealed (e.g. flange, lid, etc.) cannot lift
away from each other, for if they do the O-Ring
migrates into the gap and when the pressure is
O-Ring without pressure
released it is caught by the edge of the groove.
If the pressure changes many times it peels off.

In dynamic applications (reciprocating move-

ment only) the pressure of the fluid must never
exceed 350 bar. Very slow relative movements
are an exception to this rule.

In the depressurised condition the O-Ring creates

a seal by its elasticity and resilience between the
two contact surfaces.

O-Rings Technical Guide 46

As the pressure rises the O-Ring acts as a highly O-Ring under pressure
viscous incompressible liquid. Pressure exerted
on the O-Ring is propagated to practically the
same degree in all directions (basic law of hydro
statics, Blaise Pascal).

When the pressure rises further the O-Ring is O-Ring in the sealing gap
pressed into the gap and shears or peels off.

Under pulsating pressure the O-Ring is clamped O-Ring clamped

and damaged by the gap of structural

This migration into the gap, which often causes

an O-Ring to fail, can be prevented by using
back-up rings.

Pressure exerted on one side Pressure exerted on both sides

47 O-Rings Technical Guide

DESIGN NOTES

Permissible
clearance S

Play in the gap on the side of the O-Ring away

from the pressure determines whether back-up
rings should be used. The degrees of fit should
be checked for each pressure and, if the gap
is too large, back-up rings must be provided.
Otherwise the O-Ring will be destroyed by
extrusion of rubber material into the gap. Our
recommendations for the selection of fit for
static and dynamic applications are given below.

For back-up rings: see page 57

Permissible clearance

Pressure p Hardness of O-Ring Fit at

bar IRHD/Shore A ØA/ØF
≤ 20 60 ÷ 70 H8/f7
≤ 70 70 ÷ 90 H8/f7
≤ 100 70 ÷ 90 + back-up ring H8/f7
70 ÷ 90 H7/g6
≤ 350 70 ÷ 90 + back-up ring H7/g6

ØA ØF

For static flange or cover seals, the structural

parts must be designed so that no gaps appear.
For a static axially sealing O-Ring, there is
no need for back-up rings as the gap is only
minimal.

With sealing gap (wrong) No sealing gap (right)

S

P
P

O-Rings Technical Guide 48

For static radially sealing O-Ring applications
the gap should be kept as small as possible.

High pressure increases No sealing gap (right)

sealing gap (wrong)

S P
P

For piston and rod seals in static and dynamic S

P
applications, the sealing gaps in the high-
pressure range, which arise because of tolerance
in the fitting, must be very carefully checked.
Often back-up-rings are necessary to prevent
migration of the O-Ring into the gap.

60 IRHD/60 Shore A 70 IRHD/70 Shore A

49 O-Rings Technical Guide

DESIGN NOTES

80 IRHD/80 Shore A 90 IRHD/90 Shore A

The table below gives the permissible allowance S (mm) for the gap for different material hardnesses
and working pressures. The different groove widths C for 1 and 2 back-up-rings are also shown.

Allowance gap „s“ for cross-section diameter in relation to the hardness of the O-Ring

Pressure Allowance gap s for cross-section diameter d2 (mm)

≤ 1.8 >1.8 - ≤2.2 >2.2 - ≤2.7 >2.7 - ≤ 3.2 >3.2 - ≤3.7 >3.7 - ≤4.2 >4.2 - ≤5.0 >5.0 - ≤6.0 >6.0 - ≤8.4
bar mm mm mm mm mm mm mm mm mm
70 ±5 IRHD/Shore A < 50 0.12 0.13 0.17 0.18 0.19 0.20 0.22 0.23 0.26
< 100 0.05 0.07 0.09 0.10 0.11 0.12 0.13 0.14 0.16
< 150 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10
80 ±5 IRHD/Shore A < 50 0.17 0.18 0.22 0.23 0.26 0.27 0.30 0.31 0.36
< 100 0.10 0.11 0.13 0.14 0.15 0.16 0.18 0.19 0.22
< 150 0.05 0.06 0.07 0.08 0.09 0.10 0.12 0.13 0.13
< 200 0.02 0.02 0.04 0.04 0.05 0.07 0.08 0.08 0.08
90 ±5 IRHD/Shore A < 50 0.22 0.23 0.28 0.30 0.35 0.35 0.38 0.40 0.45
< 100 0.15 0.16 1.18 0.19 0.22 0.23 0.25 0.26 0.30
< 150 0.08 0.10 0.12 0.13 0.15 0.16 0.18 0.18 0.22
< 200 0.05 0.06 0.09 0.10 0.11 0.12 0.14 0.14 0.17
< 250 0.02 0.03 0.07 0.08 0.09 0.10 0.11 0.11 0.13
< 300 — — 0.05 0.05 0.06 0.07 0.08 0.08 0.10
< 350 — — 0.03 0.03 0.05 0.06 0.07 0.07 0.08

Width of groove C when back-up rings are used

Number of back-up rings Cross-sectional diameter d2

≤ 4.2 mm > 4.2 to ≤ 6.0 > 6.0 to ≤ 8.4

1 With of the groove C + 1.5 mm With of the groove C + 1.8 mm With of the groove C + 2.5 mm
2 With of the groove C + 3.0 mm With of the groove C + 3.6 mm With of the groove C + 5.0 mm

O-Rings Technical Guide 50

 Material
hardness

We introduce this section with a further

explanation on hardness testing methods.

The test method to DIN 53519/1/2, ASTM D 1415

e BS 903 A 26 (IRHD = international rubber
hardness degree) is the one most commonly used
internationally. It calculates the resistance when
a ball penetrates the specimen. The values that
can be read out are printed out as IRHD normal,
soft or micro (depending on the diameter of
the ball). For IRHD soft the ball diameter is 5,0
mm, for IRHD normal it is 2,5 mm and for IRHD
micro it is 0,4 mm. For IRHD normal and soft
tests the specimen must be at least 6 mm thick.
For IRHD micro, parts up to 1,5 mm thick can
be measured. The IRHD test method measures
the penetration of the ball under constant load
after the specified test period of 30 seconds has
Comparison of different test methods elapsed.

The test method to DIN 53505 (Shore A hardness)

measures the resistance of the specimen to
penetration by a truncated cone. The results
are printed out as Shore A values. Unlike the
IRHD test, the specimen must always be at least
6 mm thick. If it is less than these errors occur
which can give values up to 10 points higher.
For O-Rings with a cord diameter under 6mm,
the measuring method according to IRHD micro
is far more reliable.

51 O-Rings Technical Guide

DESIGN NOTES

• Softer materials adapt more easily and are rougher. Moderately hard materials are
better to the surface structure of the used for dynamic applications. The pressure
contact surfaces. The soft materials move resistance, wear characteristics and friction
more easy into pores and depressions. This require a hardness of 70 to 75 IRHD/Shore A.
behavior is important in the decompressed
• In high pressure applications, harder
condition or in the low pressure range,
materials prevent a certain degree of
because the additional compression caused
extrusion into the gap. The high compression
by the pressure of the fluid is absent.
force means that there are limitations in
For this reason, O-Rings with a hardness
mounting. The hardness is in the 90 IRHD/
of 60 IRHD/Shore A are used in the low
Shore A range.
pressure area where the contact surfaces

Lubrication

For static applications, the O-Ring can be compounds to system medias.

mounted dry. However, a mineral oil based or
In dynamic applications it is very important
oil protects it from ageing and makes it softer
to create good lubrification conditions. Good
during mounting.
lubrication at the slide faces considerably
Limitations: increases the durability of an O-Ring. In
addition to the wettability of the surface
• EPDM materials should not come into contact
(creation of a lubricating film on the sealing
with mineral oil based greaes or mineral oils.
face), the lubricating property of the fluid has a
Certain synthetic greases or silicone greases
considerable effect on the wear of the seal. This
are suitable.
depends on its viscosity as well as the general
• All O-Ring materials except silicone rubber suitability of the fluid.
are resistant to silicone grease.

• Please carefully note our recommendations

regarding the compatibility of rubber

O-Rings Technical Guide 52

 Viscosity

The lubricating fluid always covers the contact occurs as a result of the conversion of power
surface with a thin film. Storage in the slide face is losses into heat and this is taken up by the oil.
ensured by the wettability, i.e. the roughness, of The viscosity-temperature characteristics of
the surface. The thickness of the lubricating film mineral oils in different viscosity classes shows
is mainly dependent on the type and viscosity of a tendency towards a relatively undesirable fall
the fluid but is also affected by the compressive in viscosity. The viscosity index (VI) is the code
force of the dynamic contact surface, the slide for the viscosity-temperature characteristic. The
face and the stroke speed. higher the VI, the less the viscosity changes with
temperature. This means that the operating
The viscosity of mineral oils depends on pressure
temperature range is wide. Mineral oils that
and temperature. As the temperature rises a
have been improved by catalysts or other
rapid reduction in viscosity can be observed; for
additives, or paraffin-based hydraulic oils have
this reason, the viscosity-temperature behavior
a particularly good viscosity index.
is highly significant. The rise in temperature

Kinematic viscosity/tempeerature Fluids with a high viscosity index are charac-

Surface weight [kg/m2]
terized by good wear protection and a high
sealing effect at high temperature as well as
100
Kinematic viscosity [mm2, s-1]

70
50
good performance at low temperatures. A high
40
30
HFC VI extends the service life of sealing that are
Mineral-oil
20
susceptible to wear.
10
7
5
4
3 HFO
2

1
HFA

0,7
0,5 Acqua
0,4 Water
0,3
0,2
0,1

0 20 40 60 80 100

Temperature [°C]

53 O-Rings Technical Guide

DESIGN NOTES

Friction

Lubrication has a considerable effect on the We give below the coefficients of friction of
degree of friction that occurs. With proper elastomer materials when running dry against
lubrication, friction is low. Self-lubricating PTFE steel, as determined by the hardness of the
seals are an exception to this rule even if they material:
nevertheless do not reject lubricated ratios.
• 60 IHRD/Shore friction coefficient (µ) = 0.9
High friction not only reduces efficiency, it also
increases wear. • 70 IHRD/Shore friction coefficient (µ) = 0.8

Frictional force is affected by the prestressing • 80 IHRD/Shore friction coefficient (µ) = 0.6
on the seal, the hardness of the material, the
• 90 IHRD/Shore friction coefficient (µ) = 0.5
surface finish, the nature and viscosity of the
hydraulic fluid, the pressure and the running • For comparison, PTFE friction coefficient (µ) = 0.08
speed. It can be seen from this that it is not
possible to provide precise values for friction.
These can only be determined by trials.

Slip velocity/Coefficient of friction

Stick-slip effect

Stick-slip is a phenomenon which adversely

affects slow stroke movements. The transition
from static friction to sliding friction causes
a backwards movement in the reciprocating
piston. When stick-slip occurs, the following
conditions are combined:

• The static friction must be greater than the

sliding friction.

• The seal is not working in the hydro-dynamic When oils with a low lubricating film resistance
friction area but in the mixed friction area. are used the result is a greater stick-slip effect. This
can be avoided in practice if the wettability of the
• The compressible column of oil has a slide faces is good and an oil with a high viscosity
spring effect which stores energy during index is used. Stick-slip can also be considerably
the transfer of force until it is sufficient to reduced by selecting an appropriate seal, i.e. a
overcome static friction. different design of seal and a suitable material.
O-Rings Technical Guide 54
Wear

Friction and wear are highly interdependent and

affect the service life of a seal. It is sometimes
very difficult to distinguish normal ageing from
wear that should not be tolerated.

Common types
of wear
Abrasion: These types of wear can be reduced by various
means:
Frequent causes of failure are excessively
rough slide faces, contamination in the oil, • Correct selection of the type of seal and the
insufficient lubrication, excessively high correct material
pressure or temperature.
• The use of hydraulic fluids with optimum
Extrusion: lubricating characteristics

An excessively large sealing gap on the non- • Optimization of the slide faces involved to
pressurised side, excessively high pressure reduce wear and promote the formation of
or the absence of a back-up ring. a lubricating film

Erosion or cavitation (e.g air in the oil): • Checking the general operating conditions
such as the pressure and temperature levels,
At high pressure air bubbles are compressed
the running speed, etc.
and expand under the sealing face. They
cause the seal to be damaged.

55 O-Rings Technical Guide

DESIGN NOTES

Sliding speed

The service limits for piston and rod speeds

cannot be precisely laid down because of the
great variety of operating conditions (lubricating
fluid, service, temperature). The information in
the following graph is only for guidance. It is
valid for hydraulic fluids with good lubrication
properties and oiled air.

Even higher running speeds are permissible

if certain conditions are fulfilled (reduction of
compression to a minimum). These cases cannot
however be generalized.

Contamination
at the seal area

The fluids to be retained must not be Dirt scraper

contaminated or contain any solid matter; this
causes increased wear. The cleanliness and
surface finish of the slide faces must not be
adversely affected by any dirt, dust or other solid
matter adhering to them. If there is a danger of
foreign matter being deposited on the rod, dirt
scrapers should be used.

Dirt scrapers are available as standard in NBR,

PUR and PTFE.

O-Rings Technical Guide 56

Back-up rings

General

Back-up rings are used in conjunction with

O-Rings for static and dynamic applications.
Back-up-rings are made of harder material than
the O-Ring material – the back-up-ring reduces
the gap and prevents migration of the O-Ring into
the sealing gap. Back-up rings can be mounted
as a single ring behind the O-Ring on the side of
lower pressure. For high pressure, two back-up
rings can also be fitted from both sides. In case
of such a “sandwich” packaging of two back up
rings with the O-Ring in the middle, the risk of
potential pressure enclosure between the back
rings shall be considered in special pressurizing
conditions.

Without back-up ring With back-up ring

S
P

Back-up rings should be used if one of the

following operating difficulties arises when
O-Rings are used as seals:

• High pressure • High fluid temperatures

• Large sealing gap • Large variations in pressure or temperature

• High stroke speed or rapid stroke sequence • Contaminated fluids

57 O-Rings Technical Guide

DESIGN NOTES

Back-up ring types

Our back-up rings are available in 3 versions. Type BKW (helical) to be used up to 200 bar only

Type BKW is available from stock for O-Rings in Type BKE (endless)
American/British standard sizes. Back-up rings
for other O-Ring dimensions are available on
request, as are type BKS and BKE. The back-up
ring codes are the same as the corresponding
O-Ring reference codes.

Type BKS (one piece, slotted)

Design notes

Locating grooves should be basically rectangular and the surface finish of the area to be sealed are
in design. However, for production engineering subject to the same conditions as set out in the
reasons, a slope of up to 5° in the walls of the section «Profiles and dimensions of grooves“.
grooves is permissible. The radii of the groove

1 back-up ring 2 back-up rings

P P P P

D D

ØE ØF ØE ØF

C C

O-Rings Technical Guide 58

The cylinder diameter F is given in the section Types BKW and BKS are very simple to mount,
«Sets of dimensions» and following sections of even in closed grooves. Type BKE, on the other
Chapter 5 „Groove dimensions for O-Rings“. hand, which satisfies the highest specifications,
Deviations from the dimensions given there can only be mounted in open grooves.
also require specially designed back-up rings.
The groove depth D is the standard for dynamic
hydraulic applications.

Virgin
PTFE O-Rings

Mounting cavities

Specially designed O-Ring grooves are required Enclosed O-Ring

to prevent PTFE O-Rings from migrating (due to
the typical cold flow properties of the material).
The O-Ring must be completely enclosed, i.e.
the width of the groove must be the same as the
cross-sectional diameter d2.

Determination of mounting cavities

Groove Ø Cross-sectional Ø With of the groove Depth of groove

A-h11 d2 C± 0.1
D +0.1/0

mm mm mm mm
≤ 12 3.00 3.00 2.55
>12 – ≤ 20 4.00 4.00 3.40
>20 – ≤ 25 5.00 5.00 4.25
>25 – ≤ 30 6.00 6.00 5.10
>30 – ≤ 80 7.00 7.00 5.95
>80 – ≤ 120 8.00 8.00 6.80
>120 –≤ 1000 10.00 10.00 8.50

59 O-Rings Technical Guide

DESIGN NOTES

Limitations
• Operating temperature:
from –200°C to +210°C

• Resistance to fluids: universal

• Except for molten alkaline metals and

compounds of fluorine

• Pressure resistance

Roughness

Surface Roughness Roughness class

Ra Rt Rz
Uncoated seals 0.40 3.00 1.60 N5
Contact seals
Coated seals 0.80 6.30 3.15 N6
Uncoated seals 0.40 3.00 1.60 N5
Base of grove
Coated seals 0.80 6.30 3.15 N6
Sides of grooves 2.50 19.00 10.00 N7/N8

Metal O-Rings, metal C-Rings

Designs

Standard type
Ød2

Standard type, made of most metals, from tubing c

or solid wire; the favorite type of O-Ring.

b

Ød1

O-Rings Technical Guide 60

Self-reinforcing a

The O-Ring has holes or slots on its inner b

circumference. This creates internal pressure

that matches the pressure in the system.
Increasing the internal pressure improves the
tightness.

Pressurized c
a

Pressurized for maximum temperatures b

from +425°C to +980°C (depending on the

material). Pressure-filled O-Rings contain a gas
at a pressure of at least 40 bar. This pressure
increases at elevated temperatures and thus
compensates for the loss of pre-stressing in the
flange joint and increases the sealing capacity.

Surface finish

Surface Surface finish Roughness class

Ra Rt Rz
Uncoated seals 0.40 3.00 1.60 N5
Contact seals
Coated seals 0.80 6.30 3.15 N6
Uncoated seals 0.40 3.00 1.60 N5
Base of grove
Coated seals 0.80 6.30 3.15 N6
Sides of grooves 2.50 19.00 10.00 N7/N8

For vacuum, gases or low-viscosity liquids (water), the contact surfaces

and the base of the groove should always be finished Ra=0.4µm,
Rt=<
– 3.0µm, Rz=1.6µm, N5. If the contact surface has a coarser finish
than this, it is advisable to use metal O-Rings and C-Rings with a thicker
coating.

61 O-Rings Technical Guide

Manufacturing
tolerances

Manufacturing tolerance Cross-sectional diameter d2

for elastomer O-Rings Inside diameter d1 tolerances

Definition of quality levels

Defect limits Type characteristics N and S to ISO 3601

Definition of defect types

O-Rings Technical Guide 62

 3

63 O-Rings Technical Guide

M A N U FA C T U R I N G T O L E R A N C E S

Manufacturing O-Rings are manufactured as rubber mouldings

with very close dimensional tolerances. These
are specified in Standards ISO 3601/1. O-Rings
tolerances for are normally well within the prescribed
tolerances.
elastomer O-Rings
The values given in the table below are designed
for NBR O-Rings with a hardness of 70 IHRD/
Shore A. In the case of different base materials,
in particular FPM, MVQ, EPDM and FFKM,
different degrees of contraction may result
in values that differ from those given in the
table. However, such deviations are normally
so small that they have no effect on the sealing
function of the O-Ring in static applications, for
example. Special tooling is required to achieve
the tolerances given in the table. Please discuss
it with us if you require tighter tolerances.

Tolerances

Cross-sectional diameter Max. Tolerance Cross-sectional diameter Max. Tolerance

d2 d2
mm mm mm mm
≥ 1.00 - ≥ 2.50 ± 0.08 > 4.00 - ≤ 5.70 ± 0.13
> 2.50 - ≤ 2.70 ± 0.09 > 5.70 - ≤ 8.40 ± 0.15
> 2.70 - ≤ 4.00 ± 0.10

Inside diameter Max. Tolerance Inside diameter Max. Tolerance

d1 d1
mm mm mm mm
- ≤ 2.50 ± 0.13 > 80.00 - ≤ 95.00 ± 0.80
> 2.50 - ≤ 4.50 ± 0.14 > 95.00 - ≤ 105.00 ± 0.90
> 4.50 - ≤ 6.50 ± 0.15 > 105.00 - ≤ 120.00 ± 1.00
> 6.50 - ≤ 8.50 ± 0.16 > 120.00 - ≤ 150.00 ± 1.20
> 8.50 - ≤ 10.00 ± 0.17 > 150.00 - ≤ 180.00 ± 1.40
> 10.00 - ≤ 11.50 ± 0.18 > 180.00 - ≤ 200.00 ± 1.60
> 11.50 - ≤ 14.00 ± 0.19 > 200.00 - ≤ 240.00 ± 1.80
> 14.00 - ≤ 16.00 ± 0.20 > 240.00 - ≤ 270.00 ± 2.00
> 16.00 - ≤ 25.00 ± 0.25 > 270.00 - ≤ 325.00 ± 2.40
> 25.00 - ≤ 30.00 ± 0.30 > 325.00 - ≤ 400.00 ± 2.80
> 30.00 - ≤ 35.00 ± 0.35 > 400.00 - ≤ 460.00 ± 3.20
> 35.00 - ≤ 40.00 ± 0.40 > 460.00 - ≤ 530.00 ± 3.60
> 40.00 - ≤ 55.00 ± 0.50 > 530.00 - ≤ 600.00 ± 4.00
> 55.00 - ≤ 70.00 ± 0.60 > 600.00 - ≤ 700.00 ± 4.40
> 70.00 - ≤ 80.00 ± 0.70 > 700.00 - ≤ 800.00 ± 4.80

O-Rings Technical Guide 64

Defect limits

The values given in the table apply to all Definition of quality levels:
elastomer O-Rings. They should be regarded
GRADE N (general purpose)
as guideline values, as it is often difficult to
measure them accurately on elastomers. Grade N (general purpose) identifies acceptance
criteria for O-Rings intended for general use.
The O-Rings we keep in stock are normal grade.

GRADE S (special)

Grade S (special) identifies acceptance criteria

for O-Rings intended for applications requiring
a higher level of quality and/or precision with
respect to dimensional tolerances of surface
imperfections. For example, aerospace or
critical industrial or automotive applications
are covered by this grade. Please contact us if
you require different defects limits.

GRADE CS (critical service)

This grade identifies acceptance criteria for

O-Rings intended for applications requiring a
much higher level of quality and/or precision
with respect to dimensional tolerances of
surface imperfections. For example, critical
service aerospace or medical applications,
where the surface of the O-Ring must be near-
perfect to perform in a satisfactory manner, are
covered by this grade.

Selection of grade

If the user does not specify the grade at the time

of purchase, Grade N will be assumed to be the
quality requirement.

65 O-Rings Technical Guide

M A N U FA C T U R I N G T O L E R A N C E S

Characteristics of grades N (normal), S (special) and

CS (critical services) to ISO 3601/3.

Limits of size for surface imperfections

Limit- Maximum limits of Maximum limits of Maximum limits of

Surface
Diagrammatic ing imperfections imperfections imperfections
imperfec-
representation dimen- Grade N O-Rings Grade S O-Rings Grade CS O-Rings
tion type
sions Cross-section d2 Cross-section d2 Cross-section d2

> 0.8b > 2.25 > 3.15 > 4.50 > 6.30 > 0.8b > 2.25 > 3.15 > 4.50 > 6.30 > 0.8b > 2.25 > 3.15 > 4.50 > 6.30

≤ 2.25 ≤ 3.15 ≤ 4.50 ≤ 6.30 ≤ 8.40b ≤ 2.25 ≤ 3.15 ≤ 4.50 ≤ 6.30 ≤ 8.40b ≤ 2.25 ≤ 3.15 ≤ 4.50 ≤ 6.30 ≤ 8.40b

e e e

Off-register,
e 0.08 0.10 0.13 0.15 0.15 0.08 0.08 0.10 0.12 0.13 0.04 0.04 0.06 0.06 0.08
mismatch (offset)

x
x 0.10 0.12 0.14 0.16 0.18 0.10 0.12 0.14 0.16 0.18 0.07 0.07 0.10 0.13 0.13
Combined flash y
(combination
y 0.10 0.12 0.14 0.16 0.18 0.10 0.12 0.14 0.16 0.18 0.10 0.10 0.13 0.13 0.13
of offset, flash
and parting line
projection) a When the flash can be differentiated, When the flash can be differentiated, it Not permissible
a
it shall not exceed 0.07 mm. shall not exceed 0.05 mm.

g 0.18 0.27 0.36 0.53 0.70 0.10 0.15 0.20 0.20 0.30 Not permissible
Backrind g g 0.18 0.27 0.36 0.53 0.70 0.10 0.15 0.20 0.20 0.30 Not permissible
u 0.08 0.08 0.10 0.10 0.13 0.05 0.08 0.10 0.10 0.13 Not permissible
u

Excessive trimming Trimming is allowed provided the dimen- Trimming is allowed provided the dimen- Trimming is allowed provided the dimen-
(radial tool marks n sion n is not reduced below the minimum sion n is not reduced below the minimum sion n is not reduced below the minimum
not allowed) diameter d2 for the O-Ring. diameter d2 for the O-Ring. diameter d2 for the O-ring.

k
Flow marks (radial v 0.15a 0.15a 6.50a 6.50a 6.50a 1.50a 1.50a 5.00a 5.00a 5.00a 1.50e 1.50e 1.50e 4.56e 4.56e
orientation of flow
v 1.50a 1.50a 6.50a 6.50a 6.50a 1.50a 1.50a 5.00a 5.00a 5.00a 1.50a 1.50a 1.50a 4.56a 4.56a
marks is not
permissible) k 0.08 0.08 0.08 0.08 0.08 0.08 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05
v

t
w
0.08 0.13 0.18 0.25 0.38
Non-fills and w 0.60 0.80 1.00 1.30 1.70 0.15 0.25 0.40 0.63 1.00
0.13d 0.25d 0.38d 0.51d 0.76d
indentations "0.08 "0.13 "0.18 "0.25 "0.38
w 0.60 0.80 1.00 1.30 1.70 0.15 0.25 0.40 0.63 1.00
(including parting 0.13d" 0.25d" 0.38d" 0.51d" 0.76d"
line indentations
t 0.08 0.08 0.10 0.10 0.13 0.08 0.08 0.10 0.10 0.13 0.08 0.08 0.10 0.10 0.13
w

a Or 0.05 times the O-Ring’s inside diameter (d 1), whichever is greater.

b Limits of imperfections for cross sections < 0.8 mm or > 8.40 mm shall be agreed upon between manufacturer and customer.
c Round edges.
d Mould deposit indentations only.
e Or 0.03 times the O-Ring’s inside diameter (d 1), whichever is greater, subject to a maximum of 30 mm.

O-Rings Technical Guide 66

Definition
of defect types

Excessive trimming Non-fill

flattened and often roughened area around randomly spaced, irregularly shaped surface
the inner and/or outer diameters of an O-Ring indentation having a coarser texture than the
caused by the trimming process normal O-Ring surface, caused by incomplete
filling of, and or the trapping of air in, the mould
Flash
cavity
film-like material that extends from the parting
Off-register
line projection or inner and/or outer diameters,
caused by mould separation or present due to misalignment of O-Ring halves, caused by the
inadequate trimming lateral shift of one mould cavity plate relative
to other
Flow mark
Offset
thread-like recess, usually curved, of very slight
depth in the unflexed state, with normal surface mismatch and/or off-register of O-Ring halves
texture and round edge, caused by incomplete
Parting-line indentation
flow and knit of the material
shallow saucer-like recess sometimes triangular
Foreign material
in shape, located on the parting line at the inner
any extraneous matter embedded in the surface and/or outer diameters, caused by deformation
of the O-Ring, e.g. contamination, dirt, etc. of the mould edge at the parting line

Indentation Parting-line projection

depression, usually irregular in form, caused by continuous ridge of material situated at the
the removal of inclusions from the surface or parting line of inner and/or outer diameters
the build-up of hardened deposits on the surface caused by worn or excessively rounded edges of
of the mould cavity the mould cavity

Mismatch

cross-sectional radius in one ring half being

unequal to that of the other half, caused by
dimensional difference in mould halves

67 O-Rings Technical Guide

Mounting instructions
and accidental damage
to the O-Rings
Mounting inclinations

Designing the mounting inclination

Holes in the mounting area

Mounting instructions
Stretching during mounting

Fitting into the groove

By-passing shoulders of shafts

Working temperature too high

Poor compatibility with fluids

Pressure too high

Accidental damage to the O-Rings Excessive wear

Compression too high

Rapid decompression

Excessive stretching

O-Rings Technical Guide 68

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69 O-Rings Technical Guide

M O U N T I N G I N S T R U C T I O N S A N D A C C I D E N TA L D A M A G E T O T H E O - R I N G S

Mounting
instructions

«Technical tightness» is practically achieved in

practice with the correct selection of materials
and optimum mounting ratios. If mistakes
are made during mounting or if an O-Ring is
damaged while being fitted, this leads to loss of
tightness.

There should be no sharp-edged transitions,

projecting shavings, ghost lines, threads, access
holes etc. Even the smallest fault can make the
O-Ring leak.

Mounting
inclinations

Mounting inclinations ensure that the sealing

face of the O-Ring can be mounted without
damage. The transition from the taper to the
cylindrical surface must be free from burrs.

Piston packing Rod packing

H 15°- 20° V

15°- 20°

O-Rings Technical Guide 70

Designing the
mounting inclinations

The radial height of the mounting inclination Mounting inclinations

must be greater than the radial compression V.
Thus H > V. H 15°- 20° V

Holes in the
mounting area

If transverse holes have to be negotiated during Traverse holes

mounting, corresponding recesses must be ØE >ØE +d 2

provided with tapers. The stress in the O-Ring

is relieved in the vicinity of the hole and is then
compressed again in the taper.

71 O-Rings Technical Guide

M O U N T I N G I N S T R U C T I O N S A N D A C C I D E N TA L D A M A G E T O T H E O - R I N G S

Stretching during
mounting

During mounting the O-Ring should not be

stretched by more than approx. 80% of its
circumference. Care must be taken to ensure
that it remains below the breaking strain
quoted in the material data sheet. If elongation
reaches the upper elastic limit, the O-Ring must
be allowed time to return to its original size.

Fitting into the

groove
Torsion while fitting in
O-Rings that are deformed during mounting
have a tendency to develop surface cracks as a
result of the considerable elastic expansion they
have undergone (the internal diameter becomes
the external diameter). The O-Rings with the
highest risk are those with a poor ratio of inner
diameter to cross-section diameter ratio.

By-passing
Mounting sleeve

shoulders of shafts

O-Rings must be protected from sharp edges

during mounting. Threads, splines, gear teeth,
holes etc. must be covered with a mounting
sleeve.

O-Rings Technical Guide 72

 Sliding the O-Ring
above rod surface

Prevent the risk of drilling the O-Ring cross

section while sliding above the rod surface.
Reduce sliding distance and ensure good
lubrication while assembly (in doubt lubricating
coating of the O-Ring can help here).

Accidental
damage to O-Rings
If mounting guidelines or the operating limits
of the material are not observed, O-Rings can
rapidly fail.

The main types of failure are:

• Working temperatures too high

• Poor compatibility with fluids

• Pressure too high

• Sealing gap too large

• Excess wear

• Compression set too high

• Rapid decompression in the case of gas seals

• Excessive elongation

• Wrongly designed housing

73 O-Rings Technical Guide

M O U N T I N G I N S T R U C T I O N S A N D A C C I D E N TA L D A M A G E T O T H E O - R I N G S

Working tempe- Operating temperatures in excess of those

recommended result in secondary curing in the
O-Ring and hardening of the material. This can
ratures too high make it brittle. Overheating can also be caused
by dynamic friction.

Poor compatibility In aggressive fluids, poorly chosen materials

may swell or shrink. If the material swells,
it softens and loses its compressive force. If it
with fluids shrinks, the compression is reduced. Resistance
to pressure also decreases.

Pressure too high If the pressures are high and the sealing gap is
large and there is no back-up ring to support
the O-Ring on the side away from the pressure,
the ring will extrude into the gap. The result is
mechanical damage such as peeling, explosion
or cracking. Under pulsating pressure and with
«breathing» structural parts the O-Ring can
become caught when the pressure drops.

Excess wear Excessively high dynamic loads, absence

of lubrication, rough surfaces or excessive
compression cause undesirable wear. Under
pulsating pressure, the O-Ring moves in the
groove and this can lead to wear. Contaminants
in the fluid can promote wear.

O-Rings Technical Guide 74

Compression High compression set automatically means
loss of sealing power. It occurs when operating
temperatures are too high, if the material is of
set too high poor quality or if the groove is badly designed.
Compression set can be explained as follows: In
the sprung condition the elastomer undergoes
secondary curing as a result of heating. It is
therefore moulded once more. Temperature
and duration are factors that greatly affect
flattening. Poor quality materials are more
susceptible to compression set. A slight degree
of compression set can nevertheless be observed
in every O-Ring, i.e. no O-Ring, once mounted
and used, will revert to its original circular.

Rapid decompres- Extremely rapid release of pressure causes

bubbles or crack formation on the surface of
gas seals. Gas permeates into the O-Ring at
sion (Permeation) high pressure and if the pressure drops rapidly
it expands and escapes at the surface. This
explosive decompression destroys the surface.
Thin and/or light gases, such as CO2 or helium,
permeate the elastomer more easily.

Damage can be avoided by reducing the area in

contact with the gas (using a small cross-section
diameter) or by allowing the pressure to drop
more slowly.

Excessive Excessive stretching (more than 6% to 10% of

the inner diameter depending on the material)
causes cracks to form on the O-Ring surface.
elongation These ozone cracks form more quickly under
tension and are mainly observed in materials
that are not resistant to ozone and weathering
(e.g. NBR).

When distorted O-Rings are mounted, too much

stretch in the area of the distortion can also
cause crack formation. Elevated temperatures
and high concentrations of oxygen or ozone
accelerate this.

75 O-Rings Technical Guide

Groove dimensions

Introduction

Availability from stock at Angst+Pfister

Groove dimensions for O-Rings

O-Rings Technical Guide 76

 5

77 O-Rings Technical Guide

GROOVE DIMENSIONS

Introduction

The groove dimensions given are general «Technical notes on the use of elastomer
recommendations for the use of elastomer O-Rings» can be used for groove calculations.
O-Rings with a hardness of 60 to 90 IHRD/Shore For pneumatics, the section «Dynamic seals
A. In certain cases (inadequate lubrication, use in pneumatics» in the same chapter should be
in a vacuum, pneumatic applications, extreme consulted to enable the O-Ring compression
dynamic loads) the groove dimensions need to to be accurately determined. For other more
be adapted or altered. unusual O-Ring applications it is advisable to
contact us for advice.
For vacuum applications the section «Use of
O-Rings in vacuum applications» in the chapter

Availability • High Performance O-Rings

from stock at • PERTEC® O-Rings

Angst+Pfister •

•
HITEC® Precision O-Rings

NORMATEC® O-Rings

• Precision O-Rings

The availability of the various O-Ring types These also show the physical characteristics and
from stock is indicated in the respective product the precise operating limits for the materials
catalogs or on our website/webshop. concerned.

Special O-Ring
dimensions and Groove dimensions

materials
max.5°

S
We are, of course, able to produce special O- R1 D
R2
Rings tailor-made for your application. Just
ask us if you need special dimensions or a
particular compound. Special orders are, how-
ever, subject to minimum quantities. C

O-Rings Technical Guide 78

 Groove dimensions for O-Rings

The following table gives a quick guide to groove

dimensions. If FFKM O-Rings are to be used,
we have access to a program for calculating
the groove design. This can, under certain
circumstances, vary from the standard
dimensions.
Determination of O-Ring groove

Dynamic radial applications Static radial/axial applications Radii

Cross-
Depth of groove, Width of
sectional Width of groove Depth of groove
hydraulic groove
diameter

d2 D* C C1 C2 D +0,1/0
C R1 R2
mm mm % mm mm mm mm % mm mm mm
1.00 — — — — — 0.70 30 1.50 ±0.1 0.10 0.25
1.02 — — — — — 0.70 30 1.50 ±0.1 0.10 0.25
1.27 — — — — — 0.90 28 1.80 ±0.1 0.10 0.25
1.50 — — — — — 1.10 26 2.20 ±0.1 0.10 0.25
1.52 — — — — — 1.10 26 2.30 ±0.1 0.10 0.25
1.60 — — — — — 1.20 25 2.30 ±0.1 0.10 0.25
1.78 1.45 19 2.50 ±0.1 4.00 ±0.1 5.50 ±0.1 1.30 26 2.50 ±0.1 0.10 0.25
1.80 1.50 17 2.50 ±0.2 4.00 ±0.2 5.50 ±0.2 1.30 27 2.50 ±0.1 0.10 0.25
1.90 1.60 16 2.50 ±0.3 4.00 ±0.3 5.50 ±0.1 1.50 21 2.50 ±0.1 0.10 0.25
2.00 1.70 15 2.60 ±0.1 4.10 ±0.1 5.60 ±0.1 1.60 20 2.60 ±0.1 0.10 0.25
2.40 2.00 16 3.20 ±0.1 4.70 ±0.1 6.20 ±0.1 1.80 25 3.20 ±0.1 0.10 0.25
2.50 2.15 14 3.30 ±0.1 4.80 ±0.1 6.30 ±0.1 1.90 24 3.30 ±0.1 0.10 0.25
2.62 2.20 16 3.50 ±0.1 5.00 ±0.1 6.50 ±0.1 2.05 22 3.50 ±0.1 0.10 0.25
2.65 2.20 17 3.50 ±0.1 5.00 ±0.1 6.50 ±0.1 2.05 23 3.50 ±0.1 0.10 0.25
2.70 2.25 16 3.60 ±0.1 5.10 ±0.1 6.60 ±0.1 2.15 20 3.60 ±0.1 0.10 0.25
3.00 2.60 13 4.00 ±0.1 5.50 ±0.1 7.00 ±0.1 2.40 20 4.00 ±0.1 0.10 0.25
3.50 3.05 13 4.50 ±0.2 6.00 ±0.2 7.50 ±0.2 2.90 17 4.50 ±0.2 0.20 0.75
3.53 3.05 13 4.50 ±0.2 6.00 ±0.2 7.50 ±0.2 2.90 18 4.50 ±0.2 0.20 0.75
3.55 3.05 14 4.50 ±0.2 6.00 ±0.2 7.50 ±0.2 2.90 18 4.50 ±0.2 0.20 0.75
3.60 3.10 14 4.60 ±0.2 6.10 ±0.2 7.60 ±0.2 3.00 17 4.60 ±0.2 0.20 0.75
4.00 3.50 12 5.00 ±0.2 6.50 ±0.2 8.00 ±0.2 3.30 17 5.00 ±0.2 0.20 0.75
5.00 4.40 12 6.50 ±0.2 8.30 ±0.2 10.10 ±0.2 4.10 18 6.50 ±0.2 0.20 0.75
5.30 4.70 12 7.00 ±0.2 8.80 ±0.2 10.60 ±0.2 4.50 15 7.00 ±0.2 0.20 0.75
5.34 4.70 12 7.00 ±0.2 8.80 ±0.2 10.60 ±0.2 4.50 16 7.00 ±0.2 0.20 0.75
5.70 5.00 12 7.50 ±0.2 9.30 ±0.2 11.10 ±0.2 4.85 15 7.50 ±0.2 0.20 0.75
6.99 6.20 11 9.50 ±0.2 12.00 ±0.2 14.50 ±0.2 6.00 14 9.50 ±0.2 0.20 0.75
7.00 6.20 11 9.50 ±0.2 12.00 ±0.2 14.50 ±0.2 6.00 14 9.50 ±0.2 0.20 0.75
8.40 7.50 10 11.00 ±0.2 13.50 ±0.2 16.00 ±0.2 7.25 13 11.00 ±0.2 0.20 0.75

* The groove depth D in dynamic hydraulic applications is a theoretical value.

The tolerance is derived from the clearances given in the groove dimension tables.

C1 Width of groove with 1 back-up ring (also applies to static use)

C2 Width of groove with 2 back-up rings (also applies to static use)
s dimension of gap (not available in static axial use)
% percent compression

79 O-Rings Technical Guide

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