The Simmering PDF

Freudenberg Group
Freudenberg Group
Basics for preventing damage
www.simrit.com
30 DE 252 3.5 0408 Trurnit/Bosch Druck, Landshut
Erich Prem Rolf Vogt
The Simmerring
Reliability right from the beginning
The Simmerring
Yo u r Te c h n o l o g y S p e c i a l i s t
Yo u r Te c h n o l o g y S p e c i a l i s t
The Simmerring Reliability right from the beginning
Erich Prem Rolf Vogt
The Simmerring
Reliability right from the beginning
1. Reliable sealing 2. Shaft surfaces

Requirements and working forms
Freudenberg Simrit GmbH & Co. KG reserves all rights, especially copyright and the registration of industrial property rights. Please observe that this document contains company secrets and any reproduction or dissemination to third parties may only occur through us. Protective charge: 10.00 Euro
Freudenberg Simrit GmbH & Co. KG
Simrit and the Simmerring A 75 year success story

parameters. The complex interplay of sealing component, rotating shaft and lubricant not only present the engineers and technicians at Simrit with great challenges, they also present particular challenges to the user. Many instances of damage and dysfunction arise simply due to incorrect or at least improper handling of the Simmerring during installation. This book will help to clarify the technical possibilities of the Simmerring component and its function in the "tribological system". In this way, production losses caused by improper handling or its suboptimal application can be avoided. In the rst part, possible causes of failure will be discussed and detailed examples of damage will be presented. In the second part, the requirements placed on the shaft surface will be looked at in depth and how the current surface treatment processes are suited to the interplay with the sealing component will be shown. Over 75 years ago, Walther Simmer developed the Simmerring at Freudenberg in Weinheim on Bergstrasse. Over the last 75 years, the sealing component has been continuously improved and optimised for new application areas. The resulting wealth of experience at Simrit is unique and makes this a book from the experts.
Erich Prem Product Development Industry
Dipl.-Ing. Rolf Vogt Manager Product Development Industry
The Simmerring is a universal sealing component. Its applications range from agricultural and construction machinery, to two and four stroke engines in chain saws and motorcycles, as well as hydrostatic drives in machine engineering to washing machines and wind power plants. Simmerrings have the combined role of sealing a rotating shaft and a housing from oil loss and preventing the intrusion of moisture and dirt. To do this, the sealing ring, lubricant and the shaft surface must be precisely matched to each other. Because both lubricants as well as shaft surfaces come in countless designs, the interplay of the Simmerring with these components is determined by a multitude of
Contents
1. Reliable sealing
How a Simmerring functions Leakage denition Analysis of leakage causes Damage scenarios Handling and installation Troubleshooting Summary 10 11 13 18 25 31 37
2. Shaft surfaces Requirements and working forms

Shaft surface requirements Surface treatment process Leading test Summary 40 41 53 55 56
Supplementary literature
1. Reliable Sealing
Reliable sealing
How a Simmerring functions

The sealing effect of a Simmerring is based on a simple yet ingenious principle: Through an intelligent interplay of geometry, material and manufacturing process, a component is created that works like a microscopic pump. This "micropump" not only transports uids or gases under the sealing edge, it can also transport contamination particles as well. It is also capable of delivering microscopically small leakages back into the space to be sealed. This phenomenal characteristic is the reason why even the most varied types of seal disturbance variables can be compensated for to a certain extent (depending on the specications of the seal disturbance variables), such as I I I I Irregularities in the shaft topology Shaft eccentricities Housing misalignment Skewed installation in the housing (wobble).
Meniscus Gas or uid entry
Seal gap Sealing edge Lubricant entry Conveyance effect
Fig. 2: Active principle of a Simmerring (schematic)
It is exactly this dened leakage that is necessary for a Simmerring to achieve sufcient lubrication and thus a long operating life.
Contact pressure Fig. 1: Simmerring in the tribological system
Contact width Gap height
Dust lip
Shaft surface shear Lubricant Grease lling
Access of air Sealing zone temperature
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Leakage denition
Leakage denition: the standard, leakage terms, cause, classication

Using standard test conditions, the lack of tightness is determined by the amount of the sealed uid - over and above any moistness which may occur in normal operating conditions which gets past the sealing edge and can be collected and measured, when the seal is run for a denite time on a test-rig. This collected and measured amount of media from the test-rig experiment is dened as the leakage.
A certain amount of leakage is advantageous for a good long-term seal but is usually no longer tolerated by today's users. In practice, it is not always easy to clearly classify the leakage of a radial shaft ring. The following denitions should assist:
continue to increase with increasing running time in approx. 80 % of the cases.
Short-term leakage
Short-term fault of the sealing system, e. g. caused by small dirt particles under the sealing edge which are removed during further operation (affects approx. 20 % of leaking radial shaft seals).
Sealed
No detectable moisture at the seal.
Apparent-leakage Moist
In the case of normal operating conditions, a lm of moisture present on the sealing edge area which, however, does not exceed the back face of the seal. Temporary leakage that is usually traced back to over-greasing between sealing lip and dust lip. For further information, read DIN 3760 or DIN 3761 respectively as well as from ISO 6194, in which release procedures in conjunction with leakage classes are described (supplementary literature 11).
Wet
A lm of moisture exceeding beyond the back face with drop formation but not yet dripping.
The cause of measurable leakages can be:

I Various elongations of seal and housing on the static side for non-compliance with tolerances I Material tears, particularly in the sealing edge caused by excessive thermal load during operation
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Measurable leakage
Detectable, small rivulet on the outside of the seal housing, originating from the back face of the seal. If radial shaft seals clearly exhibit leakages (e. g. 1 g/day), these
Leakage denition
I Hardening of the elastomer caused by excessive thermal/mechanical load and/or incompatibility with the medium to be sealed I Softening of the elastomer as a result of swelling from the medium to be sealed leading to premature wear of the seal I Corrosion of the shaft underneath the sealing edge and permanent malfunction of the sealing system I Failure of the lubricant with dry running and rapid lip wear as the consequence I Ageing of the pairing elastomer medium to be sealed I Formation of "oil carbon" in the sealing edge area which oats up resulting in the malfunctioning of the sealing system I Vibrations in equipment assembly and shaft, which cannot be followed by the sealing lip I Permanent ingress of contamination on the sealing lip from the inside or outside which results in premature wear to the sealing lip I Premature wear of the sealing lip through non-compliance with regulations for the design of the running surface on the shaft (see page 15: The shaft) I Damage to the sealing edge during transport, handling or installation
Leakage class max. permissible leakage per radial shaft seal 1g 2g 3g
These causes are to be analysed and appraised depending on the running time as early failure, premature failure, failure during the operation or at the end of the part's sealing lifespan.
Classication of occurring leakages

For monitoring production parts according to DIN 3761, the leakage classes according to table 1 are to be used. Deviating test conditions are to be agreed upon. In addition, the so-called zero-leakage with testrig tests of 240 h with 12 specimens can be arranged for release for construction, or for critical installation locations with special safety requirements. These zero-leakages can be subdivided according to the following criteria: I In the course of normal operating conditions, lm of moisture at the sealing edge only I Film of moisture over the sealing edge area but not passing beyond the back face; no formation of droplets I Film of moisture passing beyond the back face and/or formation of droplets, but no dripping occurs In tests on assemblies and vehicles, zeroleakage denes that state of the radial shaft seal during static and dynamic conditions where the sealed medium does not leak beyond the outer side of the radial shaft seal.
max. permissible leakage per 12 radial shaft seals 3g 6g 12 g Table 1: Leakage classes
1 2 3
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Leakage causes
Analysis of leakage causes: Static and dynamic leakage

Two kinds of leakage are distinguished with radial shaft seals: Static leakage, which is possible on the press t and on the sealing lip, and dynamic leakage, which only occurs on the sealing lip.
Upon examining prematurely failing radial shaft seals (with < 100 operating hours or an operational performance < 10,000 km) in detail, failure can be subdivided in the following way: I 30 % attributable to an improper shaft preparation method [see chapter shaft treatment/handling] I 30 % attributable to an improper installation I 10 % attributable to a faulty seal [damage symptoms DIN 3761, part 5]
I 15 % attributable to apparent-leakage/ premature leakage I 15 % attributable to other causes such as lubricant incompatibility/excessive temperatures/vibrations/contaminants Most failures can be avoided through corresponding installation training or consulting with regards to the correct shaft surface preparation method. It is important that seal and aggregate manufacturers as well as users are co-operative and that they proceed systematically with the fault analysis. It can be
Fig. 3: Possible causes of failure for radial shaft seals
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Leakage causes
more difcult to determine the causes of leakage from seals that have already been in operation over a longer period of time (months/years or e. g. > 100,000 km). There are a number of inuencing parameters and whose interplay can affect the medium-term and long-term sealing effect of a radial shaft seal. The chart [see Fig. 3, page 13] has proven itself as a sensible analysis instrument for determining the cause of damage. Using this diagram, the causes of failure can be systematically narrowed down. It is important to know that there is almost never only one cause of a leak. The interplay of multiple factors normally leads to leakage. In approx. 80 % of the cases, the cause of failure can be directly seen on the seal and the shaft. It is therefore without a doubt of great advantage for the seal manufacturer to be able to get all the relevant information on each failure, but above all to receive the actual seal and shaft themselves for damage analysis. You can nd the "technical data analysis" form sheet at www.simrit.de/Schadensanalyse which summarises the most important information required for processing a damage claim. The following describes the most important causes of leakage and the corresponding corrective measures in more detail:
I Sharp-edged chamfer area and/or too steep a chamfer angle on the housing bore I Simmerring B1: develops longitudinal furrows I Simmerring BA: elastomer can be sheared off
Static leakage at the sealing lip

I Shaft is too rough, possibly with longitudinal furrows caused by the insertion of a bearing. I Damage to the sealing lip caused by sharp-edged chamfer or feathered key groove on the shaft in the sealing lip area I For radial shaft seals with return pumping action (single or alternating leading), the sealing lip can be so greatly released (already at pressures > 0.3 bar ) so that it only lies on the helix (with nonventilated housings) I Shaft diameter is too small and/or the housing misalignment is too great. I Chamfer at the shaft is too small or too steep so that the sealing lip can tip over or turn under and the spring can come off [compare Fig. 3, page 13] Comment: In dynamic operation of radial shaft seals, these imponderables can increase the leakage.
Static leakage at the press-t

I The housing bore is too rough which is especially critical in Simmerring B1 seal designs. Nominal: Rmax < 6.3-16 m for B1 design (metallic outer case) Rmax < 10 -25 m for BA design (rubber coated outer case)
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Dynamic leakage at the sealing lip

Dynamically caused leakages at the sealing lip occur much more frequently than static leakages. Hence the causes are also more complex. The most important inuencing parameters are:
Leakage causes
The shaft
I Sharp introduced chamfering, scratches, e. g. caused by a bearing that was drawn onto the shaft [compare Fig. 31, page 23] I Blow holes in the running track area of the radial shaft seal (pores with a diameter < 0.05 mm are permissible) I Too smooth or too rough a shaft surface which can lead to high seal lip wear I An undened leading of the shaft [compare Fig. 63, page 53] can lead to radial shaft seal failure in a very short amount of time. The shaft surface topology in particular must be given complete attention. The following roughness values must be adhered to: I Ra 0.2 - 0.8 m I Rz 1 - 5 m I Rmax < 6.3 m These roughness values ensure minimal sealing edge wear of the radial seal shaft independently from the machining method and normally independent of the operating conditions. Shaft surfaces created through plunge-cut grinding very often exhibit helical structures that can lead to leakages within just a few rotations of the shaft. Measuring these damaging helical structures is not easy. In practice, the "thread method" is a proven method. But not all structures can be easily measured using this method. Using new measuring methods, these surface structures can nowadays be precisely detected and thus the relevant grinding
process parameters can be selectively modied [Supplementary literature 7, 9, 10].
The lubricants
Not all lubricants can be easily sealed. The complex makeup of the lubricants, the interaction of the individual additives with each other and the unavoidable interactions with the elastomer of the radial shaft seal can lead to: I Radial shaft seals being chemically attacked especially at the sealing edge (Formation of bubbles and ller metal erosion occurrences or even depolymerisation). I Lubrication additives being deposited at the shaft in the immediate vicinity of the sealing lip, developing into hardened accumulations with the result being that even the slightest axial movements of the shaft cause excessive seal lip wear. I Oil carbon directly on the sealing edge of the radial shaft seal due to thermal overloading of the lubricant, caused for example by high circumferential shaft speeds, insufcient heat dissipation, poor lubrication of the sealing edge, incorrect lubricant or seal selection. These deposits can cause tears in the sealing edge, which signicantly alter the seal itself or simply blister during operation leaving holes behind. I Radial shaft seals not being lubricated sufciently despite sufcient supply of lubricant and thus wearing faster. This phenomenon can occur especially with synthetic lubricants based on polyalphaolen or polyglycol.
15
Leakage causes
Edge rounded 1525 Edge rounded and polished 1525
Fig. 4: Housing and shaft design
Operating conditions and environmental effects

When early failure of radial seal rings occurs, an incorrect seal selection or critical operating conditions are often responsible for the malfunction. A few practical examples should make this clear.
loading of the elastomer and the lubricant as well as the mechanical load increase. The results are an increased seal lip wear and reduced running times.
Contamination
Many radial shaft seals fail due to contamination, even if they have survived the rst hours of operation trouble-free. It is not so much the contamination present in the inner part of every aggregate (form sand, wear debris from rotating parts), but rather the external contamination stirred up in the proximity of the seal. The particles can be drawn into the sealing gap, accumulate there and may eventually end up underneath the sealing edge. Not only does the wear of the seal lip and shaft (shaft running-in) increase, it can cause the seal lip to loosen enough so that the lubricant can pass through the seal gap and reach the surrounding area unhindered.
Temperature
The temperatures directly at the sealing edge of a radial shaft seal are often underestimated. Depending on the circumferential speeds, oil sump temperature, lubricant, lubricant supply and seal concept, the sealing edge temperature can be from 20 C to 40 C above the oil sump temperature and in extreme cases even 60 C (!) above the oil sump temperature.
Pressure
When aggregates are not ventilated, a pressure build-up in the housing can occur due to thermal expansion and the continuous air conveyance of the radial shaft seal ("micropump"). The pressure increases the seal lip contact pressure. The thermal
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The radial shaft seal itself

Naturally, the radial shaft seal can also be
Leakage causes
responsible for the leakages. Assuming the correct material selection and the corresponding prole design are correct, it is almost exclusively inhomogenities on the sealing edge that cause a leakage. An important aid is the testing of the sealing edge footprint on a glass mandrel. The radial shaft seal is pulled onto a glass mandrel, which has the nominal diameter of the shaft and the sealing edges system is tested. If the footprint of the sealing edge on the glass mandrel is homogenous and is closed completely, the possibility of a self-caused leak by the radial shaft seal itself is quite low. Such inhomogeneities can be caused by: I An instable manufacturing process I Materials inhomogeneities (manufacture-related) I Agglomerisation of llers I Tool contamination
I Improper handling after forming (among others things) Further features that should not be present on radial shaft seals are mentioned in from the DIN 3761, part 7. Claims are often made for leaking radial shaft seals on which there are no noticeable irregularities and which are practically in a new state. A positive test run in the laboratory usually conrms the assumption that the seal itself is in a faultless state so that the cause of the failure generally focuses on two points: I On the shaft or its surface structure. This can generate leakages very rapidly. I Approx. 30 % of all early failures are caused by an improper installation [See pages 38 ff. for more information.]
I No damage, pores, scratches I Roughness Rmax Rz Ra Rp I Shaft surface topography: Grinding, finish rolling, machining in hardened material I Leading freedom I Sufficient corrosion protection
I Wear-resistance: Abrasion, adhesions, surface damage, tribo-oxidation I Precise concentricity I Cost-efficient manufacturing I Utilisation through the medium I Good heat dissipation
Fig. 5: Shaft design requirements as counter direction point of the Simmerring
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Damage scenarios
Damage scenarios: Examples of damage

The damage scenarios show examples of the most important causes of leakage that lead to the failure of the radial shaft seal. With their help, it is possible to narrow down the causes of leakage in each case.
Static part, outside diameter chamfer Back face Metal insert Inner lining Front side
Dust lip
Spring Spring retaining lip Front side contact surface
Back abutment contact surface Membrane Sealing edge Sealing edge: Pre pressed Trimmed bi directional helix Uni directional helix
The sealing edge must be completely closed. The lead impression must be clean as well Fig. 6: Design of a Simmerring
There must not be any loose or rmly attached particles on the sealing edge
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Damage scenarios
Damage caused by thermal overload

The sealing edge of new Simmerrings has a contact width of approx. 0.3 mm. The gap height amounts to approx. 1 m. Heat caused by friction is created in this narrow gap. Approx. 80 % of this is transferred to
the shaft. If this heat is not well dissipated, the lubricant "cracks" and/or the elastomer is thermally damaged. The results are oil carbonisation on the sealing edge and/or thermally-related tear formation in the elastomer.
Fig. 7: Deposits in the leading area
Fig. 8: Tears in the sealing edge
Fig. 9: Oil carbonisation beginning in the sealing edge area
Fig. 10: Extremely strong, strongly adhesive oil carbon deposits on the sealing edge
Fig. 11: Oil carbonisation and tear formation beginning on the sealing edge
Fig. 12: Advanced oil carbonisation and tear formation on the sealing edge
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Damage scenarios
Damage due to chemical-physical interplay

Not all lubricants are compatible with the seal materials. The base oil has less to do with the interplay with the elastomers. It is the additives that have more of an effect. These can attack
the seal material already at 60 80 C. It must always be observed that the sealing edge temperature in conjunction with the shearing of the lubricant under the sealing edge can signicantly accelerate damaging interplay.
Fig. 13: Strong chemical ller metal erosion of the sealing edge
Fig. 14: Chemical interplay between elastomer and medium as a result of deposits on the running surface
Fig. 15: Blister formation through chemical interplay
Fig. 16: Strong oil carbon deposits with circumferential grooving in the sealing edge area
Fig. 17: Abrasion/bronze and decomposition products from the lubricant in the sealing edge area
Fig. 18: Formation of blisters/deposits on the back face of the radial shaft seal
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Damage scenarios
Damage due to contamination

True, radial shaft seals are robust sealing components and can easily compensate for many disturbance variables. However, they react very sensitively to contamination in the sealing edge area. Even during installation, care must be taken
so that no contaminating particles of any kind are located on the sealing edge since these can quickly lead to leakages, among other problems. Depending on the application case, corresponding buffer elements such as dust lips, spring plates or labyrinth seals must be installed.
Fig. 19: Excessive seal edge wear with circumferential groove formation in the running surface
Fig. 20: Contamination between sealing edge and dust lip, e. g. form sand
Fig. 21: Metallic deposits on the running surface
Fig. 22: Contamination over the entire sealing edge area
Fig. 23: Metal shavings and lint on the dust lip caused during greasing of the radial shaft seals
Fig. 24: Contamination particles between sealing lip and dust lip caused by improper storage of the seal
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Damage scenarios
Damage due to excessive wear

Radial shaft seals wear extensively if there is partial dry running of the seal, if the housing inner pressure takes on a value of > 0.3 bar or if abrasive particles from inside (wear from gear wheels or worm gears, form sand or similar) or from the outside (water, sand, dust or similar) get under the sealing edge.
Fig. 25: Groove formation with signicant discolouration of the contact surface air side
Fig. 26: Excessive sealing edge wear due to high pressure applied in conjunction with poor lubrication
Fig. 27: Excessive wear due to poor lubrication
Fig. 28: Groove formation as a result of increased pressure at the aggregate
Fig. 29: Excessive wear of the sealing edge caused by excessive pressure being applied
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Damage scenarios
Mechanical damage
Radial shaft seals react very sensitively to mechanical damage which occur almost exclusively during handling and installation. Sharp edges on shaft or housing chamfers, assembly via grooves and gear teeth and inadequate tting tools are rst on the list.
Fig. 30: Sealing edge damage caused by sharp-edged grooves
Fig. 31: Sealing edge damage due to the use of improper tting tools
Fig. 32: Sealing edge damage caused by blind installation over a spline shaft
Fig. 33: Damage to the shaft surface due to improper handling
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Damage scenarios
Case study
Disappointing early failures are frequently associated with "apparent-leakage". What happens quite often is that the user applies too much grease to the area between sealing lip and dust lip. This can, depending on the operating conditions, lose its consistency in a very short amount of time and it oils out and thus causes an apparent leakage.
Fig. 34: Excessive greasing can lead to apparent leakages
Fig. 35: Optimally greased Simmerring
Fig. 36: Optimal sealing edge of a Simmerring after 1000 operating hours. The sealing edge is free from deposits, cleanly shouldered and has running width < 0.5 mm
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Handling and installation
Handling and installation: Practical handling and tips

The effects of improper installation of a radial shaft seal are frequently underestimated by the user. The operating lifespan is also already determined during the installation. Many unfortunate customer complaints could be avoided if preventative measures like installation training or internal auditing were performed more frequently [Supplementary literature 6].
Requirements for a proper installation

There are numerous possible imperfections. At rst glance, many appear trivial but the ramications could be severe. Even the tiniest amount of sealing edge damage can lead to a premature failure of the radial shaft seal. Therefore, it is important, for example, that: I Attention is paid to damaged packaging I Simmerrings are left in their original packaging as long as possible prior to installation I The Simmerrings are protected from dust and dirt I The Simmerrings do not come into contact with sharp objects like metal shavings (even ngernails!) or sharp edges of the tting tools or shaft and housing chamfers I That greased Simmerrings are stored closed or covered I The amount of grease between sealing edge and dust lip amounts to a maximum of 40 % of the volume (otherwise "apparent leakages" may occur) I The Simmerrings are greased in a dened manner (amount, placement, cleanliness) I The sealing edge preferably only comes in contact with the lubricant that will later be
used for sealing (starting aid with insufcient lubrication) Check in the housing and shaft design that the insertion chamfer (angle and length) are absolutely free of burrs according to the guidelines [cf. Fig. 5, page 17].
Storing Simmerrings
Simmerrings should be stored under the following conditions: Temperatures > 10 C to 25 C maximum Humidity < 65 % No direct light No direct sunlight Adequate packaging Warehouses must not use ozone-emitting equipment The storage time for Simmerrings manufactured from NBR, ACM, HNBR should not exceed 5 years. The storage time for Simmerrings manufactured from FKM, VMQ should not exceed 7 years. The storage time may be extended after a corresponding test by a maximum of 3 years for the former and 5 years for the latter [for further information see DIN 7716]. I I I I I I
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Hammer tting
For hammer tting (used frequently for large Simmerrings) a mounting plate is used. There is the risk that the seal can be deformed when an excessive punctual stress occurs during the tting. When using adhesive to glue the seal into the housing, it is essential that no adhesive gets onto the shaft or onto the sealing lip.
Fig. 37: Fitting with hydraulic or pneumatic press die. Attention: Diameter of the metallic stop must be 5 mm to 10 mm larger than the outer diameter of the Simmerring
Fig. 40: Not this way please! Too small diameter of the press die
Fig. 38: Fitting back face forward Attention: Outer diameter of the tting mandrel approx. 0.5 mm smaller than the inside diameter of the Simmerring. Ask us if needed
Fig. 41: Permissible hammer tting Attention: Fitting plate must be used!
Fig. 39: Not this way please! Seal inserted at an angle
Fig. 42: Not this way please! Incorrect hammer tting
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Fitting tool
The tting tools used must exactly match the respective Simmerring as otherwise there is the risk of irreparable damage. The Simmerring should preferably be pressed into the housing using hydraulic or pneumatic assembly equipment. Make sure that: I The Simmerring is not inserted at an angle I The Simmerring does not become deformed I The Simmerring does not spring back too far I The Simmering is precisely xed in the bore
To minimise the spring back and tangential deviation of rubberised Simmerrings, it is recommended that the seal not be tted in one press but rather that the seal be allowed to release completely for approx. 1 s at approx. 1 mm from the end position and then softly position the seal. I An inclination of more than 0.5 should be avoided with standard parts. Examples: Da 30 mm a = 0,25 mm Da 60 mm a = 0,52 mm Da 100 mm a = 0,87 mm I During the tting, the sealing lip must not come into contact with sharp-edged chamfers, edges, grooves or similar since early failures are otherwise certain to happen. Fitting collars must also exhibit no excessively rough surfaces or scratches.
Fig. 43: Fitting over a spline shaft (tongue and groove linking) (also for sharp-edged shaft section)
Fitting notes
If the tting is performed using a pneumatic or hydraulic press, the tting speed of 100 to 500 mm/min for Simmerrings with a rubberised static part and 1000 mm/min for Simmerrings with a metallic static part must not be exceeded.
Fig. 44: The permitted tangential deviation in the housing depends on the seal type and the shaft diameter
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I When tting an aggregate part with a pre assembled Simmerring, a centering bolt should be used to prevent tilting and thus damage to the sealing lip. I If additional components of the aggregate are to be pushed over the running surface, e. g. bearings with a press t and the same nominal diameter, the diameter of the running surface is to be reduced by 0.10 mm for shaft diameters up to 30 mm, 0.2 mm for shaft diameters from > 30 mm to 150 mm and 0.30 mm for shaft diameters >150 mm in order to prevent damage. The functioning of the Simmerring is not affected by this reduction. I Since elastomers have a reversible behaviour, the sealing lips can be easily stretched during the short installation time.
Replacing Simmerrings
The following information should be observed: I New Simmerrings must be installed for a repair or overhaul of an aggregate. I The sealing lip of the new Simmerring must not be located on the same running location. Measures for this are the installation of spacer rings, the exchange of shaft Sleeves or the selection of a different press-in depth in the bore [see Fig. 45].
Fig. 45: Original tting (above) and tting for repair of the aggregate (below)
Fitting of Simmerring cassette seals

Cassette seals are mainly used when very heavy dirt accumulation is present. The tting procedure as follows should be adhered to: 1. Press the cassette into the housing (as for a normal Simmerring). 2. Wet the slip ring lightly with oil or grease, but better with an alcohol-water mixture. 3. Push the shaft (diameter tolerance h8 or smaller) with roughness values Rmax < 10 m and Ra < 1.5 m (turned surface is sufcient) through the slip ring of the cassette.
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Fig. 46: Proper tting of the cassette
Fitting tips
I Simmerrings with an elastomer press t (BA design) must not be additionally glued into the housing. However, if the bore diameter is too great or if there is a high pressure in the aggregate (> 0.5 bar), the Simmerring can also be easily glued (e. g. with Loctite 480). I If a part of the elastomer static part shears off during the tting, the housing chamfer should be checked rst (geometry, dimensions, burr free).
I The tting force can be greatly reduced by using a lubricant, a wax, or a wateralcohol mixture which thus prevents shearing. The water-alcohol mixture has the advantage that the seal sits very rmly in the bore after the alcohol has evaporated. I If for whatever reason, the adhesion force of the Simmerring in the bore is not sufcient, it is recommended that a small groove be added to the bore housing [see Fig. 47, page 30].This reliably prevents
29
the seal from springing back and can increase the press-out force by a factor of two. I Simmerrings occasionally "wander" out of the housing bore after tting. The reason can almost always be found in the too small press-in depth of the Simmerring in the bore. Note: The cylindrical static part of the Simmerring must not be in contact with the housing chamfer [see Fig. 47]. I Simmerrings with a pure metallic static part should be xed with an adhesive (e. g. Loctite 480) or better with a sealing compound (e. g. Epple 33 or Loctite 574) in the bore. I Contaminated radial shaft seals should be lightly rubbed without fail before tting using a lint-free cloth or cleaned with a blast of air. Even the smallest of dirt particles like lint can release the sealing edge enough so that a leakage is certain right after the installation. I The application of grease between the sealing lip and dust lip should not be done with a brush. A dened greasing on site using a grease mandrel matched to the product is best. The amount of grease should be less than 40 % (except for compression-loaded Simmerrings). Through the grease discharge, so-called apparent leaks frequently exist since 1 g of washed out or "bleed" grease can create up to 35 drops of oil (!).
Preventing potential errors

It has proven benecial to perform an internal installation audit from time to time. A support manual was created which contains the most important parameters that affect the function and lists the corresponding remedial action [see the following chapter for this].
Direction: The Simmerring must sit deeply enough in the housing bore A holding groove prevents the seal from springing back
Not this way please! The cylindrical static part of the Simmerring must not be in contact with the housing bevel
Fig. 47: The correct press-in depth
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Troubleshooting
Troubleshooting: Sources of error and recommended remedial actions

The compilation of possible sources of error during the tting and handling of Simmerrings by the user should help our customers recognise pitfalls and choose corresponding remedial measures. Please consult our technical support.
Consequences for the sealing function
Sources of error
Receipt of goods Damage to the packaging
Possible errors
Cause of the problem
Remedial action
Contamination of Simmerrings
From reduced lifespan to immediate leakage
Incorrect transport packaging
Test the parts for contamination, visual and signicant changes, improve handling, optimise packaging
Storage (larger quantities over longer time period) Intermediate storage (consumable quantities, supply for the installation) Non-compliance with the storage conditions according to DIN 7716 Non-compliance with the storage requirements Storage conditions according to DIN 7716 must absolutely be complied with Clean Simmerring before installation using suitable cleaning agent (DIN 7716), Open original packaging rst at the installation location Open the original packaging rst at the installation location
Installation of faulty Simmerrings
Reduced lifespan
Contamination of Simmerrings
Installation and use of contaminated Simmerrings
From no inuence to immediate leakage as well as reduced lifespan
Dust, dirt
Damage of the Simmerring
Installation of damaged Simmerrings
Immediate leakage or reduced lifespan
Premature ageing due to improper storage
Transport (from intermediate storage to installation location) Damage to the packaging Contamination of Simmerrings From reduced lifespan to immediate leakage Improper handling Blocking of and special clearance procedure for parts in damaged cartons, test for contamination
Intermediate storage at the installation location (consumable amounts) Contamination of Simmerrings Installation of a contaminated Simmerring From no inuence to immediate leakage as well as reduced lifespan through added wear caused by dust, dirt Clean Simmerring before installation using suitable cleaning agent (DIN 7716)
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Troubleshooting
Sources of error
Open storage of pre-greased Simmerrings
Possible errors
Contamination of the grease
Consequences for the Sealing function

From no inuence to immediate leakage as well as shortened lifespan through added wear From no inuence to Immediate leakage as well as shortened lifespan through added wear

Caused by dust, dirt from the surroundings
Remedial action
Always cover the packaged unit and protect from dust and dirt, only remove the required consumable amount Bottom opening, easy to clean containers with no sharp edges
Unsuitable Storage containers
Contamination, damage if the Simmerring spring snaps out
Accumulation of dirt and moisture in the storage container, sharp-edged corners
Preparation of the Simmerring for installation
Improper opening or removal from the packaging
Cuts or similar From immediate damages on the outer leakage to reduced diameter, snapping lifespan out of the spring, installation of the Simmerring without spring Contamination of the Simmerring From immediate leakage to reduced lifespan through increased wear Reduced lifespan through increased wear Apparent-leakage
Sharp-edged or unsuitable tools or opening methods
Suitable packaging and tools, special caution and instruction of the assembly tter
Greasing of the Simmerring with contaminated oil or grease Unsuitable oil for lubricating the shaft Too much grease between sealing edge and dust lip Too much grease on the oil side No or too little grease
Dust, dirt
Protect the grease container from contamination and keep closed when not in use Discuss oil types with customer consultant, never use graphite grease Max. amount of grease: Approx. 40 % of the grease space No grease on the oil side
Chemical inuence on the seal material, squeaking (stick-slip) Grease discharge during installation or operation Grease discharge draws oil leakage with it Insufcient lubrication of the dust lip, increased dirt entry, rubber abrasion
Unfavourable lubrication, no contact oil with the Simmerring material Incorrect amount of grease Incorrect tting instructions Incorrect instructions or wrong dosage amount
Leakage leads to failure Reduced lifespan through increased temperatures in the dust lip area or through premature wear
Position the grease amount on the dust lip
Application of grease Insufcient lubrication Reduced lifespan to incorrect area on the dust lip through increased temperatures in the dust lip area or through premature wear, apparent leakage Application of the grease Contamination, chemical inuences, damages Apparent-leakage From immediate leakage to reduced longevity None
Incorrect instructions or wrong dosage amount. Incorrect greasing unit or incorrect greasing mandrel
Use pregreased Simmerrings, modify the construction of the grease applicator
Dirt, dust, application tool, cleaning tool, for damages or sharp edges on the greasing mandrel Insufcient/incorrect information
Check for cleanliness, suitable tools. Information and training of the tting technicians Select a different seal type
Greasing of a Simmerring without grease chamber
32
Troubleshooting
Sources of error
Possible errors
Remedial action
Installation: Fitting/mounting xture, mounting location, tting technician Incorrect design of the tting mandrel Damage to the seal, spring snaps out. Simmerring installed at an angle From no leakage to immediate leakage, reduced lifespan through uneven wear Customisation: Simmerring shaft housing tting mandrel. Mounting xture incorrect Co-ordinate adjustment with Freudenberg, observe the suggestions of the DIN 3761, Simrit catalogue recommendation Pay attention to cleanliness, clean the tting mandrel regularly
Contaminated tting mandrel
Contamination fo the Simmerring leading to possible damage Damage to the Simmerring
Premature failures or reduced lifespan
Dust and dirt at the working station
Damaged tting mandrel
From immediate leakage to reduced lifespan From immediate leakage to reduced lifespan Uneven wear, reduced lifespan, static leakage
Fitting mandrel not OK
Regular checking
Incorrect tting mandrel
Damage to the Simmerring
Mix-up/no assignment: Simmerring-tting mandrel Fitting speed/hammer tting
Correct tting instructions
Too high a tting speed
Spring back and/or skewed position of the Simmerring, Damage to the outer diameter, snapping out of the spring Damage to the Simmerring (bending of the metal part)
Comply with recommended max. speed
Too high a press-in force for a tting to stop
From immediate leakage to reduced lifespan
Press-in force too high/ tting to stop
Reduce the press-in force/ force limit/ end stop on the tting mandrel/do not press-in to stop: Path limitation Check Simmerring for correct seating/set press-in path afterwards In a series production, a hammer tting should not be used/in the case of repairs with hammer tting, select a stable seal design
Press-in path too short/too long
Sealing lip and dust lip running on incorrect location
From no inuence to Immediate failure/ early failures
Fitting mandrel or mounting xture not OK
Hammer tting
Damage to the Simmerring and of the installation chamber/snapping out of the spring, skewed position Seal or mounting xture contaminated or damaged
From immediate failure to reduced lifespan
Improper tting
Fitting location unclean (remove cigarette ashes), sharp edges/ metal chips
From immediate failure to reduced lifespan
Dirt, sharp edges
Keep tting location clean and free from damage. Qualication/clearly and simply displayed instructions: Visualisation/sensitisation for sealing components
33
Troubleshooting
Sources of error
Possible errors
Remedial action
Simmerring running location (shaft) on tting location Scratched shaft Damage to the sealing lip during insertion of the shaft From immediate failures to reduced lifespan Transportation damage/ missing shaft protection/ improper storage and handling of the shaft Check the shaft before installation/DIN 3761 observe/use suitable protective covers and transport container/do not store or transport shaft as bulk cargo
Contaminated shaft
Damage and contamination of the sealing lip during insertion of the shaft Damage and contamination of the sealing lip during insertion of the shaft
From immediate failures to reduced lifespan
Insufcient shaft protection/unsuitable transport container/ unclean handling Insufcient corrosion protection/humidity too high/ storage too long/ insufcient-transport container or missing covering
Clean shaft before installation/use suitable protective covering and transport container Check shaft before the installation for corrosion/ never use a corroded shaft Apply suitable corrosion protection/recondition corroded shafts Co-ordinate adjustment with Freudenberg/test the corrosion protection material for suitability with the Simmerring material in the laboratory Sufcient lubrication from Simmerring and shaft/observe Freudenberg recommendation to the shaft chamfer. Match Simmerring construction with the tting as well as the installation room Match Simmerring construction with the tting as well as the installation space/select suitable sealing concept
Corroded shaft
From immediate failures to reduced lifespan
Corrosion protection
Chemical reaction with the Simmerring material or the sealed oil
Reduced lifespan
Unsuitable material combination or corrosion protection material
Installation of the shaft, poor sliding on of the Simmerring sealing lip or the dust lip diaphragm onto the shaft
Spring snaps out/ upending of the diaphragm or dust lip
Reduced lifespan
Insufcient lubrication/ chamfer of the shaft not OK/SL covering too large/incorrect Simmerring design
Blind tting: Long shafts/ heavy shafts/ tipping of the shaft
Spring snaps out/ upending of the sealing lip or dust lip/skewed position or damage to the Simmerring
From reduced lifespan to immediate failure
Insufcient guiding of the shaft
Housing bore Two-part housing Combination with incorrect Simmerring static part design Static leakage Unsuitable Static part design One part housing/ select outer rubber coating or partial rubber coating/sealing lacquer or adhesive are unsuitable here
34
Troubleshooting
Sources of error
Cast housing
Possible errors
pores/blow holes/ casting sand

From static leakage/ increased wear to reduced lifespan through casting sand Insecure tting/ reduced lifespan

Casting quality not sufcient/insufcient cleaning
Remedial action
Pores and blow holes maximum 1/3 of the static part width/improve cleaning Rz > 10 m and < 25 m/ select outer rubber coating
Die-cast housing (Al, Mg)
Press t not sufcient/skewed position/spring back or wandering out of the Simmerring (with outer rubber coating) Electrochemical corrosion (for metallic press t)
Housing bore too ne/ unsuitable static part design
Static leakage/ damage from metal part or housing
Voltage potential (quiescence potential)
Suitable factory pairing/ select outer rubber coating
Damage to the bore from metallic press t
Static leakage/ reduced lifespan/ bore scratched (not OK) in the case of repair
Unsuitable static part design
Select outer rubber coating
Plastic housing
Damage to the bore from metal press t/ inuence of thermal expansion or too smooth surface
Static leakage/ reduces lifespan
Unsuitable material pairing or static part design
Select outer rubber coating
Insert chamfer in the housing in combination with an outer rubber coating on the Simmerring Housing bore
Shearing off of rubber with outer rubber coating/ skewed position/ springback of the Simmerring Shearing off of rubber/Simmerring
Static leakage
Burr formation on the transition from the chamfer to the bore/ chamfer too large or too small/Simmerring is out of round Chamfer too large
Ensure freedom from burrs/ observe recommendation of the DIN 3761 with regards to the chamfer
Static leakage
Select chamfer = 15 20
Handling of aggregates with seal already installed in the production line Seal laying open or unprotected Contamination/ hardening of the elastomeric material From reduced lifespan to immediate leakage Dirt and dust in the surrounding area UV light/ozone Select suitable covering of the seal for protection against damage and for avoiding negative inuences like ozone or UV light/select suitable sealing system, which protects itself/careful tting/detailed instructions
35
Troubleshooting
Sources of error
Seal laying open or unprotected
Possible errors
Damage

From reduced lifespan to Immediate leakage

Mechanical effect of components, objects or working processes on the seal/ insufcient transportation protection for loose parts
Remedial action
Select suitable covering for the seal for protection against damage and for avoiding negative inuences like ozone or UV light/select suitable sealing system, which protects itself/careful tting/detailed instructions
Corrosion of the shaft or housing
Corrosion at the sealing lip running location
Reduced lifespan
High humidity/ insufcient corrosion protection
Corrosion protection/ covering of the seal/ limit humidity
Transport
Spring snaps out
Reduced lifespan
Unsuitable transportation container/Simmerring centred on mandrel
Suitable transportation container/perform a check of the spring seating before the installation
Fitting
Damage to the sealing lip
From reduced lifespan to immediate leakage
Keyway gearing
Use mounting sleeve
36
Summary
Summary
Simmerrings are proven, robust and reliable sealing components. However, they are subject to a natural amount of wear due to the interplay in the tribological system. Determining the cause of leakages is therefore a difcult issue. Damage scenarios show the most important causes that lead to failure of the seal and provide the rst clues. The actual cause of the damage can, however, only be determined through a systematic limitation of the possible damaging mechanisms in conjunction with an immediate analysis of shaft, lubricant, and radial shaft seal. Experience shows that roughly 30 percent of early failures can be traced back to improper installation. Practical information for the proper storage, for the corresponding tting tools for the design of the shaft and the housing as well as for the correct greasing of the Simmerrings should help with the removal of these error sources. Moreover, regularly performed installation audits and training contribute to helping to isolate weak areas and permanently prevent them.
37
2. Shaft surfaces
Requirements and working forms
Shaft surfaces
Shaft surface requirements

To be able to ensure trouble-free functioning, the components in the tribological system Simmerring lubricant shaft surface must be optimally matched to each other. It is not always easy since the processes in the actual sealing zone are so complex due to high pressures, temperatures, shearing forces, inow of oxygen and transient interplay between the seal material and the lubricant or its additives [cf. Fig 1, page 10]. The design engineer should thus rely on the experience that the seal manufacturer can offer. If the operating conditions are known, the manufacturer cannot only recommend a corresponding seal, but rather, can also submit suggestions as to how the shaft surface should be machined. The requirements of a shaft or its surface are only signicant at rst glance. It should I be burr free I not fall below or exceed the specied roughness parameters. For ground shafts it is recommended in accordance with DIN 3760 or 3761: Ra 0.2 - 0.8 m Rz 1 - 5 m Rmax 6.3 m I exhibit no damage of any kind, such as scratches, scoring, pores, corrosion I have sufcient dimensions, abrasionresistance. For this reason, the shafts should be hardened for possible inner (casting sand, residual oil, metal particles, varnish and outer (water, dust, mud) contamination. It is also recommended that the shafts be hardened for pressurised seals and for high circumferential speeds (> 12 m/s) as well. Furthermore, I the shaft diameter should be toleranced to ISO h11 I the roundness tolerance IT 8 should not be exceeded I the lubricant should wet the surface sufciently I the surface should also maintain the lubricant lm under load (e. g. pressure) I and of increasing importance today, the machining process should be as economical as possible. In order for the shaft to withstand the technical requirements, the correct machining method is of great importance. These processes in the order of their importance are introduced below.
40
Surface treatment processes

There is an abundance of possible surface treatment processes for shafts: I Grinding I Turning I Tangential turning I Roller Burnishing I Peening I Supernishing/honing I Polishing I Quickpoint grinding I Outer grinding However, not all of these processes are suitable in combination with Simmerrings. The most important are evaluated according to the latest thinking:
Fig. 48: Grinding of shafts
Grinding Shaft surfaces for seals are often ground

Decades of experience show that plungecut grinding is a safe and proven process for creating a functional surface for radial shaft seals. However, there are early failures of radial shaft seals again and again which can be traced back to an improperly prepared shaft. One of the main requirements of a ground surface is the absence of lead. This should ensure no shaft draw direction in the form of a thread-like structure is present. This "conveying structure" can have a negative effect with the corresponding direction of rotation on the sealing function of the radial shaft seal. In practice, the requirement
for "lead-free" shaft surfaces is, however, virtually impossible. Even when plunge grinding is performed in accordance with specications, this does not guarantee a lead free surface.Important process parameters like constants and, above all, revolution speed rates are often not adhered to or checked, the dressing tool requirements for the grinding disc (feed rate, cutting depth, cycle) are not adhered to and the sparking out time is often not sufcient. External factors such as machine vibrations, bearing play etc. can have a negative inuence on the surface structures. The main problem is, however, that the effects of these process parameter changes or process uctuations are not exactly detectable and measurable.
41
Residual lead can cause leakage.

Although prescribed surface roughness values have been adhered to and the shaft surface is seen to be in a satisfactory condition, it frequently happens that radial shaft seals leak within a few operating hours. The reason for this is the microscopically small lead on the shaft surface. An individual helix ("thread"), independent of pitch, is not normally harmful to radial shaft seals, due to its small cross sectional area. The problem is, however, that the ground surface normally has several "threads". Thus, if the ratio between the grinding disk and the shaft is, for example, 10:1, it is possible for a 10-start thread structure to be set up on the shaft surface whose pitch will correspond precisely to the dressing feed of the dressing tool. The result is that the uid transport through the threads, corresponding to the direction of rotation, can exceed the natural pumping capacity of the seal.
Sparking out time is crucial

The main factor to be aware of when grinding surfaces for radial shaft seals is the sparking out time. Since a thread structure can never be avoided, irrespective of process parameters, it is necessary for the sparking out time to be adequately high to eliminate it altogether. Sparking out times of 30 seconds should be regarded as a minimum. Figure 49, however, illustrates that the surface of a ground shaft will not be homogenous, even with practically perfect processing and the appropriate sparking out time. To some degree, abrasive grit will press the surface peaks to one side or will tear out whole areas. The greater the resulting damage which arises in the axial plane on the shaft, the lower will be the resistance to uid ow, resulting in increased leakage.
Only exact adherence to the process parameters can make grinding secure
If the prescribed process parameters are adhered to, then grinding will be a reliable production process. Minor imperfections in the surface texture can and must be compensated for by radial shaft seals. The most important process parameters and their inuence on the radial shaft seal are summarised in Table 2.
Turning
In the last few years, the machining of hardened shafts has been continually improved. In the meantime, this technology is integrated in the manufacturing process at
Fig. 49: REM image of a plunge-cut shaft surface. (The sparking out time amounted to 3 minutes!)
42
Inuence of the manufacturing parameters for the grinding on the sealing effect
Process parameters
Rotational speed ratio Grinding disc/working material Rotational speed working material Rotational speed grinding disc Dressing traverse speed
Consequence
Can cause a leading
Aim
Not in whole numbers e.g. 10.5:1
Observance
Check during the process
Can cause a leading
30 300 rev/min 1500 1700 rev/min
Tool and working material must rotate in counter directions
Inuences the slope of the conveying thread
< 0.1 mm/rotation
Dressing should only occur in one direction
Dressing tool
Can cause a leading structure
Multi grain diamond Single grain diamond
Dressing infeed
Inuences roughness values
approx. 0.02 mm
Sparking out time
Inuences cross section of the conveying thread
Complete sparking out, at least 30 seconds
Most common causes for lead aficted surfaces
Infeed depth
Can cause leakage
>> as Rmax from the previous machining process Example: 60 100; Aluminium oxide 60KL8V25 (white) Dimensions 400 x 50 x 127 Concentricity as small as possible
Grinding disc/ granulation
Inuences the roughness parameters Ra; Rz; Rmax
Concentricity of the tools and working material axis
Creates leading structure on the surface
Table 2: Relevant machining guidelines for ground surfaces
43
many companies for economic reasons. With only a few exceptions, the sealing area of the shaft is still ground. Since one can create a directional lead on a shaft, this can be utilised for use in aggregates where one direction of operation is used primarily: I Engine I Gearbox input I Gearbox output and differential input (to a degree) The "helical lead" on the shaft surface can thus support the radial shaft seal and pump the sealed lubricant back into the aggregate. Many attempts under the most varying conditions have shown that Simmerrings on turned shafts function perfectly with the corresponding direction of rotation. More and more aggregate manufacturers are thus using a turned shaft as a counter direction point for the seal.
signicant potential for reducing costs in comparison to other processes. In comparison to grinding for example, the setup costs can be reduced by up to 95 %, the process times by up to 40 % and the machine purchase costs by up to 50 %. Another advantage is that the surface texture with turned shafts is precisely dened and markedly homogenous [see Fig. 51].
Matching to the direction of rotation is important

For many application cases, however, the direction of rotation is not completely clear or the rotation can occur in both directions. The seal manufacturer recommends radial shaft seals with an alternating leading or radial shaft seals according to DIN 3760 (without leading) for such applications. Turned shafts with corresponding direction of rotation can, in theory, convey sizeable lubricant volumes underneath the seal on account of their leading ("helical threads") and in dependence on the operating conditions. If one considers the use of turned shafts for applications with which the direction of rotation can vary, the seal must be capable in all operating conditions of being able to capture the leaked oil quantities and to be able to pump them back into the sealed area, thus opposed to the effect of the leading of the shaft. Of signicant importance here is that the seal be capable over a longer period of time of pumping these uid volumes back since the surface structure of the shaft normally shows little wear, i.e. remains in tact for long periods of time.
Hard turning is economical

The technical success is supported through the high efciency of the process. There is
The pumping effect of the seal is crucial

Fig. 50: Turning of shafts
The critical factor is thus the pumping action of the radial shaft seal. This is signicantly
44
In practice, the following manufacturing parameters are proven:

Feed rate: 0.03 0.10 mm/revolution (in the testing eld, even values of > 0.1 mm/revolution were tested positively, but larger values should not be specied without testing) 100 220 m/min (very good results and durability are achieved at 200 m/min)
Cutting speed:
Cutting edge radius:
0.4 1.2 mm (a radius of 0.8 mm is favourable)
Cutting depth:
max. 0.2 mm (very good results are achieved at 0.1 mm)
Cutter material:
CBN (Cubic Boron Nitride) Due to the variety of offered cutting materials, we recommend contacting the cutting material manufacturer. 55 65 HCR
Hardness:
Recommended roughness parameters:
Ra 0.1 0.8 m Rz 1 4 m Rmax < 8 m Roundness < 2 m True running < 2 m Tolerances from IT 5 IT 6 Roughness Rz von 2 4 m Roughness Ra von 0.2 0.8 m
Achievable qualities:
Table 3: Proven manufacturing parameters for the hard-turning of shafts
Comment: Simmerrings function perfectly on soft-turned shaft surfaces. Experience however, shows that the turning of soft shafts often proves to be more difcult than the hard machining. Therefore, different cutting
materials must be utilised depending on the shaft material. Furthermore, the above mentioned manufacturing parameters cannot always be copied.
45
influenced by the sealing lip design (profile, lead type), the radial force and above all, the material. Furthermore, the pumping effect is dependent on the operating conditions themselves, i.e. primarily from the circumferential speed, the lubricant temperature and thus the lubricant viscosity.
I feed rate I cutting radius I cutting material were varied for the test, but also the operating conditions: I I I I I I I Circumferential speed Lubricant temperature Lubricant type Pressure Axial movement Direction of rotation Shaft diameter
Furthermore, various sealing variants were considered in the tests: I Proles I Pumping features (uni or bi directional) I Materials (NBR, FKM, ACM, PTFE) The knowledge and experiences reveal that: I Simmerrings are perfectly capable of reliably sealing hard or soft turned surfaces (see also manufacturing parameters attachment). I Depending on the direction of rotation of the shaft, the surface structure can additionally support the sealing effect of the Simmerring. I If the Simmerring is correspondingly constructed, it can also seal reliably in both directions. I The friction torque behaviour of Simmerrings on turned shafts is qualitatively and quantitatively comparable with that of ground shafts.
Fig. 51: REM image of a milled shaft
Suitability of Simmerrings even for critical direction of rotation

Numerous tests at Simrit have shown that Simmerrings on turned shaft surfaces reliably seal even with "critical" direction of rotation of the shaft. Not only the turning parameters such as I cutting speed
46
Surface treatment process
process is based on the kinematics of the turning space with a linear feed rate and features: I Shorter main times as with conventional turning I High tool service life I Possible integration in CNC machines I Avoidance of disadvantages of plunge-cut turning (chatter marks etc.) I Almost completely burr free I Processing of hard and soft surfaces The maximum processing width amounts to 28 mm even for hard shafts. Typical, consistently achievable surface qualities lie between Ra 0.2 - 0.6 m and Rz 1 - 3 m. Fundamental tests at Simrit have conrmed that tangentially turned, hardened shaft surfaces are suitable in principle for Simmerrings.
Fig. 52: REM image of an improperly machined, turned shaft surface with typical "chatter marks" which are caused by vibrations
Producing high quality surfaces

A high quality surface is still a prerequisite for a shaft seal to work reliably. The surface quality of turned shafts is signicantly inuenced by the I machine rigidity I tool cutting geometry/cutting material I stability of machine tool Before the design engineer thus determines the "turning" process and the manufacturing parameters, he/she should consult with the seal manufacturer [enquiry form at www.simrit.com].
Tangential turning
Tangential turning is a new, innovative and highly efcient alternative to the manufacturing processes up to now for running surfaces of radial shaft seals. The
Fig. 53: Tangential turning of shafts
47
overload at the sealing edge of the shaft seal. Tests at Freudenberg have indicated that roller burnished nishes are suitable as counter surfaces for Simmerrings.
Adherence to the manufacturing parameters is important

A prerequisite is that the surface roughness values should be as follows: Ra 0.1 - 0.8 m Rz 0.8 - 5 m Rmax < 7 m Prior to roller burnishing it is important that the shaft surface is turned under dened conditions e. g.: Pre-machining of shaft at: feed: 0.05 mm cut speed: 300 m/min cut radius: 0.8 m. The subsequent roller burnishing process must also be performed under precisely controlled parameters. If it is possible to ensure that the whole process is reproducible and that the preset parameters can be adhered to, then the following points can be stated:
Fig. 54: REM image of a tangentially turned shaft
Roller burnishing
Roller burnishing promotes a strengthening of the shaft surface. Since this nishing process is often used on shafts, e.g. to increase notch impact strength for vibrating loads, especially step-diameter-changes, it is convenient to work the seal counter surface at the same time. In addition to straightforward surface strengthening, this process has the advantage of neutralising the lead in the turned basic structure [see Fig. 56]. Due to the high specic pressure on the surface, the "peaks" are pressed down into the valleys. In the normal case, this will have the primary effect of, at times drastically reducing the surface roughness value and accordingly increasing the load bearing proportion of the prole. On a surface which is too smooth, though, we know that a liquid will give relatively poor wetting. Thus, under certain loads, it is difcult for a lubricant lm to form or to be sustained. Depending on the operating conditions, this can result in thermal
48
Fig. 55: Finish rolling of shafts
Peening
Peening of shafts is also used for strengthening components (e. g. turbine blades). In this process the shaft surface is "blasted" with steel, glass or ceramic beads. This causes surface strengthening depending on the blast energy [see Fig. 57]. An addittional effect of this process is that lubricants adhere excellently to the crater-like surface structure, and, in particular, wet them effectively [see Fig. 58].
Fig. 56: REM image of a nished rolled shaft
I Simmerrings work perfectly on roller burnished surfaces. I The function is independent of the direction of rotation. I The magnitude of the frictional torque or power loss is not greater than on ground surfaces. I The wear caused by the seal into the shaft is reduced because of the strengthened surface. I Permissable limits with regard to operating conditions have not yet been completely determined. Experience indicates that peripheral speeds of 20 m/s at oil sump temperatures up to 130 C subject to the correct selection of seal, will cause no problems. Before the manufacturer nalises the roller burnishing process and the production parameters, he/she should consult with the seal manufacturer [you can nd an enquiry form for this purpose at www.simrit.com].
Fig. 57: Blasting of shafts
Fig. 58: REM image of a blasted shaft
49
For shaft seals this is an advantage, because it enables a permanent exchange of lubricant under the sealing contact. Frictional torque and hence the power loss of radial shaft seals on peened surfaces is therefore 1030 % less than on ground shafts, depending on operating conditions. The sealing edge temperature is therefore correspondingly lower. The results of this is that the service life of seals, especially at high load (peripheral speed, oil sump temperature), is substantially increased. Damaging oil carbonisation is also signicantly reduced. This effect also produces a marked reduction in harmful oil carbonisation. And although no increase in hardness can be measured by means of the normal hardness measurement methods, the localised wear on the shaft in the area of the sealing lip is also markedly less.
After the peening process, the surface has to be cleaned of peening shot dust. If axial movement of the shaft is likely to occur, it is advisable to polish the peened surface in order to achieve a slight rounding of the "crater" peaks. This will reduce wear on the sealing edge of the radial shaft seal. In the same way as was found on turned surfaces, the pump action of the seal must be large enough to compensate for the lubrication state, which may actually be too effective, or to transfer back any micro leakage into the unit being sealed.
Neutral basic structure necessary

The peening process is simple and, above all, cost-effective and can be used to coverup minor surface defects (up to approx. 50 m). Here too, the designer should hold consultations with the seal manufacturer when he stipulates "peening" and the process parameters.
Peened structures are also suitable as counter surfaces

Process parameters have to be dened and adhered to in order to produce the most favourable surface texture: I peening shot (nature and diameter of beads): corundum or steel chips are not suitable materials, because an undened structure will be produced as the result I peening pressure I peening duration I peening direction
Honing, Supernishing
A criss cross surface texture is created through honing or supernishing. This has the advantage that the lubricant binds well to it and that a sufcient lubrication is ensured even under adverse conditions. This positive structure for the lubricating lm adherence is achieved by the tool performing translatory movement while the shaft rotates. A criss cross structure results which appears neutral at rst glance.
50
Honed or supernished surfaces are only conditionally suitable as running surfaces

The lubrication ratios are excellent and the wear of the mating components is small, however, such structures are not suitable as counter direction points for radial shaft seals. While the occurring leakages are in most cases relatively small, they are not acceptable in most cases. For pure grease sealing, the problems are, however, negligible.
Polishing of surfaces
In the past it was quite common for the running surfaces of radial shaft seals to be polished. In the case of repair inparticular, polishing is still a widely used method for eliminating small damages or removing dirt. Often expensive components that were faultily ground can still be remachined by polishing [see Fig. 60].
Fig. 60: Polishing of surfaces
While the polishing of surfaces is a costeffective process, the disadvantage of this type of machining is, however, the same as with grinding: A leading structure on the surface can be created by the polishing. If polishing is used as a machining method, the same roughness parameters as for grinding are to be adhered to.
Other processes Outer grinding

Outer grinding of shafts creates a similar structure as with the honing process. The criss cross structures can not be reliably sealed.
Plunge-cut turning
Plunge-cut turning creates a neutral, i.e. lead-free, surface texture on the shaft surface. This is principally suitable as a counter direction point for Simmerrings.
51
Fig. 59: Honing process
Quickpoint grinding
Empirical data for quickpoint grinding is inconclusive. At the moment, no wellfounded statements on the general suitability can be given. Quickpoint ground shafts can only be used for one direction of rotation due to their distinctive leading structure ("conveyance" into the sealed space).
Deep-drawn plates
Deep drawn places are frequently used for repair work. Since a remachining of the shaft is often not possible, the surface is cleaned and resanded where necessary. Subsequently, a deep-drawn plate is drawn on. This then represents the running surface for the Simmerring.
Fig. 62: Deep drawn plate as counter direction point of the Simmerring
Deep-drawn plates can be sealed

Sealing can be just as reliable on such surfaces (depending on the operating conditions) as on ground surfaces. A prerequisite is no damage of any kind: I No pores or blow holes I No scratches or scoring I No material inhomogenities In order to ensure this, only materials of the correct quality should be used. Although the materials used are relatively soft, they possess sufcient abrasive wear-resistance due to the reforming process.
Fig. 61: Plunge-cut turning of shafts. While successful applications were realised for soft machining, machining with hardened material is more difcult due to the tendency to chatter
52
Leading test
Leading test
Movement of the thread = Oil conveyance direction
Pencil Mark Shaft with right turning threads = Radial shaft seal with leftleading
Movement of the thread = Oil conveyance direction
Shaft with left turning threads = Radial shaft seal with right-leading
Fig. 63: Determination of lead on the shaft with the thread method
53
Leading test
Leading measurements
Besides the adherence to the specied roughness variables like Ra, Rz and Rmax, the surfaces from plunge-cut ground shafts, as mentioned already, should be lead-free. The complete test whether the lead-free requirement is fullled is difcult to conduct. There are no measuring methods with which a lead orientation can be reliably measured. Despite this, representative results can be determined using the widely used thread method. A special thread is wetted with oil and is placed over the shaft to be tested. A weight (approx. 50 g) ensures an even enlacement of the shaft. If the shaft rotates, the thread begins to move axially if a lead is present. Although it is not possible to quantitatively record the slope of the lead, this method has proven itself in practice. It is applied in slightly varying forms around the world. In many cases, surface structures that are
damaging to a radial shaft seal can be proven using this simple method. However, the method has weaknesses. With very small or very large lead structures, the thread does not react demonstrably. All attempts to develop an alternative method of measurement have failed in the past. The approach of determining the lead structure using a mathematical description of the surface according to the measurement of the surface texture appears promising [see Fig. 64]. Still, the measurement and evaluation times are so high that an implementation in the production is not always cost-effective. But if the required hardware and software is developed in the foreseeable future, this measuring method could help solve many problems or help to understand the inuence of the various process parameters on the surface quality.
Fig. 64: Example of a "calculated" surface structure
54
Summary
Summary
The surface texture of the shaft inuences the sealing function of a Simmerring signicantly. The manufacturer must therefore ensure that the specied manufacturing process and roughness parameters are adhered to and that the process is stable. Besides these requirements, the selection of the correct machining method determines the ideal system design in terms of cost-efciency and technology. Alternatives to the proven but expensive plunge-cut grinding exist and were studied. Reliable sealing is achieved when the Simmerring is capable of returning the microleakages created by the shaft surface back into the sealed space. The design engineer has to determine the most functional and cost-effective combination for the radial shaft seal/machining method during the planning phase. But before the design engineer makes a nal selection, he/she should dene the process parameters together with the seal manufacturer and, considering the actual operating conditions, determine the ideal radial shaft seal. For protection or nal verication, aggregate tests should be performed. Use our fax form at www.simrit.de, so that we can develop the optimum solution together with you.
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Supplementary literature
You can nd further information about the topic "Simmerrings and shaft surfaces" in the following literature:
[1] Simrit Catalogue (orderable at www.simrit.com) [2] J. Schneider/L. Schreiber: Tangential turning an innovative manufacturing process for the machining of shaft surfaces for radial shaft seals. 13th International Sealing Conference Stuttgart 2004 [3] T. Kunstfeld/W. Haas: Reliable sealing with radial shaft seals: Alternative manufacturing processes for the creation of shaft running surfaces. 13th International Sealing Conference Stuttgart 2004 [4] S. Buhl/T. Kunstfeld/W. Haas: Sealing with radial shaft seals. Drive technology 42 (2003) No. 6 [5] J. Schneider/L. Schreiber: With Tangential Turning for Lead-Free Surfaces. Factory and Operation 6/2002 [6] R. Vogt/E. Bock: Shaft surface structures and their effect on the tightness and wear behaviour of radial shaft seals. VDI Seminar Reliable Sealing. Baden-Baden 2000 [7] H. Raab/W. Haas: Tribological Partners. Radial shaft seals and counter surfaces. Drive Technology 38 (1999)
[8] Shaft Requirements for Rotary Lip Seals. RMA 1999 [9] W. Guth/R. Vogt: New ndings with the surface machining of shafts for radial shaft seals. II. Hamburg Technical Sealing Colloquium 1998 [10] R. Vogt/D. Johnston: The Sealing Performance of Elastomer Rotary Lip Seals on Turned Shafts. SAE-Congress 1998 [11] DIN 3760/DIN 3761
You can nd information on new surface measurement procedures at:

[12] N. Rau/V. Kruppke/M. Seibold: Measurable observations of the functional behaviour of turned sealing surfaces. 13th International Sealing Conference Stuttgart 2004 [13] N. Rau/V. Kruppke/M. Seibold: Leading structures on ground sealing surfaces and their effect on the sealing function. 11th International Sealing Conference Dresden 1999 [14] Factory and Operation 1999 [15] Breitmeier: Lead measuring length LMT. www.breitmeier.com
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Freudenberg Group

Basics for preventing damage

Erich Prem Rolf Vogt

Basics for preventing damage

The Simmerring Reliability right from the beginning

Basics for preventing damage

Erich Prem Rolf Vogt

Basics for preventing damage

1. Reliable sealing 2. Shaft surfaces

Freudenberg Simrit GmbH & Co. KG

Simrit and the Simmerring A 75 year success story

Erich Prem Product Development Industry

Dipl.-Ing. Rolf Vogt Manager Product Development Industry

Freudenberg Simrit GmbH & Co. KG

2. Shaft surfaces Requirements and working forms

Freudenberg Simrit GmbH & Co. KG

How a Simmerring functions

Meniscus Gas or uid entry

Seal gap Sealing edge Lubricant entry Conveyance effect

Fig. 2: Active principle of a Simmerring (schematic)

Contact pressure Fig. 1: Simmerring in the tribological system

Contact width Gap height

Shaft surface shear Lubricant Grease lling

Access of air Sealing zone temperature

Freudenberg Simrit GmbH & Co. KG

Leakage denition: the standard, leakage terms, cause, classication

continue to increase with increasing running time in approx. 80 % of the cases.

The cause of measurable leakages can be:

Classication of occurring leakages

Freudenberg Simrit GmbH & Co. KG

Analysis of leakage causes: Static and dynamic leakage

Fig. 3: Possible causes of failure for radial shaft seals

Freudenberg Simrit GmbH & Co. KG

Static leakage at the sealing lip

Static leakage at the press-t

Dynamic leakage at the sealing lip

process parameters can be selectively modied [Supplementary literature 7, 9, 10].

Edge rounded 1525 Edge rounded and polished 1525

Fig. 4: Housing and shaft design

Operating conditions and environmental effects

The radial shaft seal itself

Fig. 5: Shaft design requirements as counter direction point of the Simmerring

Freudenberg Simrit GmbH & Co. KG

Damage scenarios: Examples of damage

Spring Spring retaining lip Front side contact surface

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Damage caused by thermal overload

Fig. 7: Deposits in the leading area

Fig. 8: Tears in the sealing edge

Fig. 9: Oil carbonisation beginning in the sealing edge area

Freudenberg Simrit GmbH & Co. KG

Damage due to chemical-physical interplay

Fig. 15: Blister formation through chemical interplay

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Damage due to contamination

Fig. 21: Metallic deposits on the running surface

Fig. 22: Contamination over the entire sealing edge area

Freudenberg Simrit GmbH & Co. KG

Damage due to excessive wear

Fig. 27: Excessive wear due to poor lubrication

Fig. 28: Groove formation as a result of increased pressure at the aggregate

Freudenberg Simrit GmbH & Co. KG

Fig. 30: Sealing edge damage caused by sharp-edged grooves