materials

Article
Time-Variant Reliability Analysis for Rubber O-Ring
Seal Considering Both Material Degradation and
Random Load
Baopeng Liao 1 , Bo Sun 1 ID
, Meichen Yan 1 , Yi Ren 1, * ID
, Weifang Zhang 1 and Kun Zhou 2
1 School of Reliability and Systems Engineering, Beihang University, Beijing 100191, China;
lbp2016@buaa.edu.cn (B.L.); sunbo@buaa.edu.cn (B.S.); 18241892584@163.com (M.Y.);
08590@buaa.edu.cn (W.Z.)
2 Southwest Technology and Engineering Research Institute, Chongqing 400039, China; zkdudu@163.com
* Correspondence: renyi@buaa.edu.cn; Tel.: +86-10-8231-3713

Received: 1 September 2017; Accepted: 17 October 2017; Published: 20 October 2017

Abstract: Due to the increase in working hours, the reliability of rubber O-ring seals used in hydraulic
systems of transfer machines will change. While traditional methods can only analyze one of the
material properties or seal properties, the failure of the O-ring is caused by these two factors together.
In this paper, two factors are mainly analyzed: the degradation of material properties and load
randomization by processing technology. Firstly, the two factors are defined in terms of material
failure and seal failure, before the experimental methods of rubber materials are studied. Following
this, the time-variant material properties through experiments and load distribution by monitoring the
processing can be obtained. Thirdly, compressive stress and contact stress have been calculated, which
was combined with the reliability model to acquire the time-variant reliability for the O-ring. Finally,
the life prediction and effect of oil pressure were discussed, then compared with the actual situation.
The results show a lifetime of 12 months for the O-ring calculated in this paper, and compared with
the replacement records from the maintenance workshop, the result is credible.

Keywords: rubber O-ring seal; material degradation; random load; time-variant reliability; finite
element analysis

1. Introduction
Seals are widely used in hydraulic systems. The O-ring used in hydraulic systems can prevent
the leaking of hydraulic oil and protect the piston from coming into contact with the inner wall of the
cylinder block and being scratched [1,2]. The traditional reliability analysis methods only focus on
the material or load with a single variation on the O-ring, which does not reflect the influence of both
material degradation and random load. Thus, on the basis of existing analytical methods, the reliability
analysis of the O-ring can improve the accuracy of reliability evaluation and ensure the safety of the
structure with the consideration of both material degradation and random load.
ASME (American Society of Mechanical Engineers) and ASTM (American Society for Testing and
Materials) published the standards of seal rings based on material performance and sealing performance,
which separately defining the material reliability and seal reliability [3,4]. These standards provided
evidence for analyzing the reliability of the O-ring. Besides, many researchers have studied the
reliability analytical methods for the O-ring. Lee [5] and Huang [6] tested the rubber material and
worked out the mechanical behavior of the rubber material. Shen et al. [7] studied the mechanical
behavior of rubber material influenced by long-term aging and cycling. Based on the studies of
the mechanical behavior of rubber, the degradation process of rubber and the material reliability
is studied. Marco [8] and Henning [9] obtained the degradation process based on the dissipated

Materials 2017, 10, 1211; doi:10.3390/ma10101211 www.mdpi.com/journal/materials

Materials 2017, 10, 1211 2 of 18

energy accumulating in the rubber fatigue circles and the field effect. Liu [10] and Okpin [11] studied
the degradation rule of rubber material based on the general accelerated degradation test (ADT)
model of the Wiener process and the finite element model, which improve the accuracy of material
reliability. On the basis of the degradation process and material reliability, Woo [12] proposed a life
prediction method for the O-ring with the help of the finite element method. Fang et al. [13] calculated
the reliability of rubber components under random loads on the stress-strength interference model.
Furthermore, in the study of load on the O-ring, Zuo et al. [14] studied the influence of the working
efficiency on the seals of the hydraulic systems. Li et al. [15] analyzed the maximum stress based
on the finite element method. In terms of contact mechanics, Wei [16] and Gambino [17] analyzed
the mechanical behavior in the contact surface of the seal and calculated the influence of the contact
force on the seal performance. Moreover, other researchers have suggested many other analytical
methods, such as calculating the reliability of the O-ring according to the distribution characteristics of
contact stress under linear loads [18]. The methods mentioned above can simplify the calculation of
the reliability of the O-ring. However, the influence of material degradation and random load in the
working environment of the O-ring cannot be omitted. Of the existing studies, none of them has taken
into consideration both material degradation and random load over time. Thus, studying the dual
conditions of material degradation and the load random distribution can further enhance the accuracy
of reliability evaluation.
Regarding the complexity and feasibility of reliability analysis under dual conditions at present,
Mejri and Cazuguel [19] have verified the feasibility of the time-variant reliability method and finite
element analysis. However, they have not worked out the relationship between reliability and time
variation. Jiang and Ni [20] proposed the time-variant reliability method of the structure, which is
conducted according to the non-probabilistic analytical model of dynamic structural reliability based
on Monte Carlo simulation, but this method is too complicated, consuming much time to complete
the entire calculation process. Therefore, it is necessary to combine the existing research and conduct
appropriate optimization, in order to combine the dual conditions of material degradation and random
load. This can be performed with the help of time-variant reliability methods and the discussion of the
variations in reliability trends under fluctuating parameters in order to ensure the analysis accuracy of
O-ring reliability when the hydraulic system is at work.
In this paper, we combined the analysis of the O-ring in the works cited above and conducted
further analysis. In Section 2, the methods for reliability analysis will be described. In the third section,
the parameters required in the reliability model will be obtained by experiments and simulations.
In Section 4, based on the results in Section 3, the reliability of the O-ring will be calculated when the
parameters are in a submissive distribution. Furthermore, an influential analysis is conducted under
life prediction, oil pressure and compared with the actual situation to verify the accuracy. In the last
section, some conclusions will be raised for the whole paper.

2. Methods for Reliability Analysis

2.1. Failure Modes and Criterion

Part of the structure of the hydraulic system containing the O-ring seals is shown in Figure 1a.
We extracted a plane from the structure as shown in Figure 1b and established a two-dimensional
model during the analysis. This part of the hydraulic system is made of three parts: the O-ring, cylinder
and piston. Figure 1c is the geometric model, which includes the structure, geometric size, as well
as the shape before and after deformation, within which the O-ring is the main subject of this paper.
In one certain type of hydraulic system, some parameters for the model of the O-ring are shown in
Table 1.
Materials 2017, 10, 1211 3 of 18
Materials 2017, 10, 1211 3 of 18

(a) (b)

Displacement =Δd
Cylinder
Δd
Poil

d O-ring
H

Piston
D
(c)
Figure 1. Model of the O-ring: (a) solid model; (b) part of the area; (c) geometric model.
Figure 1. Model of the O-ring: (a) solid model; (b) part of the area; (c) geometric model.
Table 1. Parameters of the O-ring.
Table 1. Parameters of the O-ring.
Parameters Value
D (mm)
Parameters 3.60
Value
H (mm) 2.10
D (mm) 3.60
d (mm) 2.65
H (mm) 2.10
d (mm) 2.65
Before confirming the failure mode of the O-ring, we created three hypotheses in regards to the
analysis of the O-ring with the geometric model:
Before confirming the failure mode of the O-ring, we created three hypotheses in regards to the
(1). Rubber is the material used in O-rings, which is isotropic and incompressible. The volume of
analysis ofrubber
the O-ring with the geometric model:
remains the same during its deformation;
(1). (2). As is shown in Figure 1a, the hydraulic system is completely axisymmetric, which means that
Rubber is the material used in O-rings, which is isotropic and incompressible. The volume of
all the cross profiles of the system bear the same stress. To reduce the computation and increase
rubber remains the same during its deformation;
the accuracy of results, one cross profile (similar to Figure 1b) has been extracted, and the three-
(2). As isdimensional
shown in Figure
sealing 1a, theishydraulic
device system
changed into is completely
a planar axisymmetric,
question to make the analysiswhich
easier;means that
all the
(3). cross
When profiles ofthe
constructing thegeometric
system bear the
model of same stress.
the sealing To reduce
device, the computation
we regard the piston and and increase
cylinder
the accuracy of results,
as rigid bodies, one cross
which means whenprofile (similar
the model to Figure
is compressed, 1b)thehas
only beenwill
O-ring extracted,
deform. and the
three-dimensional sealing device is changed into a planar question to make the analysis easier;
In summary, the O-ring bears the responsibility to perform the function of sealing the hydraulic
(3). oil.
When constructing
There are two mainthe geometric
types model
of failure modes.ofOne
the issealing device, we
the irreversible regard
failure the piston
of rubber and
material cylinder
when
as rigid
the bodies,compressive
maximum which means when the exceeds
stress model isitscompressed,
limit stress only .the O-ring
This will
is due todeform.
a stress
concentration during the compression of the O-ring. The other is seal failure, which is caused by a
In summary,
change the O-ring
in contract stress. bears
It wouldthe happen
responsibility
only whento perform the function
the oil pressure exceedsof sealing the hydraulic
contact stress [3].
oil. There are two main types of failure
In other words, the seal fails when both modes. One
(the maximum contact stress is between the O-ringwhen
is the irreversible failure of rubber material
the maximum compressive
and cylinder) and stress σsmax exceeds
(the maximum contactitsstress
limitbetween
stress σlim
the. O-ring
This isand
duepiston)
to a stress concentration
are lower than
duringoilthe compression
pressure . of the O-ring. The other is seal failure, which is caused by a change in contract
Other factors
stress. It would happenthat impact
only when thethe
O-ring, such as fatigue
oil pressure exceeds and cyclic load,
contact stressultimately lead words,
[3]. In other to material
the seal
failure and seal
maxfailure, and the material failure and seal failure studied in
fails when both Pc1 (the maximum contact stress is between the O-ring and cylinder) and Pc2 (thethis paper are the most
max

maximum contact stress between the O-ring and piston) are lower than oil pressure Poil .
Other factors that impact the O-ring, such as fatigue and cyclic load, ultimately lead to material
failure and seal failure, and the material failure and seal failure studied in this paper are the most
Materials 2017, 10, 1211 4 of 18

direct failure modes of the O-ring. Besides, as the O-ring is replaced frequently, fatigue and cyclic
load are not large enough to have a greater impact on it. Therefore, the influence of other factors,
including fatigue and cyclic load, compared with compressive stress and contact stresses, is very small.
Therefore, we take compressive stress and contact stress as the main failure criteria for the O-ring in
this paper.

2.2. Materials
In order to analyze the reliability of the rubber O-ring seal, it is necessary to perform some
experiments on the material parameters for the rubber material. However, the data obtained from the
experiments cannot be directly applied to the reliability analysis, and this needs to be expressed in
the form of a mathematical model. In this section, the mechanical and degradation experiments are
performed to determine the performance parameters of the rubber material over time.
Being different from metal material, rubber is a hyper-elastic material. Its parameters are generally
defined by the constitutive model. In subsequent simulation calculations, the constitutive model of
hyper-elastic materials, such as the Mooney–Rivlin model, the Neo–Hookean model and the Yeoh
model, can be directly defined in the simulation. Due to the Mooney–Rivlin model being widely
used and its accuracy being recognized by many researchers, the Mooney–Rivlin model is chosen for
defining the parameters in this paper [21,22].
The constitutive model is generally expressed in the strain energy density equations for
hyper-elastic materials. In our model, the strain energy density equations of the Mooney–Rivlin
model of rubber material is:
W = C10 ( I1 − 3) + C01 ( I2 − 3) (1)

where I1 and I2 are two strain invariants; while C10 and C01 are two Mooney constants obtained by
stress-strain fitting. The relationship of stress and strain can be obtained through:

σ1 1
 = C10 + C (2)
λ1 01

1
2 λ21 − λ1

where σ1 and λ1 are the amount of stress and the percentage of strain, respectively. Both parameters
are obtained by mechanical experiments. After the experiments, the stress-strain data are used in
Equation (2) to obtain the values for the material parameters of rubber, C10 and C01 .
With an increase in working hours, C10 and C01 will change with the degradation of rubber
material. In this paper, we adjusted the environmental factors of the environmental test chamber
to make it consistent with the working environment of the O-ring. A total of m rubber samples are
enclosed in the chamber, and the degradation time is zero at this time.
Set t0 = 0 to be the initial time. Combined with the actual situation, we removed k samples at
each time point of t1 , t2 , · · · , tn to perform mechanical experiments. Taking the t1 time as an example,
k samples were utilized to obtain k group stress-strain curves. According to the stress-strain curve,
the limit stress σlim of the k group rubber material can be obtained. Following this, we used the data
as inputs into the Mooney–Rivlin model in order to obtain the two Mooney constants C10 and C01 .
Compared with the k groups’ stress-strain data, the minimum limit stress σlim is selected according to
the maximum safety margin, which reflects the performance parameter of rubber material. Essentially,
at t1 time, the limit stress is [σlim ]t1 , and the two Mooney constants are [C10 , C01 ]t1 .
Therefore, at each time point t0 , t1 , t2 , · · · , tn for the rubber material, there is a set of
performance parameters such as the limit stress [σlim ]t0 , [σlim ]t1 , · · · , [σlim ]tn and the Mooney
constants [C10 , C01 ]t0 , [C10 , C01 ]t1 , · · · , [C10 , C01 ]tn . There are n + 1 groups of data of limit stress and
material parameters.
Materials 2017, 10, 1211 5 of 18

Materials 2017, 10, 1211 5 of 18

2.3. Reliability Modeling
2.3. Reliability Modeling
With an increase of the working time, the rubber material of the O-ring will degrade, which will
With
result in the an increase
variation in of
thethelimit
working time,
stress, the rubbercompressive
maximum material of thestress,
O-ring etc.
will degrade,
However, which
the will
random
result in the variation in the limit stress, maximum compressive stress, etc. However,
variation of the loads on the O-ring will result in the variation of the relative parameters. Material the random
variation of the loads on the O-ring will result in the variation of the relative parameters. Material
degradation and random load will finally result in the variation of reliability. Figure 2 shows the
degradation and random load will finally result in the variation of reliability. Figure 2 shows the
variation in parameters caused by material degradation and random load, with the variations in
variation in parameters caused by material degradation and random load, with the variations in
parameters reflected
parameters in the
reflected changes
in the inin
changes reliability
reliabilityin
inthe
the end.
end.

Figure 2. Factors that affect reliability.

Figure 2. Factors that affect reliability.
As shown in Figure 2, we need to solve comprehensively the four intermediate parameters to
As shown
calculate theinreliability
Figure 2,ofwe theneed to limit
O-ring: solvestress,
comprehensively
maximum compressivethe fourstress,
intermediate parameters
small contact stress to
and the
calculate oil pressure.
reliability Three imported
of the O-ring:parameters
limit stress, aremaximum
needed to compressive
obtain the previously described
stress, small fourstress
contact
and oilparameters:
pressure.material
Three parameters
imported of rubber, decrement
parameters are neededand oil
to pressure.
obtain the Thispreviously
relationshipdescribed
cannot be four
directly material
parameters: solved through analytical
parameters methods,
of rubber, while the and
decrement simulation can be This
oil pressure. easilyrelationship
solved. Therefore,
cannot be
simulation and analytical methods can be combined and then express the relationship between the
directly solved through analytical methods, while the simulation can be easily solved. Therefore,
parameters through the response surface method; the reliability of O-ring can be quickly obtained.
simulation and analytical methods can be combined and then express the relationship between the
In addition to the impact of material degradation on the reliability of the O-ring, the random
parameters
load is through
also a factor thethatresponse
cannotsurface method;
be ignored. the reliability
The analysis of failureofmodes
O-ringofcanthe be quickly
O-ring obtained.
is described
In addition to the impact of material degradation on the reliability of the
in Section 2.1. The loads on the O-ring are mainly reflected in both the decrement ∆ and oil pressure O-ring, the random
load is also. a factor that cannot be ignored. The analysis of failure modes of the O-ring is described in
Section 2.1. Thethe
When loads on the parameters
geometric O-ring are of mainly reflected
the O-ring remainin the
both the the
same, decrement
decrement ∆d ∆andisoil pressure
decided by Poil .
the processing
When the geometrictechnology of the cylinder
parameters and piston.
of the O-ring The the
remain distribution
same, the rule of ∆ can∆d
decrement be is
obtained
decided by
through gathering
the processing technology the dimension parameters
of the cylinder andofpiston.
the components of hydraulic
The distribution systems.
rule of ∆dHowever, the
can be obtained
oil pressure is determined by the reacting force on O-rings produced
through gathering the dimension parameters of the components of hydraulic systems. However, the oil while the hydraulic system
is working. This can be obtained by monitoring of the change in oil pressure when the hydraulic
pressure Poil is determined by the reacting force on O-rings produced while the hydraulic system is
system is at work. The distribution of and ∆ can be obtained by the analytical method, on the
working. This can be obtained by monitoring of the change in oil pressure when the hydraulic system
basis of this method, and is assigned the maximum value for safety reasons, assuming that ∆
is at work. The
is subject to distribution of Poil and
a normal distribution [23].∆d can be obtained by the analytical method, on the basis of
this method, and Pthe
Suppose oil is assigned the
probability maximum
density functionvalue for safety
of O-rings’ reasons,∆ assuming
decrement ∆d is subject
to be ∆that. Choose the to
a normal ,
data distribution
of at the initial time to define the material parameters, and choose ∆ to define the
[23].
Suppose the probability
load parameters densityThe
of the O-ring. function
maximumof O-rings’
value of decrement
oil pressure∆d isto be f (.∆d ). Choose
Thus, the data
the input
of [C10 , C01 ]t at the initial time to define the material parameters, and choose ∆d to define the load
parameters
0
for the calculation of O-rings’ reliability are shown in Table 2.
parameters of the O-ring. The maximum value of oil pressure is Poil max . Thus, the input parameters for
Table 2. Input parameters in the calculation.
the calculation of O-rings’ reliability are shown in Table 2.
Input Parameters Value
Table 2. Input parameters in the calculation.
, ,
∆
Input Parameters ∆
Value
σlim [σlim ]t0
[C10 , C01 ] [C10 , C01 ]t0
∆d ∆d
Poil max
Poil
Materials 2017, 10, 1211 6 of 18

Unlike Poil and ∆d, the compressive stress and contact stress need to be calculated by simulation.
After that, the maximum compressive stress σsmax and two contact stresses Pc1 max and Pmax when
c2
∆d = ∆d can be obtained (∆d is the mean of ∆d). According to the second failure mode in Section 2.1,
we defined the small contact stress Pcmin = min Pc1
 max max
, Pc2 . We compared σsmax and [σlim ]t0 to obtain
whether there is failure in the material. Additionally, we compared Pcmin and Poil
max to analyze whether

the seal has failed. At this time, the status of the O-ring is obtained when all parameters are in a
static state.
After this, we selected k groups of samples within the bounds of ∆d. Calculating σsmax and Pcmin ,
and based on the response surface method, the relationship of σsmax and Pcmin changing against ∆d
can be obtained. According to the relationship, a better mode exists with a higher degree of response
surface to display the relationship between σsmax , Pcmin and ∆d [24–26].
Assuming the function between σsmax and ∆d as:

σsmax = f 1 (∆d) (3)

the inverse function of Equation (3) would be:

∆d = f 1−1 (σsmax ) (4)

The material reliability of the O-ring would be:

Rs1 = P(σsmax ≤ σlim ) = P( f 1 (∆d) ≤ σlim )

  Z f1−1 (σlim ) (5)
−1
= P ∆d ≤ f 1 (σlim ) = f (∆d)d∆d
0

In a similar manner, considering the function and inverse function between Pcmin and ∆d, the seal
reliability would be shown as Equations (6)–(8).

Pcmin = f 2 (∆d) (6)

 
∆d = f 2−1 Pcmin (7)
 
Rs2 = P Pcmin ≥ Poil
max max
= P( f 2 (∆d) ≥ Poil )
  Z ∆dmax (8)
= P ∆d ≥ f 2−1 ( Poil
max
) = −1 f (∆d)d∆d
max )
f 2 ( Poil

where ∆dmax is related to the geometrical parameters of the hydraulic system, including the decrement
when there is a minimum distance between the cylinder and piston.
According to Equations (5) and (8), the interval of two groups of ∆d can be obtained, which
contribute to the adequate degrees of material reliability and seal reliability, as shown in Equations (9)
and (10).
h i
∆d Rs1 ∈ 0, f 1−1 (σlim ) (9)

and h i
∆d Rs2 ∈ f 2−1 ( Poil
max
), ∆dmax (10)

where ∆d Rs1 and ∆d Rs2 are the respective values of ∆d when the degrees of material reliability and
seal reliability are adequate. The union of these two intervals is:
h i
∆d R = ∆d Rs1 ∩ ∆d Rs2 = f 2−1 ( Poil
max
), f 1−1 (σlim ) (11)
Materials 2017, 10, 1211 7 of 18

where ∆d R is the value of ∆d when the degree of system reliability is adequate. Therefore, the system
reliability of the O-ring is:

n o Z f 1−1 (σlim )
Rs = P f 2−1 ( Poil
max
) ≤ ∆d ≤ f 1−1 (σlim ) = f (∆d)d∆d (12)
Materials 2017, 10, 1211 f 2−1 ( Poil
max )
7 of 18

At this point, the system reliability of the O-ring has 1 been received when t0 = 0, with further
f  
Rs  P  f 21  Poilmax   d  f11  lim    f  d  d d
1 lim

repeats of the above calculation in t1 , t2 , · · · , tn . Followingf this, (12)

2
1
  the time-variant reliability of
max
P
oil the O-ring
can be obtained. It should be noted that this paper proposes a method to obtain the reliability of the
At this point, the system reliability of the O-ring has been received when = 0, with further
O-ring repeats
by combining the analytical
of the above calculation in and ,simulation methods.
, ⋯ , . Following this,The model input
the time-variant is fromofthe
reliability themonitoring
O-
results or
ring can be obtained. It should be noted that this paper proposes a method to obtain the reliabilitycalculation
experiment results, which can be calculated by the analytical method. The model of
is to calculate thebystress
the O-ring of thethe
combining O-ring,
analytical which andcan be obtained
simulation methods. by The
simulation. Finally,
model input thethe
is from reliability
analysismonitoring results
is to process theorstress
experiment
by theresults, which
analytical can be calculated
method to obtain by its the analytical method.
time-variant The
reliability.
model calculation is to calculate the stress of the O-ring, which can be obtained by simulation. Finally,
the reliability
3. Experiments andanalysis is to process the stress by the analytical method to obtain its time-variant
Simulations
reliability.
3.1. Experimental Design
3. Experiments and Simulations
The degradation and mechanical experiments of rubber material should be carried out before the
3.1. Experimental Design
simulation. In this section, based on the methods described in Section 2.2, we designed an experimental
The degradation
plan to combining these two and mechanical experiments
experiments, which aimed of rubber material
to acquire should be carried
the parameters out
of the before
Mooney–Rivlin
the simulation. In this section, based on the methods
model and the limit stress of rubber material at each time point. described in Section 2.2, we designed an
experimental plan to combining these two experiments, which aimed to acquire the parameters of
At the initial time, we placed 35 rubber samples into the container filled with hydraulic oil and
the Mooney–Rivlin model and the limit stress of rubber material at each time point.
soaked them in it,
At the then
initial wewe
time, placed
placed the container
35 rubber samplesin into
an environmental
the container filledtest
withchamber. A and
hydraulic oil group was
sampled every
soaked three
them months,
in it, then we with
placedfive
the rubber
containersamples from each group.
in an environmental The A
test chamber. temperature
group was of the
environmental test chamber
sampled every three months,is 45with ◦ C,
± 5five and the
rubber relative
samples from humidity
each group.isThe50% ± 10%. Furthermore,
temperature of the
environmental test chamber is 45 ± 5 °C, and the relative humidity
the shape and dimension of the rubber samples are shown in Figure 3, while the apparatus is 50% ± 10%. Furthermore, the for
shape and dimension of the rubber samples are shown in Figure 3,
experimenting on the rubber samples is a universal testing machine. The stress and strain data while the apparatus for in the
experimenting on the rubber samples is a universal testing machine. The stress and strain data in the
test are continuously recorded by the testing computer for the universal testing machine.
test are continuously recorded by the testing computer for the universal testing machine.

(a) (b)
Figure 3. The rubber samples: (a) shape of samples; (b) dimension of samples.
Figure 3. The rubber samples: (a) shape of samples; (b) dimension of samples.
At the initial time, five samples were removed and underwent a tensile test from the universal
Attesting machine.
the initial time, Forfive
safety reasons,were
samples we selected
removed the minimum limit stress
and underwent among the
a tensile testfive
fromgroups
the of
universal
experimental results as the limit stress of rubber material at this time [27]. Following this, we used
testing machine. For safety reasons, we selected the minimum limit stress among the five groups of
the stress and strain data as inputs into the Mooney–Rivlin model by MATLAB (The MathWorks Inc.,
experimental results as the limit stress of rubber material at this time [27]. Following
Natick, MA, USA). Finally, the material parameters include the limit stress
this, we used
and Mooney
the stress and
constants strain, data as inputs into
, which are obtained at the Mooney–Rivlin
= 0. model by MATLAB (The MathWorks
Inc., Natick,The
MA, USA). Finally,
experiments the18material
lasted for months and parameters
every threeinclude
months inthe limit
order to stress σlim ]t0 and
have a [different timeMooney
constants [C10
point. At, C
each]
01 t0 , which
time point are , , ⋯ ,
obtained of at t
rubber
0 = 0.
material degradation, we removed five samples and
repeated
The the above
experiments experiments
lasted in order and
for 18 months to obtain
everythethree
material parameters
months of rubber
in order to have samples at
a different time
different degradation times.
point. At each time point t1 , t2 , · · · , t6 of rubber material degradation, we removed five samples
and repeated the above experiments in order to obtain the material parameters of rubber samples at
different degradation times.
Materials 2017, 10, 1211 8 of 18

Materials 2017, 10, 1211 8 of 18

3.2.Materials 2017, 10, 1211

Experimental Results 8 of 18
3.2. Experimental Results
3.2.Figure 4 shows
Experimental
Figure 4 shows the
Results
thefitting curves
fitting curvesofofstress-strain
stress-strainwith
withrubber
rubber materials
materials when the initial
when the time t0 =
initialtime = 0.
The0.minimum
The minimumlimit stress between five samples of rubber material at this time is [ σ ] = 20.76 MPa.
=
Figure 4 showslimit stress curves
the fitting between five samples
of stress-strain withof rubber
rubber materials
material when
at thisthetime
lim t0is time
initial =
Then taking
20.76 MPa. these data into Mooney–Rivlin model, the Mooney–Rivlin
0. The minimum limit stress between five samples of rubber material at this time is
Then taking these data into Mooney–Rivlin model, the parameters
Mooney–Rivlin of rubber
parameters material
=
of
at the
rubberinitial
20.76 MPa. time
material
Then can beinitial
attaking
the obtainedtime
these with a value
caninto
data be of [C
obtained with
Mooney–Rivlin ]t0 = of
10 , Ca01value
model,[10.20e6,, 2.55e6
the Mooney–Rivlin t0 .
= ]10.20e6, 2.55e6 .of
parameters
rubber material at the initial time can be obtained with a value of , = 10.20e6, 2.55e6 .

Figure4.4.Stress-strain
Figure Stress-strain fitting
fitting curves
curves for
forrubber.
rubber.
Figure 4. Stress-strain fitting curves for rubber.
Following this, by monitoring the variation of oil pressure during operations, the changes in oil
Following
pressure this,
in the by monitoring
mission profiles of the variation
hydraulic of oilcan
systems pressure during operations,
be obtained. the changes ininoil
Following this, by monitoring the variation of oil pressure duringFigure 5 shows
operations, the the changes
changes in oil
pressure in the
the oil pressuremission profiles
during of hydraulic
theofmission systems
profile. can
According be obtained.
to the mission Figure 5 shows the changes
pressure in the mission profiles hydraulic systems can be obtained. Figureprofile
5 showsof athe
transfer
changestask
in
in the oil
andoil pressure
thepressure P during
reliability model the mission
in Section profile.
2.3, the According
oil pressure to
should the mission profile of a transfer task
the oil during the mission profile. According to thetake its maximum
mission profile ofvalue, which
a transfer taskis
and the reliability
reliability model in Section 2.3, the oil pressure should take its maximum value, which is is
= 10 MPa.
and the model in Section 2.3, the oil pressure should take its maximum value, which
max = 10 MPa.
Poil = 10 MPa.

Figure 5. Mission profile of a transfer task.

Figure5.5.Mission
Figure Mission profile of aa transfer
transfertask.
task.
3.3. Simulations
3.3.3.3. Simulations
Simulations
Although the stress variables (compressive stress and contact stress) can be calculated by
analytical methods,
Although the analytical calculation process isand particularly complex, so be itcalculated
needs to bybe
Although thethe stress
stress variables
variables (compressive
(compressive stressstress
and contact contact
stress)stress)
can be cancalculated by analytical
deduced and
analytical calculated
methods, by many formulas,
the analytical calculationnot being issuitable
process for thecomplex,
particularly materialso degradation
it needs toand be
methods, the analytical calculation process is particularly complex, so it needs to be deduced and
random load
deduced andincalculated
this paper.by Therefore, the simulation
many formulas, is selected
not being suitableto for
calculate the stress
the material variables ofand
degradation the
calculated
O-ring.
by many formulas, not being suitable for the material degradation and random load in this
random load in this paper. Therefore, the simulation is selected to calculate the stress variables of the
paper. Therefore,
In hydraulic thesystems,
simulationthe is selected
piston to calculate
is fixed, so it hasthefixed
stress variables of
constraints. Thethecylinder
O-ring. imposes a
O-ring.
In hydraulic
displacement systems,
load with athe piston is∆fixed,
decrement so mm.
of 0.3 it has fixed constraints. The the
cylinder imposes a
In hydraulic systems, the piston is fixed, so it hasThe O-ring
fixed is located
constraints. Theincylindermiddle of the
imposes a
displacement load
cylinder and piston.
displacement
with
load with
a decrement
In ABAQUS
a decrement
∆d of 0.3 mm.
∆ ofSimulia
(Dassault The O-ring
0.3 mm.Company,
is
The O-ring
located in
Providence, the
is locatedRI,
middle
in USA),
of the cylinder
the material
the middle of the
and piston.and
properties
cylinder InofABAQUS
the
piston. In (Dassault
O-ring ABAQUS Simulia
can be defined Company,
directly
(Dassault by the
Simulia Providence,
Mooney–Rivlin
Company, RI, USA), theUSA),
constitutive
Providence, RI, material
the properties
model. The two
material
properties of the O-ring can be defined directly by the Mooney–Rivlin constitutive model. The two
Materials 2017, 10, 1211 9 of 18

Materials 2017, 10, 1211 9 of 18

of the O-ring can be defined directly by the Mooney–Rivlin constitutive model. The two contact
contact
surfaces surfaces
Materials
between between
2017,the
10, 1211
cylinder,the O-ring
cylinder, andO-ring andare
piston piston are the interacting
the interacting type oftype of surface-to-surface
surface-to-surface 9 of 18
contact.
contact. The mechanical constraint formulation includes the kinematic contact method, while the
The mechanical constraint formulation includes the kinematic contact method, while the sliding
contact
sliding surfaces between
formulation the cylinder,
reflects the O-ringFurthermore,
finite sliding. and piston arethe thecontract
interacting type of surface-to-surface
properties of two contact
formulation reflects the finite sliding. Furthermore, the contract properties of two contact surfaces
surfaces involve the tangential behavior with a friction coefficient of 0.8. Moreover,method,
contact. The mechanical constraint formulation includes the kinematic contact while the
as the hydraulic
involve sliding
the tangential
formulation behavior with
reflects the afinite
friction coefficient
sliding. of 0.8.the
Furthermore, Moreover,
contract as the hydraulic
properties of two systems
contact
systems studied in this paper is not very complicated, consider the computational costs and the use
studied
of thein refined
this paper
surfaces involve
CPE3 isthe
not very complicated,
(a tangential
3-node behavior
linear with
plane consider
a friction
strain the computational
coefficient
triangle) of 0.8.
element, costs
canand
Moreover,
which the
as the
fully use the
of the
hydraulic
meet
refined CPE3 (a 3-node linear plane strain triangle) element, which can fully meet
requirements for the calculation results. Therefore, the meshing during simulation of the O-ring use
systems studied in this paper is not very complicated, consider the computational the requirements
costs and the is for
the shown
calculation
of the results.
refined
in Figure 6. Therefore, the meshing during simulation of the O-ring is shown in Figure 6.
CPE3 (a 3-node linear plane strain triangle) element, which can fully meet the
requirements for the calculation results. Therefore, the meshing during simulation of the O-ring is
shown in Figure 6.

Figure 6. Finite element model of the O-ring.

Figure 6. Finite element model of the O-ring.
Figure 6. Finite element model of the O-ring.
After pre-processing by ABAQUS, a mesh convergence study is carried out by the finite element
After which
model, pre-processing
After pre-processingby ABAQUS,
uses different mesh
by sizes.aWe
ABAQUS, amesh
mesh convergence
defined the global
convergence study
studysize ofisthecarried
is carried mesh
out by toout
thebe byone,
finite thethenfinite
element
element model,
calculated
model, and which
which uses
compared
uses different
the results
different meshmesh
with a sizes.
sizes. We defined
step-by-step
We defined refinementthe global
the global of size
the of
theofmesh.
size the to
Figure
mesh mesh
7beshowsto be
one, the
thenone,
thentrend
calculated
calculated and
of the Mises compared
and stress
compared the
under results
thedifferent with
results withmesh aastep-by-step
step-by-step
sizes. berefinement
It can refinement
seen from of
thisthe
of the mesh.
figure
mesh. Figure
that
Figure the 7 shows
results
7 shows the
trendtrend
the obtained ofdifferent
by
of the the Mises
Mises stress
meshes
stress under different
are almost
under different meshsizes.
themesh
same sizes.the
when ItItcan
can be seen
seen from
approximate
be this
global
from figure
mesh
this that
size
figure is the
that theresults
less than
results
obtained
0.1, soby
obtained by
thedifferentdifferent
mesh is considered meshes are
meshes aretoalmost almost
be convergent.the same
the sameThus, when
whenitthe the approximate
is possible
approximateto selectglobal mesh size isless
mesh size
the approximate
global is lessthan
global than
0.1, mesh
so the0.1,
sizesoofthe
mesh ismesh
0.1 as is mesh
the considered
considered size to be convergent.
to beduring simulation
convergent. Thus, it possible
[28].it is
Thus, is possibletotoselect
select the
the approximate
approximate global global
mesh size of 0.1 as the mesh size during simulation [28].
mesh size of 0.1 as the mesh size during simulation [28].
Mises Stress/MPa

Mises Stress/MPa

X: 0.1
Y:12.95
X: 0.1
Y:12.95

Approximate global mesh size

Approximate global mesh size

Figure 7. Mesh convergence study.

Figure
Figure 7. Mesh
7. Mesh convergence
convergence study.
study.
Figure 8 is 8the
Figure is compressive stress
the compressive nephogram
stress nephogramof the O-ring.
of the O-ring. Figure 8a8a
Figure shows
showsthe themaximum
maximum
Figure 8
compressiveis the
stress
compressive stress =
compressive 12.95
stress
MPa. nephogram
However, of
the the O-ring.
limit stress Figure
of 8a
rubber
= 12.95 MPa. However, the limit stress of rubber material shows
material theis is
maximum==
20.76MPa.
compressive stress max = 12.95 MPa.
Furthermore, < However,
, so the the limit
rubber stress
material of rubber
will not material
lose is
efficacy due = to 20.76 MPa.
stress
20.76MPa. Furthermore,
σ s < σ
, so the rubber material will not lose efficacylimdue to stress
Furthermore, σsmax < σlim , so the rubber material will not lose efficacy due to stress concentration.
Materials 2017, 10, 1211 10 of 18

Materials 2017, 10, 1211 10 of 18

Thus, the O-ring is reliable under the present load condition. Figure 8b is the contact stress nephogram
concentration. Thus, the O-ring is reliable under the present load condition. Figure 8b is the contact max ) and
of the O-ring. It shows that the maximum contact stress between the O-ring and cylinder (Pc1
stress nephogram of the O-ring. Itmax shows that the maximum contact stress between the O-ring and
that Materials 2017,
between 10, 1211
O-ring and piston (Pc2 ) are respectively 23.47 MPa and 21.89 MPa. As the oil 10 pressure
of 18
cylinder ( ) and that between O-ring and piston ( ) are respectively 23.47 MPa and 21.89 MPa.
of As
thethe
sealing deviceofPthemax = 10 MPa, max
both Pc1= 10 MPa, max
and Pc2both max
than Poil are
are largerand . The O-ring performs
oil pressure
concentration. Thus, sealing
oilthe O-ringdevice
is reliable under the present load condition. Figure larger than
8b is the contact .
well in terms
Thestress
O-ring of material
performsof
nephogram wellreliability
thein
and seal
terms Itofshows
O-ring. materialreliability.
thatreliability and seal
the maximum reliability.
contact stress between the O-ring and
cylinder ( ) and that between O-ring and piston ( ) are respectively 23.47 MPa and 21.89 MPa.
As the oil pressure of the sealing device = 10 MPa, both and are larger than .
The O-ring performs well in terms of material reliability and seal reliability.

(a) (b)
Figure 8. The stress nephogram of the O-ring: (a) distribution of compressive stress; (b) distribution
Figure 8. The stress nephogram
(a) of the O-ring: (a) distribution of compressive
(b)stress; (b) distribution of
of contact stress.
contact stress.
Figure 8. The stress nephogram of the O-ring: (a) distribution of compressive stress; (b) distribution
4. Reliability Analysis
of contact stress. under Multiple Conditions
4. Reliability Analysis under Multiple Conditions
4.1.4.Material
Reliability Analysisand
Degradation under Multiple
Random LoadConditions
4.1. Material Degradation and Random Load
AsMaterial
4.1. the working time of the
Degradation O-ring increases, rubber material will degrade over time. Using the
As the working time ofand
theRandom
O-ringLoad increases, rubber material will degrade over time. Using the
stress-strain data from the results of the rubber material’s mechanical experiments at every terminal
stress-strain data
As the
point extracted
from the
working
from the
results
time of the of
degradation
theexperiments,
O-ring rubber material’s
increases, rubber
the rubber
mechanical
material experiments
will degrade
material
at every
over time.
parameters Using
at that
terminal
timethe
can
point stress-strain
extracted data the
from fromdegradation
the results ofexperiments,
the rubber material’sthe rubbermechanical
material experiments
parametersat at
every terminal
that time can be
be obtained with the help of the Mooney–Rivlin model, as shown in Figure 9.
pointwith
obtained extracted fromofthe
the help thedegradation
Mooney–Rivlin experiments,
model,the as rubber
shownmaterial in Figure parameters
9. at that time can
be obtained with the help of the C10Mooney–Rivlin
, C01   C10 , C01 model,
ti
i  1,as2,  ,
shown n in Figure 9. (13)
C , ,CC01 ] =C[C10
[C10 i=
, C, C 01 ]iti 1, 2, 1,, n2, · · · , n (13)
(13)
10 01 10 01 ti

Figure 9. Degradation of rubber material parameters over time.

Figure
Figure 9. Degradationofofrubber
9. Degradation rubber material
material parameters
parametersover time.
over time.
Materials
Materials 2017,
2017, 10,
10, 1211
1211 11
11 of
of 18
18
Materials 2017, 10, 1211 11 of 18
Following this, in order to decide ∆ by processing technology, its distribution rule can be
Following
Following
obtained this,
this, in
by gathering order
inthe size to
order decide ∆
decide
to components.
of byFigure
∆d by processing
processing technology,
technology,
10 shows its distribution
its
the frequency distributionrule
distribution rule can
can be
be
histogram
obtained
obtained
of by
by gathering
100 groups the
the size
size of
of ∆ . Obviously,
gathering of ∆components.
components.
is of normalFigure
Figure 10
10 shows
shows the
distribution. the frequency
frequency distribution
distribution histogram
histogram
of
of 100
100 groups
groups of ∆ . Obviously,
of ∆d. Obviously, ∆d ∆ isisofofnormal
normaldistribution.
distribution.

Figure 10. Distribution of decrement.

Figure
Figure 10.
10. Distribution
Distribution of
of decrement.
decrement.
4.2. Result of Reliability Analysis
4.2.
4.2. Result
Result of
of Reliability
Reliability Analysis
Analysis of the geometric model of the O-ring in Table 2, we extracted ∆
According to the parameters
whenAccording
∆ ∈ 0,0.55
According to the
to theevery
parameters ofofthe
0.01 seconds.
parameters the geometric
Altogether,
geometric model
modelthere ofare
of the the O-ring
= 56
O-ring in Table
groups
in Table of2,extracted
2, we ∆we samples.
extracted ∆
∆d when
The
when ∆ ∈
∆d ∈ [0, 0.55
maximum 0,0.55
compressive every 0.01
] every 0.01 stress seconds. Altogether,
and the small
seconds. Altogether, there
contact
there are k = 56are
stress = 56 groups
groups ofare of
∆d calculated∆
samples. The samples.
by maximum
ABAQUS.The
maximum
Following compressive
this, the max
two stress
curves of and
andthe small contact
over min
the stress
variation of ∆
compressive stress σs and the small contact stress Pc are calculated by ABAQUS. Followingare calculated
can be by
obtained, ABAQUS.
as shown
this,
Following
in
theFigure this, the two curves of and over the variation of ∆
11. of σs and Pc over the variation of ∆d can be obtained, as shown in Figure
two curves max min can be obtained, as11.
shown
in Figure 11.

Figure
Figure 11.
11. The
Themaximum
maximumcompressive
compressive stress
stress and
and the
the small
small contact
contact stress
stress vary
vary with
with decrement.
decrement.
Figure 11. The maximum compressive stress and the small contact stress vary with decrement.
In the step of stress variables’ reliability, in the study of this paper, curve-fitting is an analytical
In the
In the step
step of stress
stress variables’ reliability,
reliability, inin the
the study
study of this
this paper,
paper, curve-fitting
curve-fitting is an analytical
analytical
method derived of
from the variables’
response surface method, and theof accuracy requirements canisbean guaranteed.
method derived
method derived from the response
from the response surface method,
surface method, and the accuracy
andrelationship requirements
the accuracybetween
requirements can can be guaranteed.
Therefore, the curve-fitting was selected to fit the , be guaranteed.
and ∆ .
, is∆d.
Therefore, the curve-fitting was selected to fit the relationship between max , Pmin and The results
Therefore,
The the shown
results are curve-fitting was selected
in Equations to fitThe
(14) and (15). thedegree
relationship σ s
between
of fit of the c
two formulae and
99.8%, ∆ .
which
are
The shown
results in Equations
are shown in (14) and (15).
Equations The
(14) and degree
(15). of
The fit of
degreethe two
of fit formulae
of the two is 99.8%,
formulae which
is meets
99.8%, the
which
meets the accuracy requirements for estimating , and varies with ∆ [29].
accuracy requirements for estimating σ
meets the accuracy requirements for estimating
max , and Pmin varies
s c , and with ∆d [29].
varies with ∆ [29].
Materials 2017, 10, 1211 12 of 18

σsmax = f 1 (∆d) = 0.2477 + 44.37∆d (14)

and
Pcmin = f 2 (∆d) = 1.981 + 66.77∆d (15)

Take σsmax as an example; Equation (4) can be:

σsmax − 0.2477
∆d = f 1−1 (σsmax ) = (16)
44.37
Thus, the material reliability of the O-ring can be obtained from Equation (5):
Z f −1 ( σ )
1 lim
Rs1 = f (∆d)d∆d = 1 (17)
0

Similarly, the seal reliability of the O-ring is:

Z ∆dmax
Rs2 = f (∆d)d∆d = 1 (18)
f 2−1 ( Poil
max )

From Equation (12), the system reliability of the O-ring at initial time can be obtained, that is:
Z f −1 ( σ )
1 lim
Rs = f (∆d)d∆d = 1 (19)
f 2−1 ( Poil
max )

When the initial time t0 = 0, the reliability of the O-ring is Rs (t0 ) = 1. Following this, we
used the rubber material parameters at t1 , t2 , · · · , t6 as inputs for the reliability model. Following
this calculation, the parameters of the O-ring at each time point can be obtained as shown in Table 3.
Furthermore, Figure 12 shows the reliability of the O-ring over the degradation time. Table 3 and
Figure 12 can be used to decide that after 12 months of degradation time, the material reliability of the
O-ring starts to decrease and drops to 0.2398 at the 18th month. However, the degradation speed of
seal reliability is higher than material reliability, and the O-ring totally loses its seal function at the
15th month. O-ring completely failed at this time.
From the calculations at each degradation time point, the reliability of the O-ring remains higher
than 0.9 in the previous 12 months. However, in practical work, all types of special states would result
in the non-linear fluctuation of parameters, which could lead to serious consequences. Therefore,
we analyze its influence on those parameters.

Table 3. Parameters at each time point of the O-ring.

Time/Month σlim /MPa ∆dL /mm ∆dU /mm Rs1 Rs2 Rs

0 20.79 0.12 0.46 1 1 1
3 16.55 0.15 0.42 1 1 1
6 12.86 0.18 0.39 1 1 1
9 9.66 0.21 0.36 1 1 1
12 7.61 0.28 0.33 0.9831 0.9214 0.9044
15 5.06 0.42 0.31 0.7603 0 0
18 2.83 out of range 0.29 0.2398 0 0
Materials 2017, 10, 1211 13 of 18
Materials 2017, 10, 1211 13 of 18

Figure 12. Reliability

Figure 12. Reliability changes over time.
changes over time.

4.3.
4.3. Discussion
Discussion

4.3.1. Life Prediction and Model Error Analysis

From Table 3 and Figure 12, we can see that the reliability reliability of the O-ring
O-ring drops
drops dramatically when
rubber material degradation reaches a certain time point. However, the production cost of the O-ring
is low, and the life cycle cost of replacing its material is even more than replacing the O-ring. On this
premise of not replacing the O-ring, according to the results of material degradation and reliability
analysis, inin order
order to
toensure
ensurethe
thesafety
safetyofofthe thehydraulic
hydraulicsystems,
systems, wewesetset
thethe
replacing
replacing period
period of the O-
of the
ring to to
O-ring bebe1212months.
months.Moreover,
Moreover,the thestandard
standard[30] [30]stipulates
stipulatesthat
thatsealing
sealing element’s
element’s overhaul
overhaul period
should not be over 12 months. months. This paper provides further scientific evidence of quantifying the
replacing period.Therefore,
replacing period. Therefore,we wesetset 1212 months
months as the
as the replacing
replacing period
period ofO-ring
of the the O-ring to ensure
to ensure the
the safety
safety of the hydraulic system in its whole
of the hydraulic system in its whole life circle. life circle.
Furthermore, the the technological
technological limitation
limitation wouldwould result
result inin variations
variations in in the decrement ∆∆d..
the decrement
However, we we took
took the ∆ data
the ∆d data gathered
gathered before before and
and parameters
parameters of of production
production equipment
equipment into into
consideration, and the values of ∆
consideration, and the values of ∆d are not completely in the normal distribution, but within a
are not completely in the normal distribution, but within a
certain
certain section
section [31].
[31]. Therefore,
Therefore,regarding
regardingthe theprobability
probabilitydensity functionofof∆∆d in
densityfunction ∆ ),, we
in f (∆d we added
added
aa correction
correction factor
factor k andandestablished
establisheda new a new probability
probability density
density function
function f M (∆d∆) forfor
∆d, ∆which
, which is
is the
the following:
following:
(
k f (∆d) 0.25 ≤ ∆d ≤ 0.35
(∆d   d  0.25  d  0.35
 kf
f Mf M d  )= 0
(20)
(20)
other
other
 0
We used the revised probability density function of ∆d to calculate the reliability of the O-ring at
We used the revised probability density function of ∆ to calculate the reliability of the O-ring
t0 , t1 , t2 , · · · , t6 again. The results are shown in Table 4, which displays smaller changes in reliability
at , , , ⋯ , again. The results are shown in Table 4, which displays smaller changes in reliability
compared to Table 3. Thus, processing technology has a low influence on the reliability of the O-ring,
compared to Table 3. Thus, processing technology has a low influence on the reliability of the O-ring,
and the influence of the processing technology on life prediction is also low. Therefore, the error of the
and the influence of the processing technology on life prediction is also low. Therefore, the error of
model will not have a greater influence on life prediction, which provides support for the reliability of
the model will not have a greater influence on life prediction, which provides support for the
the method used in this paper to predict the life cycle. Following this, we discussed the influences
reliability of the method used in this paper to predict the life cycle. Following this, we discussed the
from other factors on reliability.
influences from other factors on reliability.
Materials 2017, 10, 1211 14 of 18
Materials 2017, 10, 1211 14 of 18

Table
Table 4.
4. Parameters
Parameters at
at each
each time
time point
point of
of the
the O-ring.
O-ring.

Time/Month Deviation Deviation Deviation

Time/Month Rs1 Deviation Rs2 Deviation Rs Deviation
0 1 0.00% 1 0.00% 1 0.00%
0 1 0.00% 1 0.00% 1 0.00%
3 1 0.00% 1 0.00% 1 0.00%
3 1 0.00% 1 0.00% 1 0.00%
6 6 1 1 0.00%
0.00% 11 0.00%
0.00% 1 1 0.00% 0.00%
9 9 1 1 0.00%
0.00% 1 0.00%
0.00% 1 1 0.00% 0.00%
12 12 0.9835
0.9835 0.04%
0.04% 0.9217
0.9217 0.03%
0.03% 0.9048
0.9048 0.04% 0.04%
15 15 0.7606
0.7606 0.04%
0.04% 00 0.00%
0.00% 0 0 0.00% 0.00%
18 0.2399 0.04% 0 0.00% 0 0.00%
18 0.2399 0.04% 0 0.00% 0 0.00%

4.3.2. Effect
4.3.2. Effect of
of Oil
Oil Pressure
Pressure
In real-life
In real-life scenarios,
scenarios, loads
loads directly
directly affect
affect oil pressure Poil ,, and
oil pressure and incidents
incidents outside
outside the the mission
mission
profile can occur, such as impacts. When the hydraulic system is
profile can occur, such as impacts. When the hydraulic system is influenced by the impact load, influenced by the impact
the
load, the instantaneous oil pressure may exceed the maximum oil pressure
instantaneous oil pressure may exceed the maximum oil pressure in the mission profile. We assumed in the mission profile.
We assumed
that the maximum that the oilmaximum oil pressure
pressure under impactunder impact
is twice is twice the
the maximum maximum
value value ofoil
of the original thepressure
original
oil pressure P max , which defines the maximum oil pressure under impact as Pimpact = 20 MPa. The oil
, which defines
oil the maximum oil pressure under impact as = 20 MPa.
oil The oil pressure
mainly affects seal reliability. Therefore, the changing features of reliability are shown inare
pressure mainly affects seal reliability. Therefore, the changing features of reliability shown
Figure in
13 in
Figure 13 in the situation where the hydraulic systems are under impact load.
the situation where the hydraulic systems are under impact load. It can be seen that this impact load It can be seen that
this
is impact
likely load leakage
to cause is likelyin
tothe
cause leakagesystems
hydraulic in the hydraulic
within thesystems within
whole life circlethe
of whole life circle
the O-ring. of the
Therefore,
O-ring. Therefore, we artificially restricted the probability of impact in the hydraulic
we artificially restricted the probability of impact in the hydraulic systems or used other methods systems or used
other methods [17], to add several hydraulic systems into parallel connection.
[17], to add several hydraulic systems into parallel connection. These can disperse the impact caused These can disperse the
impact
by caused by and
oil fluctuation oil fluctuation
the damageand the damage
to O-rings when tothe
O-rings
cost iswhen the costThe
acceptable. is acceptable.
cost of thisThe cost of
method is
this method is large, which is applicable to the situations where
large, which is applicable to the situations where the risk of leakage is serious. the risk of leakage is serious.

Reliability changes
Figure 13. Reliability
Figure changes under impact.

4.3.3. Comparison
Comparison with
with the
the Actual
Actual Situation
Situation
According
According to tothe
thereliability
reliabilitymodel
model proposed
proposed in this paper,
in this the relationship
paper, between
the relationship the time-
between the
variant reliability
time-variant of the
reliability of O-ring can can
the O-ring be calculated, butbut
be calculated, it also needs
it also needstotobebecompared
comparedwithwiththe
the actual
actual
situation. In
In order
order to
to ensure
ensure the
the applicability
applicability of
of the
theresults
results between
betweenthetheactual
actualsituation
situationand
andthis
thispaper,
paper,
the
the working
workingconditions
conditionsofofthetheactual
actualsituation
situationshould
shouldbebe
thethesame as as
same experiments
experiments andand
simulation. In
simulation.
the actual
In the situation,
actual thethe
situation, working
working temperature
temperatureisismaintained
maintainedatat42 42±±22°C;◦ C;the
therelative
relative humidity
humidity is
maintained
maintained at at 48% ±±5%;
5%;and
andthe
thedimensions
dimensionsand andload
loadofof O-ring
O-ring are
are the
the same
same asas those described
described in
this paper; so there is reason to believe that the working conditions between the actual situation and
this paper are the same.
The O-ring works under the mission profile shown in Figure 5, and monitoring the replacement
until the O-ring failed, then the statistical data of use time can be obtained. Therefore, we compared
Materials 2017, 10, 1211 15 of 18

The
Materials O-ring
2017, works
10, 1211 under the mission profile shown in Figure 5, and monitoring the replacement 15 of 18
until the O-ring failed, then the statistical data of use time can be obtained. Therefore, we compared
the statistical data
data with
with the
theresults
resultsofofthis
thispaper
papertotoverify
verifythe
theaccuracy
accuracyofof
the reliability
the model.
reliability Figure
model. Figure 14
Materials 2017, 10, 1211 15 of 18
shows
14 showsthetheuseusetimetimeof the O-ring
of the obtained
O-ring obtainedfrom thethe
from maintenance
maintenance workshop.
workshop.
the statistical data with the results of this paper to verify the accuracy of the reliability model. Figure
14 shows the use time of the O-ring obtained from the maintenance workshop.

Figure
Figure 14.
14. The
The frequency
frequency distribution histogram of use time.
Figure 14. The frequency distribution histogram of use time.

By
By inputting
By inputting
inputting the use
thethe time
useusetimetimeinto
intoEquation
into Equation(21),
Equation (21), the
(21), the reliability
reliabilityofof
thereliability the
the
of the O-ring
O-ring
O-ring cancan be
be obtained
be obtained
can in anin
obtained in an
an
actual
actual situation
actual
situation at
at various
situation at various
various times.
times.
times. These
Thesecomparison
These comparison results
comparison results between
resultsbetween
between the
the calculated
calculated
the calculated andand actual
actual
and values
actual values
values
are
are shown
shown in
in Figure
are shown in Figure
Figure 15. The
15. 15.
The results
The resultsof
results this
ofofthis comparative
thiscomparative experiment
comparative experiment
experiment show
show
showthatthat
thethe
that calculated
calculated
the results
results
calculated results
are similar to
are similar the
to actual results,
the actual results,which
whichverifies
verifiesthatthat the method
the method ofofthis
this paper
paper
are similar to the actual results, which verifies that the method of this paper is suitable. Therefore, is suitable.
is suitable. Therefore,
Therefore, the the
reliability
reliability model model of this
of this paper
paper inininpredicting the
predicting the time-variant
time-variant reliability of the O-ring in the actual
the reliability model of this paper predicting the time-variantreliability
reliabilityofofthe theO-ring
O-ringin in the
the actual
actual
situation
situation is is accurate.
accurate.
situation is accurate.
= n  t
N Nn− t n(t)
RRt(t) N
R  t 
(21) (21)
N N (21)
N
where R(t) is theisreliability
where at time
the reliability at t, N is ,the number
time of O-rings
is the number monitored
of O-rings and nand
monitored (t) is the number
is the of
where
O-rings that is
have the reliability
been replaced at time
at time
number of O-rings that have been replaced at time . ,
t. is the number of O-rings monitored and is the
number of O-rings that have been replaced at time .

Figure
Figure 15.15.Comparison
Comparison of
of calculated
calculated and
andactual
actualvalues.
values.

5. Conclusions
5. Conclusions Figure 15. Comparison of calculated and actual values.
This paper examines the influence of the dual effect of material degradation and random load
This paper examines the influence of the dual effect of material degradation and random load on
on the performance of the O-ring. This is conducted by combining the influence of random
5.
theConclusions
performance ofreliability
the O-ring. This is conducted by combining theelement
influence of random parameters
parameters on from other studies, establishing the finite model and analyzing the on
reliability
This from other
paper
performance of thestudies,
examines establishing
theThis
O-ring. influence ofthe
paper takes the finite
dual element
multiple effect model
factorsofinto anddegradation
material analyzing
consideration, whichthecanperformance
and random load
overcome of
the the
on O-ring. This paper
the performance
limitation takes
of themultiple
of calculating O-ring. factors into
Thisof is
the degree consideration,
conducted
reliability with aby which
combining
single can the
variable. overcome thethe
influence
Furthermore, limitation
oftime-
randomof
parameters on reliability from other studies, establishing the finite element model and analyzing the
performance of the O-ring. This paper takes multiple factors into consideration, which can overcome
the limitation of calculating the degree of reliability with a single variable. Furthermore, the time-
Materials 2017, 10, 1211 16 of 18

calculating the degree of reliability with a single variable. Furthermore, the time-variant reliability
predicted in this paper considers material reliability and seal reliability at the same time. According to
the results of the case studies, the conclusions are as follows:

(1) In view of the time-variant degradation of rubber material parameters, its degradation rule can
be obtained by using the experimental method in this paper. According to the experimental
results, the performance of rubber material worsens with an increase in working hours.
(2) The maintenance and replacement period of the O-ring predicted in this paper is 12 months,
with the number of failures having increased sharply after the 12th month according to the
actual situation. There is ample evidence to support why 12 months is used as the replacement
cycle for the O-ring. Furthermore, the flaws in the processing technology would lead to varying
decrements of the O-ring, despite the variations in decrement caused by the processing technology
having little impact on the reliability.
(3) The variation in working load would lead to a variation in oil pressure. Furthermore, the impact
load creates considerable damage in the O-ring, which would trigger accidents. We optimized
the input of the load and properly distributed the impact load to ensure the safe operation of this
hydraulic system.
(4) From the analysis results, the reliability model of the O-ring is obtained and calculated through the
case analysis with consideration of both material reliability and seal reliability. In the case study,
the reliability of the O-ring is high enough, as confirmed by the actual situation. The method in
this paper can accurately and promptly calculate the reliability of the O-ring.

Author Contributions: Weifang Zhang designed the experiments. Kun Zhou contributed the materials and
performed the experiments. Bo Sun conceived of the idea. Yi Ren proposed the method. Baopeng Liao and
Meichen Yan analyzed the data. Baopeng Liao and Bo Sun wrote the paper.
Conflicts of Interest: The authors declare no conflict of interest.

List of Symbols/Nomenclature

Symbols Nomenclature Definition Unit

The maximum value of the stress applied to the rubber
σsmax The maximum compressive stress MPa
during compression.

max and Pmax The maximum value of the stress generated by the contact
Pc1 c2 The maximum contact stress MPa
surface when contacting each other.
Pcmin The small contact stress max and Pmax .
The minimum value between Pc1 c2 MPa
The stress value of the rubber in the compression process
σlim Limit stress MPa
when the normal working capacity is lost.
The pressure of the hydraulic oil on O-ring during
Poil Oil pressure MPa
hydraulic system work.
max
Poil The maximum oil pressure The maximum value of oil pressure. MPa
∆d Decrement of O-ring Decrement of O-ring during compression. mm
∆d The mean of ∆d. The mean of ∆d. mm
Rs1 Material reliability The probability that rubber material does not fail. /
Rs2 Seal reliability The probability of no leakage. /
Rs System reliability The probability of O-ring working properly. /
∆d Rs1 /∆dU The upper limit of decrement Decrement which satisfies with Rs1 . mm
∆d Rs2 /∆d L The lower limit of decrement Decrement which satisfies with Rs2 . mm
∆d Rs The limit of decrement Decrement which satisfies with both Rs1 and Rs2 . mm
/ Contract properties The properties of the two contact surface in ABAQUS. /
/ Nephogram A photograph of a cloud. /
/ Deviation The degree of deviation from the initial value. %
Materials 2017, 10, 1211 17 of 18

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