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Counter Surfaces of Hydraulic Sealing Systems for Heavy-Duty

Applications

Dipl.-Ing. Frank Steep, Dr.-Ing. Guido Wüstenhagen

Merkel Freudenberg Fluidtechnic GmbH, Hamburg

1. Introduction
To ensure long-term operation of a hydraulic sealing system two main partners in the
systems should be adjusted to each other:

x the sealing ring of the seal made of PTFE, Polyurethane or Elastomer

x the counter surface made out of coated or hardened steel.

For successful analysis and adjustment of the two partners it is a detailed

understanding of the tribological system essential (figure 1).

Field reports have proved, that the initial contact between counter surface and
sealing ring is crucial to the life expectations of a sealing system.

During the first operating hours the direct contact influences both partners. The
counter surface loses abrasiveness. The expected lifetime of a seal mounted first
could be outlasted by a seal mounted second. In this case the first seal has super
finished the counter surface by taking off the abrasiveness. On the other side the
sealing edge could be damaged within the first few strokes by the abrasiveness of
the counter surface. This could cause a reduction of the sealing function or lifetime
compared to a seal mounted second. In statistic terms: The abrasiveness of the
counter surface during the first operating hours could cause changes in the
performance of a sealing system with respect to leakage and lifetime. In terms of
operation: Improved surfaces will extend the operating time.
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Due to these differences the character of the counter surfaces has been analysed.
Common and additional parameters of the counter surfaces were studied in detail.
Additional parameters out of the Rk-group have been investigated.

Merkel Freudenberg
Fluidtechnic

Counter surface inside the sealing technology

Rod:
• Dimensional accuracy
• wear-resistant
• Surface quality
• Shape and position
• Sealing function

Sealing component

Rod surfaces
Counter surfaces

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Figure 1: Sealing contact as tribological system

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2. Common recommendation for counter surface parameters

Until now recommendations offer limits for surface parameters such as Rmax, Rz, Ra,
Mr e.a.

Merkel Freudenberg
Fluidtechnic

Simrit catalogue recommendation

surface parameter Rmax, Ra and material proportion Mr
Surface parameters

Rmax Ra Material proportion Mr

Mr > 50% to max. 90% for cut

0.05 – 0.3 µm off c = Rz/2 and reference line
Sliding surface d 2.5 µm
(Optimal Ra = 0.2µm) Cref = 0%
(Optimal Mr = 80%)
Ground of the
d 6.3 µm d 1.6 µm
groove

Sides of groove d 15 µm d 3 µm

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Figure 2: Example for recommendations of counter surface parameters

Figure 2 shows common recommendation for counter surface parameters.

Parameters like Rmax, Rz, Ra, Mr are well proved parameters and established in the
marked. Some recommendations may differ in the definition of Mr, either in the
baseline Cref or in the definition of the cutting depth. In particular, the difference in the
baseline could be crucial. Cref 0% takes into account single peaks in the counter
surface (figure 3). These peeks could have an initial effect on a soft-hard contact as
in between sealing ring and counter surface of a piston. Cref 5% ignores these peeks.
This is recommended in a hard-hard contact as the peeks are deformed by the very
first contact.
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3. Additional surface parameters

Figure 4 shows the parameters of the Rk-group and figure 5 the proposal for
common and additionally recommended surface parameters. The Rk value is an
excellent indicator for the general character of a counter surface quality. Rpk und Rpkx
values are indicating an initial abrasiveness. Values have been defined to an
uncritical limit regarding abrasiveness. In particular Rpkx will change during the first
hours of operation. Rvk and Rvkx are indicating the ability of building up a dynamic
lubricant film. In particular Rvkx is of minor interest, and the recommended values
have been set to a quite high value. Rvk is of major interest and has been
recommended to achievable values. The parameters of the Rk-group are real values
and no mean values.

Merkel Freudenberg
Fluidtechnic

Additional surface parameters

µ [mm] Rpkx, full peak height

Rpk, reduced peak height

Rpkx Rk, Kernel surface roughness

Rvk, reduced valley depth

Rpk Abbott curve
Rvkx, full valley depth

Mr1, material percentage contact area, dependant on Rpk

Mr2, material percentage contact area, dependant on Rvk

Rv

Rvkx
Values see Norm DIN ISO 4287 and DIN ISO 13565-1 and 2.

Mr1 Mr2 Mr [%]

0 10 20 30 40 50 60 70 80 90 100

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Figure 4: Parameters of the Rk-group

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Fluidtechnic

µ [mm]
Mr for Cref = 0%
2
Please follow the numbering 1 to 5

3 = Rz/2

3 Abbott curve
4
Rk

1 Start at 0% 5 End Mr = 48% Mr [%]

0 10 20 30 40 50 60 70 80 90 100

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Figure 3: Detecting Mr by Cref 0%

Sealing systems which showed a wide range in lifetime were investigated. The wide
range occurred although the counter surface parameters were within the
recommended limits. In a first step the reasons for the variation were analysed. For
this purpose additional parameters were taken into consideration: The Abbott-graph
and the Rk-group. The surfaces showed almost similar values except for the Rpkx
parameter. This analysis highlighted the Rpkx parameter. In other words: the common
recommendation has been fulfilled but the variation in lifetime has been significant.
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Fluidtechnic

Proposal: Recommended surface parameters

dynamic (stroke) loaded steel counter surfaces, hardened; hydraulic oil, e.g. HLP 46

µ [mm] Development status

Ra 0.10 to 0.30 µm Rpkx 0.00 to 0.50 µm
Rz 1.20 to 2.00 µm Rpk 0.00 to 0.50 µm
Rpkx
Rk 0.25 to 0.75 µm
Rvk 0.20 to 0.65 µm
Rpk Abbott curve Rvkx 0.20 to 2.00 µm

This is a development project. For further information:

Frank Steep
Anwendungstechnik, Merkel Freudenberg Fluidtechnic GmbH, 21107 Hamburg
Tel. +49 (0)40 75306 409 E-mail:frank.steep@freudenberg.de
R

Rvk

Rvkx
Values see Norm DIN ISO 4287 and DIN ISO 13565-1 and 2.

Mr1 Mr2 Mr [%]

0 10 20 30 40 50 60 70 80 90 100

11.10.2006 / 5

Figure 5: Proposal of recommended surface parameters

In a close partnership with OEMs this proposal has been implemented. Lifetime of a
sealing system has been extended and the variation in lifetime has been reduced.
This proposal refers to hardened rods without coating.

Investigations were made parallel on a test rig. To compress testing time, the
conditions have been on the ruff side: Only single seals without guide ring and
permanent pressure. No influence to the counter surfaces due to the guide rings. To
prove the influence of parameters like Rpk and Rpkx on the wear of the sealing ring
and vice versa, in a first test surfaces with values not according to the
recommendations were used (see figure 6). The surface has been measured before
testing, after the first test and after the second test. Wear and Rpkx changed
significantly. The values of the others parameters remained the same. This proves
the dependency of wear and Rpkx. Even if Rpkx shows only a small amount of peaks in
the surface, it could be a strong hint with regard to the general appearance of the
surface. Taking into consideration that the area of a surface measurement covers
only a minor part of the full surface, a few Rpkx peaks might be several of many on the
full surface.
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Fluidtechnic

Test results
Verschleißuntersuchungen mit Nutringen auf Plunger A2
2,6 130
5,68 6,49 6,79
Oberflächen - Rauheit Oberflächen - Rauheit Oberflächen - Rauheit
2,4 vor dem Versuch nach dem 1. Versuch 120
nach dem 2. Versuch

2,2 110

2,0 100

1,8 90

1,6 80
Rauheit [µm]

Abrieb [%]
1,4 70

1,2 60

1,0 50

0,8 40

0,6 30

0,4 20

0,2 10

0,0 0
Rmax Ra Rk Rpkx Abrieb Rmax Ra Rk Rpkx Abrieb Rmax Ra Rk Rpkx
Prüfgrößen

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Figure 6: Some results of test rig runs

To prove the connections between wear and Rpkx, an additional rod with surface
parameters inside the common but outside Rpkx recommendations has been tested.
During the first run more wear occurred than during the second. The surface had
changed from the first to the second run. After the first run, all parameters were
within the recommended values. The parameters did not change during the second
run. This needs to be confirmed.

4. Summary/Zusammenfassung
Rpkx has been proved as a strong indicator for wear and lifetime of a hydraulic sealing
ring. A proposal for additional parameters from the Rk-group is available and refers to
hardened steel surfaces. This proposal should increase the performance of sealing
systems.

Rpkx konnte als deutlicher Indikator für den Verschleiß einer Hydraulikdichtung
herausgearbeitet werden. Ein Vorschlag für zusätzliche Parameter aus der Rk-
Gruppe liegt vor und bezieht sich auf gehärtete Stahl-Oberflächen. Dieser Vorschlag
sollte die Leistungsfähigkeit des Dichtsystems erhöhen.