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ADVANTAGE SAP PARTS
Mechanical Face – Duo Cone Seals
__________________________________________________________

INDEX
1. INTRODUCTION.
2. SAP SEAL DESIGN PRINCIPLE.
3. MECHANICAL FACE, DUO CONE SEALS FEATURES.
4. DEVELOPMENT.
5. APPLICATION ENGINEERING.
6. NEW DEVELOPMENT – TECHNOLOGY SOLUTION.
7. PRODUCT DESIGN CONSIDERATIONS.
8. SEAL RING MATERIALS.
9. TORIC RING ( O RING) MATERIALS.
10. DUO-CONE SEAL RAMP ANGLES.
11. DESIGN INFORMATION.
12. LOAD DEFLECTION.
13. PRESSURE VELOCITY.
14. SIGNIFICANT FACTORS INFLUENCING THE DESIGN SELECTION.
15. SEAL WEAR MEASUREMENT.
16. LUBRICANT REQUIREMENTS.
17. SPECIALTY SEALS.
18. SAP PARTS’ UNIQUE SEAL LIFE TESTING.
19. CUSTOMER SPECIFIC SEAL DESIGN & DEVELOPMENT.
20. FUNCTIONAL TEST LAB CAPABILITIES.
21. QUALITY ASSURANCE.
22. SOLUTIONS TO SEAL FAILURE MODES.
23. SAP PARTS’ MECHANICAL FACE SEALS MANUFACTURING PROCESS CONTROL.

ADVANTAGE SAP PARTS
Mechanical Face – Duo Cone
Seals
IIIIntroductionntroductionntroductionntroduction:
SAP Parts is ISO 9001: 2008 CertifiedISO 9001: 2008 CertifiedISO 9001: 2008 CertifiedISO 9001: 2008 Certified leading manufacturer of Precision Mechanical
face-Duo Cone Seals.
Based in PUNE – INDIA, it is the most advance facility catering the innovative Design-Development and technology
Solutions for your Sealing Requirements.
SAP Parts Duo Cone Seals are accepted and used by most of the leadingSAP Parts Duo Cone Seals are accepted and used by most of the leadingSAP Parts Duo Cone Seals are accepted and used by most of the leadingSAP Parts Duo Cone Seals are accepted and used by most of the leading Construction EquipmentsConstruction EquipmentsConstruction EquipmentsConstruction Equipments OEM based inOEM based inOEM based inOEM based in
Europe, USA & Asia.Europe, USA & Asia.Europe, USA & Asia.Europe, USA & Asia.
SAP Parts’ Seals are technologically developed for
protection of equipment working in the extreme and
most adverse conditions like mud, rock-dust, sand,
and water, desert heat and sever cold. These Seals
provide very effective lubricant retention and exclude
contaminates in all applications across all types of
conditions have proven a long service life with low
maintenance.
SAP Parts seal designs use elastomeric O-Rings to
provide loading for the metal component. The design
uses the contact area between the metal sealing rings
to create a static and dynamic seal.
These Seals serves under most of the drastic and hostile service conditions and applications where all other radial-
lip type elastomeric seals do not withstand.
SAP SEALSAP SEALSAP SEALSAP SEAL DESIGNDESIGNDESIGNDESIGN::::
These Seals are fitted in Groove of a retaining Housing
to form the sealing at the adjoining faces. Metal faces
are precision Lapped to Rt < 0.5. The seals having faces
profiled to spherical shape of R 2032 mm. This face is
further lapped to form a flat band at the outer side The
ramp angle of Seal and Housings are slightly different
and form a wedge for the rubber ring to slide into and
form a compressed profile giving load on the seals and
making it intact.
In the application, one of the metal seal is always
stationery while other is rotating with respect to the
roller.
The friction in the lapped faces transmit the load and
sealing caused retains the oil filled in small cavity formed
1
2 3
4
1− SEAL RING, STATIC 3. SEAL RING,ROTATING
2.O−RING 4.O−RING
F
FG
FL
COMPRESSED O-RING
FACE LOAD

by the faces. The Flat Portion of seal 2 mm wide will start wear from the end i.e. from OD and will go on towards
ID. Till it reaches to the area where spherical radius starts.
Mechanical faceMechanical faceMechanical faceMechanical face, Duo Cone Seals, Duo Cone Seals, Duo Cone Seals, Duo Cone Seals FeaturesFeaturesFeaturesFeatures::::
- Corrosion-resistant seal rings
- Precision lapped, self-renewing sealing surfaces
- Minimum face load variations
- Special seal and O-Ring materials to match application requirements
Rotating speed, lubrication, temperature, and differential pressure are factors to consider when determining seal
face loads. Mechanical face, Duo Cone Seals provide good performance across a wide range of face loads,
therefore, compensating for considerable assembly tolerance buildup, misalignment, and wear.
DEVELOPMENTDEVELOPMENTDEVELOPMENTDEVELOPMENT::::
To avoid the high cost of equipment downtime it needs the best available seal. The SAP Parts Mechanical face Seals
provides superior performance in extreme applications where positive lubricant retention and the ability to keep out
damaging and/or abrasive materials are essential.
Application EngineeringApplication EngineeringApplication EngineeringApplication Engineering::::
At SAP PARTS, its engineers can analyze your sealing requirements, recommend the metal face seal that would
best meet your needs, work with your engineers to design the installation and even provide drawing to aid in your
design.
PARAMETERS DESCRIPTION SPECIFICATIONS
Material Forged by Ring Rolling Process
Loss Wax Investment Casting
SAE 52100 /100Cr6
Special Alloy Steel
FC15Cr3MO
Hardness Through Hardened and Tempered in
controlled atmosphere. Fine tempered
Marten site Microstructure
60-63 HRc
The Flatness guarantee
on the surface
Within 3 light Bands of Optical
interference
1~3 Micron Max
The surface roughness
on the Lapped surface
Flatness Attained By Diamond Lapping
Process
< 0.5Rt
The Dual cone angle
range
Conforming to OEM Specifications.
Specially Designed Ramp angle
profile with Higher Grip texture
to hold the O rings firmly.
8-15-20 Degree
Operating Speed With Oil 10 Meter/Sec Max
Operating Speed With Grease 3 Meter/Sec Max
Pressure / Load Bearing
Capacity
3 Bars Max
1
2 3
4 5
1. SEAL STATIC
2. O−RING
3.SEAL ROTATING
4.O−RING
5.HOUSING

NEW DEVELOPMENTNEW DEVELOPMENTNEW DEVELOPMENTNEW DEVELOPMENT –––– TECHTECHTECHTECHNOLOGY SOLUTIONNOLOGY SOLUTIONNOLOGY SOLUTIONNOLOGY SOLUTION
* DUAL FACE UNITIZED, SILICONE GEL FILLED MECHANICAL CASSETTE SEAL ASSEMBLY.
*Under Patent Registration
Customer INPUT Conditions For DevelopmentCustomer INPUT Conditions For DevelopmentCustomer INPUT Conditions For DevelopmentCustomer INPUT Conditions For Development SAP PARTS Development SolutionSAP PARTS Development SolutionSAP PARTS Development SolutionSAP PARTS Development Solution
Purpose:
The Seal Assembly is designed to protect the spindle from dust, dirt, mud in the
environment of application and prevent the Oil filled in, from leakage, while in function
and to provide a stable sealing for higher life.
Design Solution :
It is comprised of two mechanical face seals - Sealing Discs, duly hardened - tempered to
60 HRc and Precision lapped, achieving the surface finish level Ra<0.08, retained by 4
Torric Rings i.e. O- Rings out of NBR60SH and the cavity formed by the Sealing Discs, filled in with Special Silicone Gel to
dissipate the frictional heat generated in working.
The entire assembly is enclosed by two formed Seal Casings (Plasma Nitrided and Corrosion Protected), the inside and outside
dia. of which is in contact with the Spindle OD & housing ID, is bounded by rubber. Thus forming a *dual face unitized, silicone
gel filled mechanical cassette seal assembly.
Function:
The cover fixed on the spindle is stationery and so do the mechanical seal associated with it, however the cover & seal at
Housing side will undergo the wheel dynamics and cause the high pressure at the opening of the seal lead to pump out the dust
particles. The seal case is formed inverted on outer face. It will arrest the environmental debris to come and in case they travel
through the space between two covers will get arrested at O – rings (Big Dia.) In non-moving condition the dirt will settle by
gravity in the gap at the outside periphery of the cover track and hence it will not ideally cross the barrier formed by mechanical
seals’ lapped faces in contact. Similar is the case for the oil filled in the spindle, it will be arrested to come out by the virtue of
inner O-Ring (Small Dia.) Thus the Seal assembly can perfectly serve the purpose it is intended to be used for.
Special Features & Advantages:
1. Balanced face load - on the sealing discs by virtue of 4 Torric rings placed inside the case.
2. Nick provided on Sealing Discs - leads to spring action for stability. This gives proper sealing even after wear.
3. Rubberized casing - protects spindle & Housing from wear due to metal contact.
4. Silicone Gel - dissipates the frictional heat generated in working and arrests dirt to move any further.

Product DesignProduct DesignProduct DesignProduct Design ConsiderationsConsiderationsConsiderationsConsiderations
Seal Ring MaterialsSeal Ring MaterialsSeal Ring MaterialsSeal Ring Materials ::::
SAP Seals uses Alloy Steels of various Grades, following various Manufacturing Processes like Forging, Sheet Metal
Forming and Investment Casting etc. Most preferably used are the forged Alloy Steel of Grade SAE:52100 also
called as Bearing steel and Special Alloy Steel Castings, detail Specifications of these Seal Ring materials are as
below:
SEAMLESS ROLLED BARS, TUBES, FORGED &
TURNED RINGS, CRCA Sheet - Formed Seals
SPECIAL ALLOY IRON CASTINGS - FCCrMo
(FOR FLOATING SEALS)
Grade SAE 52100 FC5Cr6Mo× FC9Cr6Mo× FC15Cr3Mo× FC15Cr6MoNiV× G-Cr Mo V 17.3.1
Chemical
Composition
% Min. Max. % Min Max Min Max Min Max Min Max Min Max
C 0.93 1. 05 C 3.60 4.00 3.50 3.90 3.20 3.60 3.20 3.60 3.40 3.80
Si 0.15 0. 35 Si 1.50 2.00 1.20 1.70 1.10 1.60 1.10 1.60 0.70 1.20
Mn 0.25 0.45 Mn 0.50 1.00 0.50 1.00 0.50 1.00 0.50 1.00 0.70 1.00
Cr 1.35 1 .60 Cr 4.50 6.00 8.30 10.50 14.00 16.00 14.00 16.00 15.00 18.00
P - 0.025 - - - - - - - - - - -
S - 0.015 - - - - - - - - - - -
Mo - 0. 10 Mo 5.00 8.00 5.00 8.00 2.00 4.00 2.00 4.00 2.00 3.00
Cu - 0. 30 Co 0.20 MAX 2.50 3.50 0.20 MAX 0.20 MAX - -
Ni - 0. 25 Ni 1.70 2.10 1.70 4.30 1.00 2.00 1.00 2.00 - -
Al - 0.05 - - - - - - - - - - -
Sb - 0.005 - - - - - - - - - - -
Sn - 0.03 V 0.20 MAX 1.70 2.40 0.20 MAX 1.30 2.00 0.50 1.00
As - 0.04 W 3.50 4.50 3.50 4.50 0..2 MAX 0..2 MAX - -
Manufacturing Made by Electric Arc
Furnace, Ladle Refining
Furnace & Vacuum De -
Gassing.
By Investment Casting Loss of Wax Process
Surface Free from surface defects
such as Cracks, Seams,
Laps, Pit- marks, Rust &
Scale etc
Free from surface defects such as Blow Holes, Cracks, Seams, Laps, Pit- marks, Rust & Scale etc
Heat Treatment Through Hardening,
Quenched in Oil &
Tempering.
Shall be used as casting state Air cooled after maintaining 500 ~
550˚C for 1.5 Hr & maintaining for 2 Hr
Air cooled after maintaining
850~900˚C For 20~40 min
Hardness 62 ± 3 HRC62 ± 3 HRC62 ± 3 HRC62 ± 3 HRC HRC 65HRC 65HRC 65HRC 65----72727272
Microstructure Uniformly distributed
small carbides in
tempered martensite
matrix
Uniformly distributed small carbides in tempered martensite matrix
Retain Austenite RA < 4% RA < 4%

TorricTorricTorricTorric RingRingRingRing ( O Ring)( O Ring)( O Ring)( O Ring) MaterialsMaterialsMaterialsMaterials ::::
SAP Parts uses several materials for its Torric rings are available to meet a variety of application requirements. The
most common materials are nitrile (NBR) and silicone. Viton and highly saturated nitrile (HNBR) are available for
more specialized applications. The table listed below gives a brief comparison between available O- ring options.
Nitrile LT Nitrile Viton HNBR Silicone
Service Temp(-)ᑻC -25 -50 -10 -40 -60
Service Temp(+)ᑻC 100 105 190 135 165
Abrasion Resistance Excellent Excellent Good Excellent Poor
Tear Resistance Good Good Good Good Poor
Water Resistance Excellent Excellent Fair Excellent Excellent
Oil Resistance Excellent Excellent Excellent Excellent Poor
Cost Low Low High High Medium
DuoDuoDuoDuo----Cone Seal Ramp AnglesCone Seal Ramp AnglesCone Seal Ramp AnglesCone Seal Ramp Angles
Seal Ramp Angle ∝ This design of Ramp angle offers a more uniform load profile over its operational face gap
range. In the application due to external pressure, debris packing, or vibration the torics can
force down the ring and can cause sudden decay of the face load and sealing integrity to
avoid this specified Ramp angle is provided which forms a wedge in between housing and
retains the Torric more firmly.
8ᑻ ∝ By this extent it offers increased toric retention and a more uniform face load profile.
15ᑻ ∝ By this extent , the sealing design offers resistance to internal operating pressure and an
ability to achieve higher sealing face loads than those available with the 8ᑻ seals. This design
is most commonly used in final drive, axle, and wheel applications.
20ᑻ ∝ This is similar to the 15ᑻ seal design in that it resists internal pressures. The 20ᑻ design
produces higher face loads than either the 8ᑻ design. It is most commonly used in
undercarriage applications.
Seal RSeal RSeal RSeal Ring Sizesing Sizesing Sizesing Sizes
SIZES(mm) Min Max
AAAA 50 395
BBBB 39 365
CCCC 14 38
DDDD 52.2 400

Design InformationDesign InformationDesign InformationDesign Information
Seal Housing:
The installation dimensions of the seal housing are
shown in the Figure.
.
The axial gap S in the housing is such that it meets
the demands of the construction machinery industry.
For high sliding speeds it may be necessary to
reduce the axial compression, thus reducing the load
of the seal faces and the heat generation in the seal
face. This is achieved by increasing the axial gap S.
The following gaps are possible , depending on the
O—Ring cross section.
SAP Parts recommend that tests be carried out to find the most appropriate setting. Since the O —Ring is always
oversized to the housing, the edges of the housing must be rounded. Surfaces Under pressure, elastomers adapt
themselves to irregular surfaces. However, for liquid-tight conditions, certain minimum requirements have to be
made on the surface finish of the faces to be sealed.
Scores, scratches, pores and concentric or spiral
machining scores are not permissible. For the surface of
the seal installation chamber we recommend a
machining quality of Mechanical Face Seals
Load DeflectionLoad DeflectionLoad DeflectionLoad Deflection ::::
The typical load/deflection chart for a Duo-
Cone Seal illustrates the flat curve
developed by its design. These seals work
satisfactorily over a wide range of the curve.
Load deflection characteristics vary by
Mechanical face, Duo Cone Seals type, O-
Ring material and seal group size. SAP
PARTS engineering should be consulted for
design assistance concerning proper
loading of Mechanical face, Duo Cone
Seals.
DEFLECTION IS USED FOR APPROPRIATION OF CONTACT PROFILE
Pressure VelocityPressure VelocityPressure VelocityPressure Velocity
Mechanical face, Duo Cone Seals performance capability can be described by its Pressure-Velocity (PV) or load
speed
O - Ring Cross Section
d1
Gap 'S'
d1 < 8.0 4
8 እ d1 እ12.7 5
d1 > 12.7 6
Ra < 3.2 µm
Rz < 10.0 µm
Rmax < 16.0 µm
GAP
COMPRESSED
O−RING
RAMP ANGLE
1
2 3
4
1. SEAL STATIC
2. O−RING
3.SEAL ROTATING
4.O−RING
5.HOUSING

533 mm
457 mm
146 mm
Face Load
Rotational Speed
rating. The face load required to keep the metal seal rings in contact is related to the allowable speed, as described
by the following chart. Many factors influence this relationship, including seal ring material, seal ring diameter,
operating temperature, lubricant viscosity, differential pressure across the load rings and action of centrifugal force
on the load ring.
In low speed applications or with light lubricants,
face pressures are generally increased to insure
sealability. The same is true when seals are
exposed to high differential pressures and/or
large endplay or deflections. Lower face loads
are
specified for applications producing high
peripheral speeds or high ambient temperatures.
High speeds tend to centrifuge lubricant away
from the seal face, and centrifugal forces tend to
roll the torics up the seal ramp, increasing the
face load. Both conditions contribute to scoring
failures. Mechanical face, Duo Cone Seals have
been used successfully to 456 mpm (1500 fpm).
Consult SAP Parts Precision Seals when selecting
face load to insure appropriate design target.
Significant Factors Influencing the design SelectionSignificant Factors Influencing the design SelectionSignificant Factors Influencing the design SelectionSignificant Factors Influencing the design Selection
The selection of the proper Mechanical face, Duo Cone Seals is contingent on a thorough application review.
Differences in operating conditions have a significant impact on the optimum Mechanical face, Duo Cone Seals
for your product. Shown in the table below are significant application variables and the component
of the Mechanical face, Duo Cone Seals product they affect.
VariableVariableVariableVariable Design ConsiderationDesign ConsiderationDesign ConsiderationDesign Consideration
Speed Metal Seal Ring Material
Internal/External Pressure Metal Seal Ring Material and Ramp Angle
External Operating Environment Metal Seal Ring and Torric Ring Material
Temperature Torric Ring Material
Available Space Mechanical face Seal Type
End Play Metal Seal Type and Seal Ramp Angle

Seal Wear MeasurementSeal Wear MeasurementSeal Wear MeasurementSeal Wear Measurement
SAP Duo Cone Seals automatically compensate for wear.
SAP PARTS has developed technology for Wear Re – countering Profile,
enables lapped metal seal faces automatically and continually renewed.
The mating faces form a contact band
around 0.5 to 1.0 mm wide that retains
the oil lubricant and seals out all foreign
material. As wear occurs, the contact
band will widen slightly and migrate
inward until the inside diameter is
reached. As shown in the figure, the seals
wear down the spherical radius.
Remaining life can be easily estimated by visual inspection of the seal band location. Remaining wear life can be
estimated based on a linear relationship of service hours and contact band position.
Physical measurement of wear can be determined by measuring the distance between the sealing contact band
and the inner diameter of the sealing ring. To calculate the wear life remaining on the seal, measure the distance
between the seal inner diameter and the sealing contact band. If this distance is greater than 50% of the distance
between the seal inner diameter and outer diameter, there is adequate seal life for this seal to be reused.
Formed seals are more flexible than the cast rings they replace and, as a result, produce a wear pattern different
than cast ring designs. Typically, formed seals wear in an axial rather than radial direction, as depicted below, due to
their increased flexibility.
The total thickness of the flange is usable wear material on the formed seal rings, and good seal performance can
generally be expected until the flange is completely worn away. Measuring the ring flange thickness and using the
chart below can estimate remaining service life. Minimum flange thickness required for usability is 1.27mm
With formed seal rings, the measured parameter used to check the remaining seal life is flange thickness at the
outer edge. The measurement must be made carefully since the shoulder is only 1.52 mm from the edge of the
flange. Estimates of expected seal life are difficult because there are many differences in machine applications,
job conditions, maintenance and other factors that affect seal service life.
Formed Seal Wear Chart
Flange Thickness Seal Wear
mm % Worn
1.91 0
1.59 25
1.27 50
0.95 75
0.64 100
0.32 125
0.00 150

Lubricant RequirementsLubricant RequirementsLubricant RequirementsLubricant Requirements
Because the dynamic sealing surfaces are metal, lubricant is always required on the inside diameter of the seals. Oil
lubricant should be used with all Mechanical face, Duo Cone Seals. A detergent type SAE 10W-40 is the
recommended lubricant type. However, other mineral base oils ranging from 10WT to 90WT are commonly used,
depending on ambient temperature requirements. EP gear lubricants should be used with caution, as some EP
additive packages are incompatible with silicone torics.
In some slow rotating or oscillating applications, certain types of grease may be used, but mineral base oils are
always preferred. Grease is not recommended in applications where the seal face surface speed exceeds 30.5 mpm
Oil not only provides lubrication to the sealing faces, but also serves to cool the seal rings. Lubricant must cover a
minimum of one third of the sealing surface to properly lubricate and cool the rings. Mechanical face, Duo Cone
Seals work best in clean, closed systems. To allow adequate volume for thermal expansion, closed cavities should
not be filled more than 90% full. Maximum care should be taken to insure lube cavities are clean at assembly – free
from dirt, scale and other foreign materials. Cleanliness levels of 500mg mass per square meter of surface area and
a maximum particle size of 1.0mm should be maintained at assembly to provide maximum life.
Specialty SealsSpecialty SealsSpecialty SealsSpecialty Seals
SAP PARTS not only offers “off-the-shelf” designs – its engineering team is also
available to work with your engineers to design ‘non-standard’ metal face seals.
Whether developing a new seal size or type to fit your application, or utilizing a new
metal seal or O-Ring material, SAP PARTS engineers have the experience necessary to
design, procure and test these concepts and follow them to production.

SAP PARTS’ UNIQUE SEAL LIFESAP PARTS’ UNIQUE SEAL LIFESAP PARTS’ UNIQUE SEAL LIFESAP PARTS’ UNIQUE SEAL LIFE TESTINGTESTINGTESTINGTESTING
The Seal Life , Leakage & Endurance Test Rig is designed to
1. Test the Possible Oil Leakage from the seals in
assembled condition inside the housing.
2. Test the seal wear pattern and face load experienced by
the seal while on run.
3. Test the life of the seal to an extent of maximum wear
causing failure
For this testing, there is an arrangement made in the Test
Rig, to hold the housings or similar grooved flanges in which the seals fits. There are two halves of Housing flanges
holding the seals in as like actual assembled conditions which are posted on two axial spindles in front of each
other.
One being stationary which has the load cell in linear axis that can record the desired load applied when seal
surfaces meet each other. Another flange is mounted on the moving spindle of which the RPM can be controlled by
a frequency drive. The cavity formed by the seals in
assembled condition contains the Oil, the pressure
and temperature of it can be controlled by the
hydraulic system and heaters and thermocouples.
There are various controls of each constituent system
on the Control panel which can indicate and record
the intervals of test and the parameters associated.
Collectively the seal in assembled condition is put for
test for various test with a set force and the respective
face load is monitored. The test is taken at various
intervals of 100 Hrs altering the Load, RPM, Oil
Pressure, Temperature , ambient conditions , and in
presence of Mud ( Kantalome:i7 Grade) for 500,
1000,2000 Hrs respectively, based on the test plan for
the particular seal.
Customer Specific SEAL Design & Development:Customer Specific SEAL Design & Development:Customer Specific SEAL Design & Development:Customer Specific SEAL Design & Development:
SAP PARTS have set Design Guidelines for Duo Cone Seals. SAP PARTS furnish Design Input Data Sheet to
Customers and get maximum application and service condition inputs from them. Its Design Team study and
analyze this data with its existing database and considering application suggest a proto design marching to the
requirement . SAP PARTS categorically focus on the Rubber Ring Compression Set and set Force needed to fit the
Seals in Assembly. For this SAP PARTS have Seal Face Load Determination Test Rig as a part of its Design Validation
Process from which SAP PARTS collect information to Plot set Force against the Gap distance between the housings
likely to be in actual operations at the customer end. In the design Data input sheet you can identify SAP PARTS ask
your Housing Groove Profile . If it is not given SAP PARTS determine it based on its knowledge bank and suggest
you .
Functional Test LabFunctional Test LabFunctional Test LabFunctional Test Lab CapabilitiesCapabilitiesCapabilitiesCapabilities
SAP Parts Precision Seals has a fully operational functional test laboratory located at its facility in PUNE ,INDIA.
SAP PARTS utilizes this lab for customer support and the development and validation of new seal designs. The lab
equipment is designed to effectively simulate the operating variables that impact the performance of metal face
seals. A number of different tests are available.

Seal abilitySeal abilitySeal abilitySeal ability and Scoring Resistanceand Scoring Resistanceand Scoring Resistanceand Scoring Resistance
(Pressure vs. Velocity Testing)(Pressure vs. Velocity Testing)(Pressure vs. Velocity Testing)(Pressure vs. Velocity Testing)
Sealability tests evaluate the seal’s ability to operate under certain conditions. Scoring resistance tests are run to
determine a metal seal ring material’s resistance to scoring/galling of the seal faces. The seal is assembled to match
the operating conditions found in the application. This includes seal face loads, internal operating temperatures,
internal operating pressures, rotational speeds, etc.
Load (Load vs. Deflection) TestingLoad (Load vs. Deflection) TestingLoad (Load vs. Deflection) TestingLoad (Load vs. Deflection) Testing
Load deflection tests evaluate the loading characteristics of the
elastomeric ring for a given size. This information is used to effectively
determine the O-Ring compression required to obtain optimal loading on
the metal seal faces.
Wear (Mud Box) TestsWear (Mud Box) TestsWear (Mud Box) TestsWear (Mud Box) Tests
Wear testing utilizes mud box equipment to evaluate a metal seal ring
material’s resistance to abrasive wear. Seals are assembled, the seal cavity
is filled with oil, and the seal exterior is exposed to mud slurry. Test cycles
are run to accelerate the wear process. Wear is quantified by the amount
of movement of the sealing band during the test.
Oil Compatibility TeOil Compatibility TeOil Compatibility TeOil Compatibility Testing (sting (sting (sting (Compression SetCompression SetCompression SetCompression Set, Heat Resistance, etc.), Heat Resistance, etc.), Heat Resistance, etc.), Heat Resistance, etc.)
Oil compatibility tests can be run to evaluate the elastomeric O-Ring
material’s compatibility with oils or greases that may be used in your
application. A compression set test is the most common test run to
evaluate these characteristics.
O-Ring specimens are compressed and held at a specific amount of
compression while exposed to the oil and high temperatures for long periods of time. At the conclusion of the test,
the amount of permanent set of the O-Ring materials is recorded.
Quality AssuranceQuality AssuranceQuality AssuranceQuality Assurance
SAP PARTS has a fully functional Quality Assurance laboratory. Equipment includes two Exclusive and unique test
Rigs for Life Testing, Validation and Face load estimation of the duo cone seals and state-of-the-art surface finish
analyzer, Monochromatic Optical Prism to identify flatness accuracy at light bands level.
Solutions To SEALSolutions To SEALSolutions To SEALSolutions To SEAL Failure ModesFailure ModesFailure ModesFailure Modes
While Mechanical face, Duo Cone Seals generally perform very satisfactorily, premature failure can occur for a
number of reasons but can be avoided or minimized through proper seal design and/or installation.
Uneven or Excessive Face LoadUneven or Excessive Face LoadUneven or Excessive Face LoadUneven or Excessive Face Load
This results from improper seal assembly. Either the seal ring is tilted in the assembly or the toric is twisted. Both
result in uneven face loads circumferentially around the seal face. This can cause the seal rings to either separate,
allowing oil
to flow outward, or gall from localized high face load.
Mishandling of SealsMishandling of SealsMishandling of SealsMishandling of Seals
Mishandling of seals during assembly can cause immediate leaks or premature failure. Failure can occur due to
cutting or tearing of the elastomeric load ring, breakage of the sealing ring, contamination of the seal face with dirt
or lint, etc.
When assembling Mechanical face, Duo Cone Seals, please carefully observe assembly instructions provided by SAP
PARTS.
Internal Pressure SpikesInternal Pressure SpikesInternal Pressure SpikesInternal Pressure Spikes
Mechanical face, Duo Cone Seals can withstand a varying amount of internal pressure, depending on the design.
Generally, internal pressure should be maintained below 1.0-1.7 Bar to guarantee satisfactory sealing performance.
If your application exceeds these requirements, please consult SAP PARTS’ engineering staff for further information.
Improper Housing DesignImproper Housing DesignImproper Housing DesignImproper Housing Design
EVEN
PRESSURE
1
2
3
1. SEAL
2. O−RING
3.SEAL HOUSING.

It is critical that the application seal housing conform to the design information provided by SAP PARTS. The
relationship between the seal assembly and its mating component is critical to the acceptable performance of the
sealing system.
Improper Use of OilImproper Use of OilImproper Use of OilImproper Use of Oil
Selection of improper oil can cause premature failure due to degradation of both the elastomeric O-Ring and metal
sealing ring. Some oils are incompatible with elastomers and cause long-term degradation with exposure, especially
when combined with heat. Improper oil usage can cause metal seal failure due to scoring from inadequate
lubrication flow.
Mud PackingMud PackingMud PackingMud Packing
Mud packing can be a problem in environments where the Mechanical face, Duo Cone Seals is continually exposed
to
dirt and mud. Mud can pack the cavity between the seal housing, seal ring and load ring. Over time, this can cause
the O-Ring to be pushed out of position, resulting improper face loads or mud being pumped past the load ring.
Guarding arrangements are not highly recommended as they trap mud in. However, some are used for severe
applications such as landfills. In this case, it is recommended that a slotted design be utilized.
OOOO----RingRingRingRing AbrasionAbrasionAbrasionAbrasion
Abrasion of the O-Ring can occur in applications where it is exposed to abrasives such as dirt, sand and rocks.
Abrasion of the O-Ring causes deterioration and tearing of the elastomer, leading to failure. This can be minimized
through proper O-Ring material selection.

SAP PARTS’ Mechanical Face Seals ManufacturingSAP PARTS’ Mechanical Face Seals ManufacturingSAP PARTS’ Mechanical Face Seals ManufacturingSAP PARTS’ Mechanical Face Seals Manufacturing ProcessProcessProcessProcess Control:Control:Control:Control:
Q C D Units OD <100 OD: 100 -200 OD:200 -300 300 <OD
OUTSIDEDIAMETER mm ±0.300 ±0.500 ±0.500 ±0.8
INSIDEDIAMTER mm ±0.300 ±0.500 ±0.500 ±0.8
TOTAL WIDTH mm ±0.300 ±0.300 ±0.300 ±0.500
TOTAL WIDTH mm ±0.100 ±0.200 ±0.200 ±0.300
TOTAL WIDTH mm ±0.100 0.200 0.300 0.300
O-RING GRROVEDIAMETER mm ±0.3 ±0.3 ±0.5 ±0.5
SMALL DIAMTER mm ±0.3 ±0.4 ±0.4 ±0.5
TRACK DIAMETER mm ±0.3 ±0.25 ±0.5 ±0.5
RAMP ANGLE DEG ᑻ Min ' ±30' ±30' ±30' ±30'
SURFACEROUGHNESS OF TRACK Ra
FACEDISTORTION Max mm 0.150 0.200 0.250 0.300
OVALITY Max mm 0.300 0.400 0.800 1.000
HARDNESS HRC-62
MICROSTRUCTURE
SPHERERADIUS mm
SURFACEFINISH Ra
6 FLATLAPPING
48"Flat Bed Lapping
Machine
3 3 2 FLATNESS mm 0.01 0.02 0.03 0.04
FLATNESS mm 0.005 0.01 0.015 0.02
SURFACEFINISH Ra
1 2 3 Q C D
LOW MEDIUMHIGH QUALITY COST OUTPUT
MACHINE
COMPETITIVE
ADVANTAGEOF
PROCESS
CRITICAL PARAMETER/S
SEAL OD RANGE: Tolerances
Duo Cone Seal Manufacturing - Quality Control of Critical Process Flow
SRNO PROCESS
3
2
1 FORGING
RingRollingForging
Setup
3 2 3
2 PRE-TURNING Centre Lathe Machine 2 1
3 2
2.500 ~6.300
4 HEATTREATMENT
Contineuous Mesh
belt furnace with
Atmosphere Control &
Cryogenic treatment
3 2 3
±3
Fine Tempered Martensite
3 CNC MACHINING CNC TurningCentre 3 2
INDEX
±100
0.400
7 DIAMOND LAPPING
Flat bed Diamond
LappingPolishing
Machine
3 3 1
0.030 ~0.080
5 SPHERICAL LAPPING
48"Spherical Bed R
2032 mm Lapping
Machine
3

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