Overview: This document is a comprehensive catalog of Koyo oil seals and O-rings, detailing their features, specifications, and applications. It is based on ISO, JIS, and JASO standards and includes insights from JTEKT and KOYO SEALING TECHNO's extensive experience and research.
Koyo Oil Seals:- Features: Lightweight, compact, energy-saving, high sealing performance due to optimized lip design, low heat generation, and long service life due to self-lubricating rubber materials.
- Design: Includes various types such as Perfect Seal, Helix Seal, and Super Helix Seal with hydrodynamic ribs for enhanced performance.
Koyo O-Rings:- Features: High sealing performance and reliability against various substances, available in diverse designs and sizes, and easy handling.
Koyo Functional Products:- Products designed to improve machine performance, reduce weight, size, noise, and vibration. Includes center bearing units, vibration isolating rubber bearings, and more.
FEM Analysis:- Utilizes Finite Element Method for analyzing non-linear materials like rubber, aiding in the development of new products and enhancing research and product development.
Technical Sections:- Oil Seals: Covers nomenclature, functions, selection, design, characteristics, handling, and failure countermeasures.
- O-Rings: Discusses classification, numbering systems, selection, technical principles, groove design, handling, and failure countermeasures.
Application Examples:- Includes applications in automobiles, motorcycles, rolling mills, geared motors, and hydraulic motors.
References:- Provides engineering data such as rubber-material properties, conversion factors, and tolerance tables.
Request Forms:- Includes forms for oil seal design and production requests.
Conclusion: The catalog emphasizes the importance of selecting appropriate seals and O-rings for specific applications and encourages consultation with JTEKT for custom solutions.
Seal Specifications and Numbering System: The document outlines the specifications for oil seals, including dimensions such as shaft diameter, housing bore diameter, and seal width. It introduces a seal numbering system used by Koyo, which includes codes for different seal types and features.
Common and Special Seal Types: Seals are categorized based on the outer diameter (O.D) wall material, lip type, and the presence of a spring. Common seal types are specified in ISO 6194 and JIS B 2402 standards. The document provides a table of Koyo oil seal type codes and their corresponding codes in ISO, JIS, and JASO standards. Special seal types are also discussed, including Perfect Seals, Helix Seals, and Super Helix Seals, each designed for specific applications and motion types.
Seal Selection Criteria: The selection of seal types is guided by operational conditions such as housing material, pressure, and peripheral speed. Flowcharts are provided to assist in selecting the appropriate seal type based on these conditions. The document also discusses the selection of rubber materials based on temperature conditions and the substances to be sealed.
Rubber Material Properties: Different rubber materials are evaluated for their operational temperature ranges and stability with various fluids. The document provides guidelines for the upper limits of normal operation temperatures for rubber materials when used with different oils.
Shaft and Housing Design: The document provides specifications for shaft design, including material, hardness, dimensional accuracy, and surface roughness. It emphasizes the importance of proper shaft design to ensure good sealing performance. Recommendations for shaft end chamfer and finishing methods are also provided to prevent seal damage and ensure effective sealing.
Housing Design:- Material: Steel or cast iron is preferred for housings. Aluminum or plastic requires careful consideration due to different linear expansion coefficients, which can lead to seal dislocation or leakage.
- Dimensional Accuracy: Housing bore tolerance should be H7 or H8 for bores up to 400 mm, and H7 for larger bores.
- Chamfer: Chamfers should be provided at the housing bore inlet to facilitate seal mounting and prevent damage.
- Housing Shoulder Diameter: Specific dimensional requirements must be met if the housing bore has a shoulder.
- Surface Roughness: Bore surface should be finished to specified roughness to ensure proper seal seating and prevent leakage.
Total Eccentricity:- Total eccentricity, the sum of shaft runout and housing-bore eccentricity, affects sealing performance. It is expressed in TIR (Total Indicator Reading).
- Allowable total eccentricity depends on seal characteristics, shaft diameter tolerance, temperature, and rotational speed.
Seal Characteristics:- Sealing Property: Oil seals prevent fluid leakage by creating a pumping effect through the main lip shape and contact with the rotating shaft.
- Seal Service Life: Influenced by factors like temperature, eccentricity, rotational speed, and lubrication. Service life estimation is based on rubber material, lubricant, and lip temperature.
- Lip Temperature: Estimation involves calculating peripheral speed and considering ambient temperature.
- Allowable Peripheral Speed: Influenced by shaft runout and rubber material. It determines the speed at which sealing performance deteriorates.
- Allowable Internal Pressure: Dependent on shaft runout and housing-bore eccentricity.
- Seal Torque: Determined by lip radial load, coefficient of friction, and shaft diameter. Initial torque may be high but stabilizes over time.
Handling of Seal:- Storage: Proper storage conditions are crucial to prevent oil leakage. Store seals in air-conditioned environments with temperatures not exceeding 30°C and humidity between 40% and 70%. Use older seals first and avoid direct sunlight, ozone, and mechanical damage. Seals should not be stacked or hung to prevent deformation.
- Mounting: Before mounting, ensure seals are clean and undamaged. Apply suitable lubricant to the seal lip. Use lithium-based grease for lubrication, avoiding silicone or urea-based greases for specific rubber types. In cold areas, warm the seal before mounting. Ensure the shaft edge is chamfered to prevent damage during installation.
- Handling: Avoid excessive impact and use kerosene for cleaning. Do not use corrosive fluids or hang seals by wires, which can cause deformation.
- Press-Fitting: Use appropriate jigs for press-fitting seals into housing bores. Ensure seals are mounted at right angles to prevent leakage. Refer to diagrams for required pressing loads based on seal dimensions.
- Seal Failures and Countermeasures: Common causes of seal failures include improper handling, excessive pressure, and poor lubrication. Countermeasures involve correcting shaft chamfers, improving lubrication, and using high-pressure proof seals. Tables provide detailed causes and solutions for various seal failure symptoms.
Specifications and Standards:- Oil seals are categorized by type, including standard and special seals, with dimensions ranging from d1 6 to d1 3,530.
- Rubber materials used include nitrile, acrylic, silicone, and fluoro rubber, each with specific applications and limitations.
- Seal numbers are constructed using type codes and dimensional numbers, indicating bore diameter, outside diameter, and width.
Common Symptoms and Phenomena:- Lip Deformation: Caused by rubber hardening and oil temperature rise. Countermeasures include using high-temperature proof rubber and examining temperature increase causes.
- Lip Face Contact: Issues like excessive inside pressure and shaft runout require structural changes, clearance adjustments, and shaft accuracy improvements.
- Blistering: Due to high-temperature oil agglomeration, requiring improved lubrication and shaft surface finish corrections.
- Oil Leakage: Often results from improper seal dimensions, surface finish, or mounting direction. Solutions include correcting bore diameter, replacing seals, and improving surface finishes.
Causes and Countermeasures:- Detailed tables list symptoms, phenomena, causes, and countermeasures for various seal failures, emphasizing the importance of correct dimensions, material selection, and installation techniques.
- Common causes include improper housing bore dimensions, poor lubrication, and incorrect seal mounting.
- Countermeasures focus on improving material properties, adjusting dimensions, and refining installation processes.
Dimensional Tables:- Tables provide boundary dimensions for different seal types, indicating the range of sizes available for various applications.
- Specific dimensions are provided for metal and rubber O.D wall seals, with notes on production capabilities and inventory considerations.
Conclusion: The document serves as a technical guide for diagnosing and addressing oil seal failures, emphasizing the importance of proper material selection, dimension accuracy, and installation practices to ensure optimal performance and longevity of seals in machinery.
Standard Types: The document lists standard oil seal types such as HM, HMA, HMS, HMSA, MH, MHA, MHS, and MHSA. It provides boundary dimensions for bore diameter (d1) ranging from 70 to 670 mm, with specifications for metal and rubber outer diameter walls.
Material Codes: The rubber codes are defined as N for nitrile rubber, A for acrylic rubber, S for silicone rubber, and F for fluoro rubber. These codes are used to specify the material composition of the seals.
Production Details: JTEKT owns molding dies for seals marked with a dot (●), indicating their capability to produce these seals. The document advises consulting JTEKT for inventory, delivery, and production lot information.
Seal Number Construction: Seal numbers are constructed using a combination of type code and dimensional numbers, which include bore diameter, outside diameter, and width. An example provided is HMSA55729 (55✕72✕9 mm).
YS Type Seals: This section covers YS type seals with dimensions ranging from 220 to 1,000 mm. It includes additional material codes such as K for hydrogenated nitrile rubber and provides examples of seal numbers with spacers.
Spacer Information: Seals with spacers are available, and the document provides examples of seal numbers with spacer widths, such as 5 mm and 10 mm.
Key Recommendations: For specific inventory and production details, it is recommended to consult JTEKT directly. The document emphasizes the importance of selecting the correct material code based on the application requirements.
Oil Seals: The document outlines specifications for oil seals, including full rubber seals and MORGOIL seals. It specifies the use of nitrile rubber for all seals and provides mounting width deviations based on size. The document includes boundary dimensions and seal numbers for different types of oil seals.
MORGOIL Seals: These seals are detailed with boundary dimensions and design variations. The document specifies the use of nitrile rubber and includes special type codes for seals with steel bands or wires.
Scale Seals: Specifications for scale seals include boundary dimensions, fixing holes, and special remarks about the use of nitrile rubber and consultation for drain-provided seals. The document provides detailed tables for scale seal dimensions and fixing hole specifications.
Water Seals: The document provides specifications for water seals, including boundary dimensions and seal types. It highlights the use of nitrile rubber and provides examples of seal number construction.
V-rings: Specifications for V-rings include mounted dimensions, boundary dimensions, and shaft diameter. The document specifies the use of nitrile rubber and provides detailed tables for V-ring dimensions.
O-Rings: The document covers the classification of O-rings and backup rings, detailing their application in various industries such as general industrial machines, automobiles, and aircraft. It provides a guide for O-ring materials, selection criteria, and technical principles. The document also includes guidelines for fitting groove design, handling, and typical failures.
Key Recommendations: The document emphasizes the importance of using nitrile rubber for all seals and provides specific mounting width deviations. It also highlights the need for consulting JTEKT for certain seal types and provides detailed tables for dimensions and specifications.
O-Ring Classification and Application Guide:- Material Resistance: The document outlines the resistance of various O-ring materials to different substances, including mineral oils, gasoline, animal and vegetable oils, and brake fluids. It categorizes materials based on their resistance to high temperatures and other conditions.
- Material Classes: O-rings are classified into different classes such as JIS NBR-70-1, NBR-90, and FKM-70, each with specific applications and resistance properties.
- Applications: O-rings are used for dynamic use, static sealing, vacuum flanges, and slim static sealing. The document specifies which materials are suitable for each application.
Backup Rings:- Purpose: Backup rings are used with O-rings to prevent extrusion from the groove, especially under high pressure.
- Types and Materials: Backup rings come in spiral, bias-cut, and endless designs, made from tetrafluoroethylene resin, which is chemically stable and corrosion-resistant.
- Applications: Different designs are recommended based on pressure and temperature conditions, with specific guidelines for installation.
O-Ring Numbering Systems:- Designation Numbers: O-ring and backup ring designation numbers consist of material, application, and dimensional codes, providing a standardized way to identify and select the appropriate O-ring.
Selection of O-Ring:- Material Selection: The document provides guidance on selecting O-ring materials based on chemical stability with the substances they will contact.
- Cross Section Diameter: Recommendations are given for the compression rate of O-rings to ensure effective sealing without permanent deformation.
Technical Principles:- Deformation Under Pressure: O-rings provide a self-seal through elasticity at low pressure and better sealing at higher pressure. Backup rings are recommended for high-pressure applications to prevent extrusion.
- Backup Ring Installation: Guidelines for installing backup rings to extend O-ring service life and prevent damage are provided.
O-ring Technical Principles:- Sealing Mechanism: O-rings are used for sealing under various pressure conditions. Proper installation is crucial to prevent slack, especially for large O-rings. For sizes 150 mm or more, a slightly smaller O-ring may be used to ensure proper compression.
- Static Sealing: For cylindrical surfaces, groove accuracy is critical. For flat surfaces, the O-ring compression should be slightly larger. In vacuum applications, careful machining and material selection are necessary.
- Installation in Triangular Grooves: The groove dimension should be 1.3 to 1.4 times the O-ring cross-section diameter.
Fitting Groove Design:- Compression Amount and Rate: The compression rate should be between 8% and 30%. The groove width should ensure the O-ring occupies no more than 90% of the space.
- Extrusion and Surface Roughness: The gap and pressure influence extrusion. Surface roughness should meet specified standards to ensure sealing performance.
- Material and Surface Finishing: Steel is recommended for dynamic sealing applications. Surface finishing methods include honing and hard-nickel plating for durability.
Handling of O-rings:- Storage: Store O-rings away from sunlight, heat, and ozone. Maintain a temperature below 30°C and humidity below 65%.
- Handling: Avoid reusing O-rings. Apply lubricant during installation and avoid twisting. Protect O-rings from sharp edges and cleaning oils.
O-ring Failures and Countermeasures:- Common Issues: Twisting, chipping, permanent set, abrasion, hardening, swelling, scratching, protrusion, tearing, and ozone cracking.
- Solutions: Improve installation techniques, use appropriate materials, and ensure proper groove dimensions and surface finishes.
Specifications:- Materials: The O-rings are made from various materials including JIS NBR-70-1, NBR-90, EPDM-70, EPDM-90, VMQ-70, FKM-70, FKM-90, HNBR-70, HNBR-90, ACM-70, and SBR-70. These materials are not standardized in the JIS.
- Dimensional Tolerances: The tolerance for bore diameter d1 is specified in JIS B 2401 for certain materials, with variations for others like VMQ-70 and ACM-70 (1.5 times the standard) and FKM-70, FKM-90, HNBR-70, and HNBR-90 (1.2 times the standard).
Design Guidelines:- Static Sealing: For static sealing on flat surfaces, grooves should be designed according to dimension d8 for external pressure and d7 for internal pressure. This ensures the O-ring maintains close contact with the groove walls.
- Dynamic Sealing: Backup rings are recommended for dynamic sealing and static sealing on cylindrical surfaces to enhance performance.
- Eccentricity: Defined as the difference between the maximum and minimum values of dimension K, or double the coaxiality measurement.
Tables and Data:- The document includes extensive tables listing O-ring numbers, groove dimensions for both static and dynamic sealing, and corresponding fitting codes. These tables provide precise measurements for bore diameter, cross-section diameter, and groove dimensions.
Notes:- Design considerations for O-rings under different pressure conditions are emphasized to ensure optimal sealing performance.
- Backup rings are suggested for certain applications to prevent extrusion and improve sealing efficiency.
Specifications:- O-ring Dimensions: The document lists various O-ring numbers with corresponding groove dimensions for static sealing on flat and cylindrical surfaces. It specifies bore diameter (d1), cross-section diameter (d2), and groove dimensions (d3, d5, d8 for external pressure and d4, d6, d7 for internal pressure).
- Material Specifications: O-rings are made from materials such as JIS NBR-70-1 and FKM-70, with specific tolerances for each material type.
Procedures:- Design Guidelines: For static sealing on flat surfaces, grooves should be designed according to dimension d8 for external pressure and d7 for internal pressure. This ensures proper contact between the O-ring and the groove walls.
- Compression Rate: The groove depth (K) should be determined to achieve an O-ring compression rate between 8% and 30%.
Norms and Standards:- Fitting Codes: The fitting codes correspond to the tolerances of d4 and d6 dimensions, ensuring proper fit and function of the O-rings.
- Old ISO 3601: The document references the old ISO 3601 standard for general industrial applications, specifying dimensions and tolerances for O-rings.
Recommendations:- Backup Rings: For dynamic sealing and static sealing on cylindrical surfaces, the use of backup rings is recommended to enhance sealing performance.
- Eccentricity Measurement: Eccentricity (E) is defined as the difference between the maximum and minimum values of dimension K, or double the coaxiality measurement, which should be minimized for optimal sealing.
Key Data from Tables:- The tables provide detailed dimensions for various O-ring sizes, including bore diameter, cross-section diameter, and groove dimensions for both static and dynamic sealing applications.
- Specific tolerances are provided for each dimension to ensure proper fit and sealing performance.
Specifications:- O-ring Dimensions: The document lists various O-ring sizes with specific cross-section diameters (d2) and bore diameters (d1), along with tolerances. Materials include JIS NBR-70-1, NBR-90, and FKM-70.
- Backup Ring Dimensions: Backup rings are specified with dimensions for spiral, bias-cut, and endless rings, made from tetrafluoroethylene resin. The document provides detailed measurements for each type.
Procedures:- O-ring Installation: Guidelines are provided for determining groove depth (K) and width (b) to ensure proper compression rates and occupancy percentages. The radial gap should be minimized as per specified values.
- Backup Ring Installation: Instructions include maintaining specific cut angles and thickness deviations for bias-cut and endless rings.
Standards and Norms:- The document references JIS B 2401 standards for bore diameter tolerances and material specifications.
- It also mentions specific tolerances for different materials, such as VMQ-70 and ACM-70, which have different tolerance multipliers.
Recommendations:- For FKM-70 products, consultation with JTEKT is advised for specific tolerance values.
- Ensure that O-rings do not occupy more than 90% of the groove space to maintain functionality.
Application Examples:- Automobile: Includes applications in automatic and manual transaxles, engines, and electric power steering systems.
- Motorcycle: Focuses on engine applications.
- Rolling Mill and Stock Axles: Discusses the use of rolling bearings and oil-film bearings.
- Hydraulic and Geared Motors: Provides examples of seal applications in these systems.
Introduction: This document provides technical specifications and application examples for various types of seals and O-rings used in different mechanical systems, such as motorcycles, rolling mills, rolling stock axles, geared motors, and hydraulic motors.
Application Examples:- Motorcycle Engines: Utilizes rubber-covered seals with minor lips for effective sealing.
- Rolling Mill Roll Necks: Employs scale seals, water seals, and large-size oil seals for oil-film bearings and rolling bearings.
- Rolling Stock Axles: Features metal ring integral seals with reinforcement rings for double row cylindrical and tapered roller bearings.
- Hydraulic Motors: Uses pressure-resistant seals and rubber-covered seals without springs.
- Geared Motors: Incorporates rubber-covered seals with minor lips and sludge lip integral rubber-covered seals.
Material Properties:- Rubber Material Varieties: The document compares properties of various rubber materials, including Nitrile Rubber (NBR), Hydrogenated Nitrile Rubber (HNBR), Acrylic Rubber (ACM and ANM), Silicone Rubber (VMQ), and Fluoro Rubber (FKM).
- Properties: Each material is evaluated based on specific gravity, Mooney viscosity, hardness, tensile strength, elongation, temperature range, and resistance to various chemicals and environmental conditions.
Standards and Conversion Tables:- SI Units and Conversion Factors: Provides conversion tables for various units of measurement, including length, area, volume, mass, force, pressure, and more.
- Shaft and Housing Tolerances: Details the deviation classes for shaft diameters and housing bore tolerances, ensuring precise fitting and performance.
References: The document references Japanese Standards Association and Society of Rubber Industry, Japan, for guidelines and handbooks on rubber material selection and industry standards.
Summary of Technical Document:
Specifications:- This section outlines the nominal shaft and bore diameters, along with their respective tolerance classes. It includes detailed tables specifying the permissible deviations for various diameter ranges, ensuring precision in manufacturing and assembly processes.
Procedures:- The document provides guidelines for calculating temperature conversions between Celsius and Fahrenheit, as well as viscosity conversions using different scales such as Saybolt, Redwood, and Engler. These procedures are crucial for ensuring accurate measurements in engineering applications.
Standards:- Standards for steel hardness conversion are detailed, including Rockwell, Vicker's, and Brinell scales. This ensures consistency in material properties across different measurement systems.
Recommendations:- Recommendations for shaft surface speed and rotational speed are provided, along with a quick reference diagram. This aids in selecting appropriate speeds for different shaft diameters to optimize performance and longevity.
Request Forms:- The document includes request forms for oil seal design and production, which require detailed information about the application, including dimensions, motion type, and environmental conditions. This ensures that the correct oil seal is selected for specific applications.
Key Data from Tables and Charts:- Tables provide critical data on permissible deviations for shaft and bore diameters, temperature conversion values, viscosity measurements, and steel hardness scales. These are essential for ensuring compliance with engineering standards and optimizing component performance.
Conclusion: This technical document serves as a comprehensive guide for engineers and manufacturers, providing essential specifications, procedures, and standards necessary for precision engineering and manufacturing processes.
Specifications:- Mounting Direction: The oil seal can be mounted in X/Y direction into housing and A/B direction onto the shaft. The shaft can rotate in Right, Left, or Bi-direction.
- Rotational Direction: Clockwise when viewed from the air side face of the oil seal and counterclockwise from the same perspective.
Mounting Specification:- Direction: Right and Left options are available.
- Internal/External: Options for internal and external mounting are provided.
Design and Production Request Form:- Shaft Diameter: Changeable with specified maximum and minimum values.
- Oil Seal Type: Specify if the requested type is available.
- Housing Bore Diameter: Changeable with specified maximum and minimum values.
- Rubber Material: Specify if the requested type is available.
- Width: Changeable with specified maximum and minimum values.
- Oil Seal Life: Specify the requested lifespan.
- Mounting Location Details: Attach a drawing if possible.
Contact Information: Head Office/Plant located at No.39, Aza-nishino, Kasagi, Aizumi-cho, Itano-gun, Tokushima 771-1295, JAPAN. Contact via TEL: 81-88-692-2711 or FAX: 81-88-692-8096.
Product Information: Oil Seals & O-Rings, Catalog No. R2001E-4, printed in Japan.
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