O Ring Guide Superior

TECHNICAL GUIDE
FOR PRECISION MOULDED SEALS
DESIGN. DEVELOP. IMPROVE.
THE SUPERIOR TECHNICAL GUIDE
THE SUPERIOR
TECHNICAL GUIDE
We believe that this latest edition of the guide will become an

invaluable resource for anyone involved in the specification and
application of elastomer seals. We have not designed it to be a
catalogue, but a reference to guide you through the relevant
selection and design processes.
It will become clear as you use the guide that we are not in the business of commodity production.
Superior manufactures precision components from specialised high performance rubber compounds.
As a result, we actively seek the most demanding customers. We relish involvement at the earliest
point in their product development cycle. And its the customer who benefits most: more effective
application of seals means better product design everyone wins.
To this end, we have committed to a culture of continuous, aggressive improvement in the design,
manufacture and supply of precision O rings and special mouldings.
We like to exceed expectations. Innovation and Investment are the keys to this.
Natural curiosity and the desire to find better processes and methodologies feeds the Superior
promise to innovate.
Re-investment in state-of-the-art facilities and valued, accountable people increases our ability to
convert ideas into production reality.
This guide is a part of that investment. Use it with confidence. It is fully backed by both our
Engineering and Technical Service teams who are on hand to offer advice and support: we strongly
recommend using these services as part of your design development process. You will find the contact
number at the foot of each page.*
*These services have been developed with you in mind. If you have any issues or comments arising from them,
please contact us in the first instance.
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CONTENTS
03 Research, Development
20 Bespoke Seal Design
and Partnership
Precision Mouldings / Bespoke Seals
Consultation
Seal Integrity
Testing
Seal Performance
Optimising
Development of a Seal Profile
Tooling
Staying Ahead
22 Quality
Standards Compliance
04 Specifying Compounds
Important Environmental Parameters
Temperature
Approvals
Media Compatibility Rating
O ring Size Range Standards

Quality Acceptance Criteria ISO 3601-3
Limits of Surface Imperfections
Quality Control: Documentation
Seal Surface Inspection Levels
Materials Reference Guide
Special Moulding Tolerances
Elastomer Properties
Certification
Hardness
Environmental Compliance
Compression Set
Ageing
Low Temperature Flexibility
Fitting Aids
Tensile Strength
O ring Stretching for Assembly
Elongation
Cleanliness/Cleaning Materials
Tear Strength
Preparation of Housing/Mating Parts
Gas Permeability
Light
Abrasion
Humidity
Colour
Contaminants
Media Table
Producing an Order Specification
13 Seal Design
Introduction
Precision O rings
Sealing Types
Groove Layouts
Static Sealing Axial and Triangular
Static Axial Face Housing
Static Triangular Housing
Static/Dynamic Sealing Radial
O ring Stretch in Piston Sealing
Reduction of Cross-Section due to Stretch
Gough-Joule Effect
O ring Size & Compound Selection Program
Pressure
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25 Assembly, Care and Storage
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Stress
Temperature
Oxygen and Ozone
Shelf Life
28 Going Forward
RESEARCH, DEVELOPMENT AND PARTNERSHIP
RESEARCH, DEVELOPMENT AND PARTNERSHIP:

A RELEVANT APPROACH TO DESIGN
FOR TODAYS MANUFACTURING
CONSULTATION
We actively encourage and cultivate early involvement in customer projects. This helps to ensure
that the seal element is optimised within the environment demanded by the customer. This ensures
that our products are reliable, fit for purpose, correctly specified with all critical features identified,
controlled and costed at an appropriate and agreed level.
TESTING
We control all aspects of seal test and development programs closely with our customers.
All testing procedures are carried out under ISO 9001 accreditation.
We offer a diverse range of compounds, to satisfy the vast majority of market needs.
If a customer has specific working parameters that cannot be met within our existing elastomer
range, we will develop new compound grades at our in-house laboratory even for unique needs.
We are able to conduct extensive test programs to fully validate specific elastomers to customer
parameters (eg, temperature/media exposure and mechanical property testing).
Customer Service lies at the heart

of everything we do at Superior.
Also we will validate to specific accreditation standards (eg, EN681, WRAS, DVGW, ACS, KIWA,
NSF, EN 549).
Our philosophy is based upon three

key constituents:
OPTIMISING
Material Science & Technology
and application.
Seal Engineering
State-of-the-Art Manufacturing
The combination of these 3 factors

provides the high integrity of our
precision O rings and seals and in turn
provides the long term performance
and high integrity in our customers
products. Our fast response culture
is applied to each individual factor to
help reduce our customers overall
project lead time.
Through the customer partnership exchange, we can assist with optimised seal profile design
TOOLING
Our Tooling Manufacture Department designs and machines precision prototype and production
moulds to exceed conventional tolerancing. Pilot tooling can be provided economically and rapidly
to further expedite customer test programs.
With our extensive tooling expertise, we can optimise critical surface features to facilitate reliable
function with mating parts.
STAYING AHEAD
Our continuous capital investment program allows us to remain at the leading edge of our field.
We continually implement latest technology systems, ensuring batch-to-batch consistency
throughout the manufacturing process.
With such broad customer support facilities, Superior will always strive to provide added value
with our customer programs.
Indeed, we find that each new project challenges our thinking and creates a springboard to
increasingly enlightened manufacturing practices.
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SPECIFYING COMPOUNDS
IMPORTANT ENVIRONMENTAL PARAMETERS
TEMPERATURE
At Superior we are able to develop and manufacture the

majority of elastomer compounds used in most market sectors.
Awareness of specific limitations on each elastomer is fundamental, in terms of both mechanical and
chemical characteristics.
The most relevant influential working criteria should then be carefully matched to elastomer parameters.
Only then is it possible to achieve accurate selection of the most suitable elastomer for any given
environmental condition.
Please refer to the Media Table on page 6.
Terms and environmental aspects related to working with compounds, are highlighted in the
following pages.
Each elastomer type has a specific working temperature range, assuming media compatibility
is optimised.
The temperature guide below is generic
All dynamic and shock loads should be avoided at temperatures below the minus limit of a
for each elastomer type. We have
given compound.
developed particular compounds
However, elastomers stored in static conditions, below the low temperature flexible range,
which exhibit improved upper or lower
will recover full physical properties during the warm-up period.
temperature performance. Please consult

our Technical Department.
At elevated temperatures, consideration must be given to the long term running limit and the
short term peak limit of each elastomer.
Elastomers exposed to the extreme limit can suffer an accelerated loss of flexibility, resulting in
excessive compression set. This can dramatically shorten effective sealing life. Also there is an
influence in volume swell and age hardening at high temperatures, dependant on compound type.
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APPROVALS
MEDIA COMPATIBILITY RATING
We are able to develop and provide a
Virtually all elastomers exhibit a physical or chemical change

when exposed to working media, whether gas or fluid.
comprehensive range of elastomers

specific for;
Water Industry:
WRAS, NSF, DVGW, KTW, ACS, KIWA, UL
Gas Industry:
The degree of change depends upon media composition in combination with the elastomer exposed.
Aggressive media become more active with subsequent increase in temperature. Physical changes
become apparent in two ways and can occur simultaneously;
EN549, EN682 Compliance
the elastomer absorbs a medium creating a volume increase or swell;
Food & Beverage Industry:
a base constituent (such as plasticiser) is extracted creating a volume decrease or shrinkage.
FDA, AAA, NSF51
The degree of volume change is dependant upon:
Pharmaceutical:
USP Class XI
the media type;

the elastomer chemical structure;
Please consult our Technical Department

for specific accreditations.
the geometric shape of the seal (section thickness);

the stressed condition of the seal;
temperature;
time.
A rubber will swell significantly less when compressed in the working envelope than in the free state
(up to 50% less).
Chemical changes tend to affect the cross-linking structure of the elastomer (eg, embrittlement).
Any application where the media can create high shrinkage changes to the elastomer should be
avoided, due to squeeze reduction and resultant leakage risk.
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MATERIALS REFERENCE GUIDE
Material
Nitrile
Butyl
Epichlorohydrin
Polyacrylate
Designation
NBR
IIR
ECO
ACM
Superior Elastomer Code
MN, LN, HN, WN, FN
BB
ECO
PA
Hardness Range (IRHD)
40 90
40 80
50 80
50 80
Colours
Limited Range
Black
Limited Range
Limited Range
120
130
135
150
Heat Resistance C
Peak
Normal
100
110
120
135
Low Temp C
-30
-50 low temp version
-50
-20
-20
Mineral Oil (low aromatic)
Oxidisation
Ozone
Weathering
Radiation
Tear Strength
Compression Set
Abrasion Resistance
Resilience
Gas Permeability
Resistances
Integrity
Electrical Insulation
Inflammability
Rating
Very Good
Good
Fair
Unsuitable
Data not available
It should be noted that the parameters

specified in this table illustrate the
typical working band of commercially
available elastomers. Material
development is constant and we are
able to assist, for parameters outside
of the stated values if required.
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Ethylene Propylene
Hydrogenated Nitrile
Ethylene Acrylate
Fluorosilicone
Silicone
Fluorocarbon
EPDM
HNBR
AEM
MFQ
MVQ
FPM
EP
TH
VA
FSIL
SIL
VF, VP
40 90
50 90
50 80
40 80
30 80
55 85
Limited Range
Limited Range
Limited Range
Limited Range
Full Range
Limited Range
160
170
175
230
230
250
140
150
150
200
200
200
-50
-40
-40
-55
-60
-20
-35 low temp version
Grade Dependant
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ELASTOMER PROPERTIES
To fully specify and select a compound, the most relevant

physical characteristics should be known, being:
HARDNESS
The term hardness is the measure of a materials resistance to a set deforming force exerted by
a given standard indentation implement over a defined length of time.
Hardness is measured in degree units of IRHD (International Rubber Hardness Degrees).
It is generally the unit of measure on standard dimensioned test pieces. It is also the unit used for
measuring the finished component (eg, O ring cross section) by the Micro Hardness Test.
Standard compounds are nominally 70 IRHD. Superior can however, provide compounds from
20-90 IRHD range, depending upon material type. Selection of hardness is dependant upon specific
application requirements.
For example:
Softer compounds
deform more readily under load (eg, cover/housing assembly) conform to surface irregularities
lower stick/slip effect
higher running friction
Harder compounds
higher extrusion resistance
lower running friction
higher stick/slip effect
The hardness is usually expressed and controlled as a nominal figure with 5 points tolerance.
COMPRESSION SET
This is the measurement of a compounds loss of elastic memory. A standard cylindrical test piece of
rubber is subjected to a deformed pre-load at given temperature/time parameters (eg, 24hrs/100C).
The test deformation is usually 25% of the original height.
The measured recovery of the cross-section is carried out at ambient temperature. The end result is
recorded as the height not recovered, expressed as a percentage of the amount by which the part
was compressed.
Usually it can be stated that the better the elastomeric memory, the lower is the compression set. This
is regarded as an important feature of any compound, as leakage will occur if high set (and therefore
loss of memory) occurs.
% Compression Set =
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original height recovered height

original height compressed height
x 100
AGEING
TENSILE STRENGTH
Heat ageing tests are widely used to record
This is the force necessary to rupture a standard test piece at a given rate of elongation and expressed
changes in property of an elastomer.
as force per unit area.
Usually, hardness, tensile strength and
In practical terms this property result does not assist the end user to select a compound, because
elongation are measured and compared to
a correctly assembled O ring does not rely on its tensile strength to achieve effective sealing.
original properties.
Air and relevant fluid ageing over standard
ELONGATION AT BREAK
time/temperature durations are meaningful
Elongation at break is measured at the moment of rupture of a test piece under tensile load
to compare life expectancies of rubbers.
expressed as a percentage.
Standard test conditions are:
This is a useful indication of a compounds suitability as a large percentage of stretch may be
NBR
necessary during assembly (eg, piston seal).
24/70 hrs @ 100C
EPDM 24/70 hrs @ 120C
TEAR STRENGTH
FPM
24/70 hrs @ 200C
Resistance to tear propagation from a point of initial damage, sustained for example during assembly.
MVQ
24/70 hrs @ 200C
GAS PERMEABILITY
If elastomers are pushed beyond their ageing
resistance parameters, they will suffer from
Elastomers allow gas to enter into the structure. They will diffuse or permeate through and escape via
cracking, splitting and/or hardening.
the low pressure side.
LOW TEMPERATURE FLEXIBILITY
critical for vacuum and gas containment.
The TR test (low temperature retraction)
To reduce permeability:
The rate of permeation is governed by temperature, pressure, gas type and elastomer type. This may be
provides a measure of the rate of recovery

of an elastomeric material after it has been
use larger O ring sections
subjected to low temperature.
apply more compression
The test, which is described in ISO 2921,
optimise surface finish
consists of stretching a dumb-bell test piece

with an effective length of 50 or 100mm
and placing it in a bath at -70C.
The test piece is allowed to retract freely
whilst the temperature is raised at the rate
select high-density elastomers.
ABRASION
Abrasion resistance is a general term indicating wear resistance.
of 1 degree C per minute.
It can be noted, generally, that HNBR compounds perform best.
The percentage retraction of the test piece
NBR, EPDM and CR have relatively good abrasion resistance. FPM has a lower abrasion resistance.
is plotted against temperature.

Retraction values are calculated automatically
Abrasion resistance improves with hardness (up to 80 IRHD). However, Silicone and Fluorosilicone
have poor properties and should only be applied to static environments.
with TR10, TR30, TR50 and TR70 values being

most commonly recorded.
TR10 and TR70 values are of particular interest.
COLOUR
Rubbers are usually formulated with the addition of carbon black fillers. Hence, the majority of
compounds are black in colour. Rubbers gain much of their strength and heat resistance from the
TR10 values correlate with brittle points
addition of carbon black fillers.
in vulcanizates based on polymers of a

similar type.
However, at Superior we have the expertise to formulate and produce colour pigmented compounds
for most of the elastomer range.
TR70 values correlate well with low

temperature compression set.
Colouring is mainly used as a means of identification, allowing differentiation of compound grades

in safety-critical applications.
In addition, colour can be used to separate similar sizes on a customers production line.
Please consult our Technical Department on application and colour range availability.
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10
MEDIA TABLE
For dynamic applications it is recommended that a swell up to 8% maximum be

adhered to ( rated).
For static seals a volume change up to 25% can be tolerated (/ rated) as long as the
groove volume accommodates any increase.
Recommended
Compound
Superior Designation
LN/MN
HN
ECO
PA
EP
TH
VA
FS
SIL
VF/VP
Maximum service temperature C

Low service temperature C
Water/Steam Resistance
Water/Steam resistance <60C
Water/Steam resistance >150C
Fluid Resistance
Acids
Acetic 10%
Formic
Hydrochloric 20%
Nitric 30%
Phosphoric 20%
Sulphuric 30%
Alkalis
Baruim hydroxide
Calcium hydroxide
Sodium hydroxide
Alcohols
Butyl alcohol (Butanol)
Ethyl alcohol (Ethanol)
Methyl alcohol (Methanol)
Amines
Ethylene diamine
Ammonia cold gas
Ammonia hot gas
Chlorides
Ammonium chloride
Calcium chloride solution
Magnesium chloride
Zinc chloride
100
-45/-30
100
-20
120
-20
135
-15
150
-50
150
-40
160
-40
200
-55
200
-60
230/200
-20/-35
x
x
x
x
x
x
x
x
/
/
* /
* / x
WN70/3
EP1/1/5, WN12/7/1
EP7/3/7
VF12/99/3, EP11/7/4
x
x
x
x
/ *
/ *
/ *
/
/
/
EP10/00/2
EP10/00/2
EP10/00/2
VF3/00/10
EP10/00/2
VF3/00/10
x
x
o
o
o
/
/
/
EP7/3/7
EP7/3/7
EP7/3/7
x
x
x
x
x
x
/
/
x /
EP70, MN70
EP70, MN70
EP70, MN70
o
o
x
x
x
o
o
o
x
x
x
x / *
x/
x/x
EP7/3/7
EP7/3/7
EP7/3/7
x
x
o
o
o
o
/
/
/
/
EP7/3/7
EP7/3/7, MN70
EP7/3/7, MN70
EP7/3/7, MN70
This table refers to room temperature tests.

For other conditions and additional media
advice please refer to Superior Technical
Department for advice.
Rating
Excellent Recommended (5-8% swell)
Good Minor to moderate effects (8-15% swell)
Fair Moderate to severe effects (1-25% swell)
Poor Not recommended (>25% swell)
Insufficient data available
*Conditions Apply
Temperature or other limitation affecting polymer choice
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Please note that in some

conditions a negative
swell (shrinkage through
extraction) may occur.
Superior Designation
Fluids Resistance (continued)
Gases
Butane
Carbon dioxide (dry)
Chlorine (wet)
Freon 12 (R12)
Freon 21 (R21)
Freon 22 (R22)
Freon 134a (R134a)
Natural gas
Methane
Propane
Oils and Fuels
ASTM No 1 oil
ASTM No 2 oil
ASTM No 3 oil
ASTM fuel A
ASTM fuel B
ASTM fuel C
Diesel oil
Diesel oil + RME (10%)
Mineral oil (low aromatic)
Hydraulic oils (petroleum base)
Lubricating oils
Paraffin
Petrol
Silicone oil / grease
Transformer oils
Vegetable oils
Solvents
Acetone
Benzene
Carbon tetrachloride
Dimethyl formamide
Ethyl acetate
Methyl ethyl ketone
Tetrachloroethylene
Toluene
Turpentine
Xylene
Miscellaneous
Ethylene glycol
Detergents
Dioctyl phthalate
Formaldehyde
Hydrogen peroxide (90%)
Phosphate esters
Potassium nitrate
LN/MN
HN
ECO
PA
EP
TH
VA
FS
SIL
VF/VP
Recommended
Compound
x
x
o
x
x
o
o
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
o
x
x
/
/
/
/
x/x
x/x
x/x
/
/
/
TH5/03/1, HN75
TH5/03/1
VF75B
HN75
EC0391
EP7/3/7
EP7/3/7
TH5/03/1, HN75
TH5/03/1, HN75
TH5/03/1, HN75
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
o
o
x
x
x
x
x
x
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
MN70
HN75
HN75
HN75
VF75B
VF75B
HN75
VF5/4/4, TH8/5/6
MN70
MN70
MN70
MN70
VF75B
EP7/3/7
MN70
FN70
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
o
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
o
o
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x/x
/
/
x /
x/x
x/x
/
/
/
/
EP7/3/7
VF75B
VF75B
EP7/3/7
EP7/3/7
EP7/3/7
VF75B
VF75B
HN75
VF75B
x
x
x
x
o
o
x
x
x
x
x
o
x
x
o
o
/
/
x / *
x/x
/
/
/
EP2/9/10
EP7/3/7
EP7/3/7
EP7/3/7
VF3/00/10
Consult
MN70
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12
PRODUCING AN ORDER SPECIFICATION
Highest peak temperature/duration

Highest operating temperature
Lowest temperature at which components are expected to still function
Media contact on assembly and during operation
Approval for Water, Gas or other legislative requirements
Static or dynamic working condition (cycle rates/duration)
Weathering/ozone resistance required
Likely material being considered: refer to Materials Reference Guide or provide
compound designation number (eg, MN70)
Specific physical property minimums eg. Tensile Strength, Elongation,
Compression Set
To ease liaison with our Sales
Department and ensure the
correct compound and size of
seal is ordered, we advise that
you apply the following
considerations to your specification:
System Pressure
Colour/hardness requirements
Quality and Documentation requirements
Lead time plan
Size of seal (in the case of O rings, inside diameter and cross section)
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SEAL DESIGN
13
SEAL DESIGN
INTRODUCTION
This section of the guide is intended to assist engineers when

considering sealing criteria.
It is important to keep in mind that reliability, standardisation and ease of manufacture around
mating parts is achieved through consultation with our Engineering Department at the earliest
possible stage of development.
Practicality demands that this is a concise guide, as each application could present infinite
parameter variables compared with previous examples. As a result, guidelines and trends tend
to focus in general areas, so we always encourage additional direct contact with our Engineering
Department to fine tune and elaborate where conditions are not covered specifically within
this guide.
PRECISION O RINGS
These are the most versatile and economical form of sealing device available. O rings will conform
most readily to general design guideline recommendations, as they have the most extensive record
of service life in diverse conditions.
The first part of this section considers

design criteria for O rings.
O rings are mainly used in static applications, sealing against liquids, gas and general environments.
Superior is able to select from an

extensive range of standard and
non-standard O rings. (see our
Superior Size List for further details
or download from our website
www.superiorltd.com)
consideration given to individual working conditions.
We can also recommend and

manufacture bespoke sizes. We will
then produce precision moulds which
exceed recognised industrial standard
tolerances quickly and efficiently,
in-house.
Our Engineering Department is able to assist in specifying for dynamic applications, with special
O rings are not generally recommended for dynamic applications.
SEALING TYPES
The various configurations can be defined according to the type of sealing, as described below:
Radial Compression
Axial Compression
Face sealing
Type C & D
Piston sealing
Type A
Rod sealing
Type B
A correctly designed housing with the appropriate sized seal is important. However, this function is
not solely responsible for an effective seal: the compound used influences the sealing performance.
In all applications, where possible the largest O ring cross section diameter d2 should be specified
for the application to overcome tolerances and rolling.
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14
GROOVE LAYOUTS
To identify each feature of the housing standard letter symbols can be applied in all cases.
Piston sealing (Radial) Type A
Letter symbols:
In most cases the inside diameter (d1) of an

O ring should always be smaller than the
housing diameter (d3). The maximum stretch
mush be limited to keep the resultant loss in
cross sectional diameter to an acceptable level
and keep the tensile stress to a minimum.
Seal housing width

(b1 and b2 for anti-extrusion devices)
d1 O ring inside diameter

d2 O ring cross-section diameter
d3 Groove diameter
d4 Bore diameter
d5 Shaft diameter
d6 Groove diameter
d7 Outside diameter:
axial application internal pressure
d8 Inside diameter:
axial application external pressure
d9 Shaft diameter
d10 Bore diameter
Rod sealing (Radial) Type B
Radial clearance
The ideal condition is for the O ring outside
Seal housing depth: axial sealing
diameter to be equal to, or slightly greater than,
r1 Corner radius
the housing diameter (d6). Too higher an
r2 Edge radius
interference of the seal outside diameter (d6)
seal housing depth: radial sealing
will result in distortion of the seal profile. This
Lead-in chamfer: piston and rod housing
is due to its inability to cater for the difference
Please note that d10H7 applies to

dynamic application.
in circumferential length.
A maximum outside diameter interference of 3%
is considered optimum but on small diameters
this could be up to 8%.
Face sealing (Axial) Type C & D

This in the simplest use of O rings, provided the
basic rules are remembered. Seal compression is
controlled by the depth of the groove and should
be in the region of 15% to 30%.
For external pressure, the O ring should be
supported by the housing diameter (d7) whilst for
external pressure the inner diameter (d8) is used.
It is possible to remove the internal spigot, where
there is internal pressure, provided there is no risk
of cavitation.
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Housing widths (Radial)
SEAL DESIGN
15
GENERAL HOUSING GUIDELINES

Housing diametrical tolerances
For Radial sealing it is important to use tight tolerances as specified for the Shaft and Bore.
This reduces possible eccentricity and possible loss of compression.
For Face sealing it is important to use a tight tolerance to reduce the range of stretch or
O ring outside diameter as applicable.
Bore diameter
Shaft diameter
Axial outside diameter
Axial inside diameter
d4 /d10
d5 /d9
d7
d8
H8
f7
H11
H11
Lead in chamfers Z (30 40 inclusive)

To enable the O ring to be fully assembled without undue risk of damage, the appropriate lead in
chamfer needs to be applied to the housing.
Surface finish or texture

Sealing efficiency can be directly related to surface finish. The application must be considered from a
number of aspects to establish the most effective and economic surface finish.
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16
STATIC SEALING AXIAL AND TRIANGULAR
O ring housing data for axial and triangular sealing applications
STATIC AXIAL FACE HOUSING

The O ring is compressed in the axial direction.
Under pressure the O ring is subjected to a
relative displacement. If pressure acts from
inside, then the O ring outside diameter
should be in contact with the housing outside
diameter (optimally between 1 and 3 %
of circumference).
If pressure acts from outside, then the O ring
inside diameter should be in contact with
the internal diameter of the housing (up to
6% stretched).
STATIC TRIANGULAR HOUSING

Location grooves with a triangular shape are
sometimes used for screwed flanges and caps.
However, manufacturing these to accurate sizes
r1
Typical Compression Range
t
Axial Compression or Face Seal
is difficult.
35
30
Since the sealing function of the O ring
25
s
45
groove, the dimensions and tolerances given in
+44 (0)1202 854300
min.
15
h8
Installation in a
triangular groove
max.
20
10
the following table are to be strictly observed.

Installation in rectangular grooves is preferable.
squeeze %
depends on the exact shape of the locating
0
d2 (mm)
static-axial
SEAL DESIGN
17
STATIC/DYNAMIC SEALING RADIAL
O RING STRETCH IN PISTON SEALING

When an O rings internal diameter is less than 50mm, the maximum stretch should be less than
8%. When an O rings internal diameter is greater than 50mm, the maximum stretch should be less
than 6%. The maximum stretch is defined as the largest groove diameter and smallest O ring
internal diameter.
REDUCTION OF CROSS-SECTION DUE TO STRETCH

When an O ring is stretched, the cross-section distorts to assume an oval form. In critical
applications, such distortion can cause leakage and result in O ring failure.
The O ring cross section reduces when subject to stretch. As rule of thumb, approximately
half of the stretch e.g. 5% stretch equals 2.5% reduction in cross section.
This reduction in cross section lowers the compression and thus the sealing stress.
Interference of the O ring outside diameter should not exceed 3% in the assembled condition.
Piston sealing (Radial)
Static O rings are squeezed to higher

percentages than dynamic, as friction
concerns are reduced.
Surface finish requirements can be relaxed
in comparison to dynamic applications
(except where pulsating pressure is present).
Dynamic O rings are exposed to lower
Rod sealing (Radial)
Oscillating and rotating conditions are

regarded as dynamic.
Although suitable for dynamic work,
O rings are best applied to short stroke/
small diameter applications.
The preferred O ring hardness is 60 to 80 IRHD.
Media compatibility and temperature are
squeeze percentages compared to static to
critical, as swell or shrinkage should be
reduce friction and wear.
minimised for reliable function.
Surface finish requirements are critical to

reduce friction, seal wear and damage.
The groove width will need to be increased
for one/two back up rings, if system pressures
Compounds with the highest wear resistance

should be selected.
Pneumatic and hydraulic applications can
be accommodated.
are exceeded beyond normal O ring capability.

Superior does not generally recommend the use of O rings as rotary seals.
GOUGH-JOULE EFFECT
An O ring can be used as a rotary seal in some short running applications, however the following
points should be observed;
When using a stretched elastomer in a rotary application, it will contract because of the Gough-Joule
effect. This states that when a stretched elastomer is heated, it will try to regain a less stressful state.
Bearing this phenomenon in mind, this effect can be prevented by ensuring that the O ring
internal diameter is approximately 2-5% larger than the shaft to be sealed.
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18
Whilst the adjacent table is a

guideline for O ring compression,
the following graphs display a more
accurate representation.
Typical O ring housing data for piston and rod sealing applications
Typical Compression Range

Hydraulics, dynamic
30
squeeze %
25
20
max.
15
10
min.
5
0
1.8
2.65
3.55
5.3
O ring cross section d2 in mm

P
Pneumatics, dynamic
30
squeeze %
20
25
max.
15
10
min.
1.8
2.65
3.55
5.3
Hydraulics, Pneumatics, static

30
m
max.
squeeze %
25
20
15
min.
10
5
0
1.8
2.65
3.55
5.3
*BS4518 Recommendations
NOTE: All dimensions in mm
O RING SIZE & COMPOUND SELECTION PROGRAM

Superior has created a program to assist the selection process for a specific O ring. The program
allows the user to enter the criteria required and media in which it will be used as well as the
housing information if known, and the program will select a number of options available. There is
also an option to contact the sales department for a quotation based on the information entered.
Our O ring Size & Compound Selection Program can be found on our website www.superiorltd.com
+44 (0)1202 854300
SEAL DESIGN
19
PRESSURE
Elastomers tend to act as a viscous fluid when under pressure,

resulting in migration into the extrusion gap.
Therefore under certain conditions, a supporting back-up ring is used in conjunction with an O ring
to reduce the risk of extrusion. The back-up ring effectively bridges any gap due to a tolerance and
clearances between the shaft and bore.
For axial face-sealing applications, extrusion gaps should be eliminated, ensuring that pulsating
pressures do not create panting between mating faces.
When exceeding the recommended gap size (in accordance with the below graph) an anti-extrusion
A good quality 70 IRHD compound

will resist extrusion at room
temperature up to 100 Bar. However,
extrusion resistance is influenced by:
device is required.
Recommended extrusion gap is based upon radial clearance if eccentricity is zero, or diametral
clearance if concentricity of mating diameters cannot be assured.
It should be noted that Silicone and Fluorosilicone (due to low tensile strength) should only
Temperature
be applied in grooves with extrusion gaps at half the recommended radial clearance for other
Pulsating Pressure Spikes
compounds.
Seal Cross Section
Housing Design (radii, draft angles)
Please consult our Engineering

Department for detailed information
regarding particular working conditions.
If a selected radial clearance will not achieve a given pressure, then the next hardness range
should be considered.
If a 90 IRHD rubber compound does not satisfy the given parameters, then a PTFE or Thermoplastic
back-up ring should be selected.
Anti extrusion rings are required when considering conditions to the right of the hardness curve.
For temperatures above 100C use the curve for the next harder rubber.
SUPERIOR SEALS
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20 THE SUPERIOR TECHNICAL GUIDE
BESPOKE SEAL DESIGN
PRECISION MOULDINGS / BESPOKE SEALS

Where a specific moulding profile is required, we apply our extensive experience to guide the design
evolution to achieve the most reliable and cost effective solution.
Our broad design capabilities at Superior enable us to supply unique profiles for applications where
traditional O rings are not suitable.
Our portfolio includes generic profiles such as:
Diaphragms
Precision flat washers
Spherical balls
Although there is an infinite number of different seal profiles which can be used to suit individual
applications, there are a number of more commonly used bespoke seal profiles. Listed below are just
a small number and their advantages;
Lip Seals / U-Seal / V-Seals
Moulded Gaskets
Self energising when pressure acts against
Low assembly force
the lips
Lower assembly force than the equivalent
O ring
Lower dynamic running force than the
equivalent O ring
Require less space than the equivalent
O ring
Less creep in housing
Able to cope with larger tolerances
Able to cope with eccentric conditions
Tailored profile
Able to cope with larger tolerances
Able to cope with out flatness
Plastic housings
Retention
Axial (face) sealing
Multiple sealing ports
Customer Information
Location tags
Stabilising features
Able to cope with out flatness (axial sealing)

Bespoke Radial Seals
Symmetrical Seal
Low Dynamic Force
Lower assembly force than the equivalent
O ring
Greatly reduces the chance of spiralling
Symmetrical design enables seal to be
assembled both ways
Less volume than the equivalent O ring
Can cope with pressure from both sides
Quad Ring
Two sealing beads in contact with both the
groove and bore
Greatly reduces the chance of spiralling
Symmetrical design enables seal to be
assembled both ways
For Dynamic applications
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Eccentric conditions
Tolerances
Special Conditions
Profile
BESPOKE SEAL DESIGN
The exciting question facing any

design engineer is this: How will
my design behave in the field,
in practical application?
21
SEAL INTEGRITY
We are focused on the fact that our precision O rings and
special mouldings are a crucial part of the bigger picture.
The integrity and quality of Superior products are fundamental
As early as in the concept phase,

our experts are capable of detecting
weaknesses on the computer to optimise
compounds or geometries. This clearly
reduces development time and costs.
DESIGN
to the integrity of each end product, helping to achieve
SEAL
INTEGRITY
COMPOUND
outstanding product performance and enhance our

customers hard-won reputations.
The unique integrity of our products is achieved through
MANUFACTURING
PROCESS
a combination of 3 Key Elements; Compound, Design and

Manufacturing process.
Traditional Method
SEAL PERFORMANCE
Design
The performance of the seal is dependant on 5 factors;
CHANGE
Mould Making
Sample Production
System Media
Seal Design
Hardware
Seal Compound
Service Conditions
DEVELOPMENT OF A SEAL PROFILE
Functional test of sample
Getting involved at the earliest possible stage of development, our engineering department aim to
Does sample
meet specifications?
become an integral part of our customers team, providing services such as;
NO
YES
Successful completion
of development
Seal Design
FEA/CAD
Housing recommendations
Problem Solving
Design for Manufacture and Assembly (DFMA)
Advice
All these services combined assist in reducing project lead times.

Modern Method
Owing to their non linear material properties, elastomer compounds, in particular, cannot be
described by means of standard software.
CHANGE
Design
FEA Investigation
Will samples be likely to

meet the specification?
YES
Mould Making
NO
That is why Superior uses mathematical models for describing complex material properties and
special measuring methods for determining compound parameters. In addition to enabling static
load tests, these tools allow temperature influences to be considered.
Material parameters can be determined by standardised tests performed on material samples and
are valid for a wide spectrum of operating and/or simulated conditions.
Mathematical modelling is based on stress versus strain data for each material. The stress strain data
is generally non linear.
To simulate elastomeric or plastic components as well as composite parts we use the non
linear finite element analysis method. In certain cases, we combine numerical tools, like the FEA
method with conventional analytical techniques.
Typical bespoke FEA results
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QUALITY
STANDARDS COMPLIANCE
O RING SIZE RANGE STANDARDS

At Superior, we pride ourselves on our precision O ring range which exceeds the cross sectional
tolerances for the following dimensional standards;
ISO3601-1
DIN 3771 Part 1
BS 4518
The benefit of close tolerances on an O ring cross section (d2), is the ability to reduce our customers
tolerance chain and improve the overall performance of the customers product.
In the Superior Precision range of O rings, the internal diameters conform to ISO 3601-1 tolerances
and the cross section diameter has a reduced tolerance. These precision O ring tolerances apply to
NBR 70 compounds.
O rings manufactured in other materials and hardness are produced to conform to ISO 3601-1
tolerances. Dimensions for the internal diameter may be towards the lower end of the ISO3601-1
tolerance when manufactured from different compounds.
High shrinkage compounds may require dedicated tooling to comply with ISO3601-1 dimensions
Quality is an integral part of the

Superior Customer Service Philosophy.
Total control of all aspects of seal
manufacture ensures that we always
comply with recognised standards
applied by the industry.
and tolerances, but will still allow for the principle of a more accurate cross-section. Superior can also
supply O rings to customers specifications.
A continually updated version of the Superior Size List can be downloaded from the website
www.superiorltd.com
With our tooling expertise we can

closely define and control seal
tolerances and surface characteristics.
Our continual investment programs
enable us to apply the latest control
and inspection techniques.
This section is designed to give guidance
to Quality and Design Engineers.
We thoroughly recommend that all
quality and specification issues are
addressed at the earliest point in the
development stage of any new program.
This ensures that all customer-critical
features and commercial issues are
identified from the outset.
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QUALITY
23
QUALITY ACCEPTANCE CRITERIA ISO3601-3
LIMITS OF SIZE FOR SURFACE IMPERFECTIONS

FOR GRADE N O RINGS
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QUALITY CONTROL: DOCUMENTATION

All documentation for despatch to the Customer conforms to the ISO 9001 standard.
The documentation issues and details are continually being revised and updated according
to demands from individual customers and the industry in general.
Please consult our Quality Department for specific requirements.
SEAL SURFACE INSPECTION LEVELS

All our O rings are inspected to ISO 3601-3 DIN 3771 part 4. The standard level is grade N.
For inspection sampling procedure levels please consult our Quality Department.
SPECIAL MOULDING TOLERANCES

Dimensional tolerances on special mouldings will relate to customer specification.
CERTIFICATION
Certification can be provided with the product, but must be stated at point of order.
ENVIRONMENTAL COMPLIANCE
Superior is able to provide materials compliant to current European and worldwide legislative
requirements e.g ROHS, REACH and IMDS.
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ASSEMBLY, CARE AND STORAGE
25
FITTING AIDS
Suitable assembly tools, as detailed, aid location and avoid contact with sharp edges. The aid should
be made from materials which will not damage sealing locations and surfaces (eg, plastic or brass).
For manual assembly or removal of an O ring from a groove (eg, in small runs or when servicing) a
spatula-type tool can be manufactured from a soft material such as brass. All edges should be
smooth, rounded and free from burrs.
O RING STRETCHING FOR ASSEMBLY

An O ring can be stretched by 50% of the inside diameter during assembly.
With small inside diameters the percentage can be significantly greater, though it will eventually
become critical. In this case the O ring will require more time to recover. It is therefore important
to ensure that the stretch remains less than the specified elongation at break indicated in
compound data sheets.
If an O ring is stretched to near its elastic limit, it will return to its original size after a short delay.
However, some compound types will take longer to recover (eg, FPM and HNBR) and this must be
considered, especially during automatic assembly.
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CLEANLINESS / CLEANING MATERIALS

At Superior we rigorously control cleanliness at all process stages, particularly during the final
post-deflashing cleaning cycle.
All seals are supplied to the customer free from surface silicone film and surface particle contamination
(eg, flash particles).
Foreign particle contamination on seals can cause leakage after assembly.
If applying lubricants, the seal should be assembled immediately into the housing, or protected if
placed in storage or transition.
All cleaning media must be compatible with the elastomer.
PREPARATION OF THE HOUSING / MATING PARTS

CHAMFERS
To prevent damaging the O ring section during assembly, chamfers are necessary on all leading edges.
All edges must be free from burrs; sharp edges must be bevelled.
TRAVERSING CROSS DRILLED PORTS

An O ring can be sheared when a spool or a rod moves in a bore broken by cross-drilled ports.
The deformed O ring returns to its original round cross-section as it enters the port and is sheared
as it leaves the drilled area. To avoid this, connection holes should be repositioned. If repositioning is
not possible, an internal chamfer is recommended.
SHARP EDGES AND ROLLING
O rings should not be drawn over sharp edges, threads, slits, bores, glands, splines etc, during fitting.
Such sharp edges must be removed or covered. Fitting aids assist assembly and avoid sharp edges.
O rings are at risk from rolling when fitted over a diameter. This risk can be accentuated on large
inside-diameter/small section O rings. This can result in spiral failure with additional leakage risk.
To assist, we recommend that suitable initial lubrication be applied to the O ring.
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Recommended storage conditions

for products based on Superior
rubber compounds.
Optimum service is the primary objective
in the development of any compound
at Superior.
We give careful consideration to
minimising the compound factors that
may adversely affect seal performance.
It is in the very nature of rubbers that
changes can occur during extended
component storage and become
exacerbated by inappropriate conditions
and practices.
Recommended conditions should always
be followed.
27
STRESS
Always store O rings in their unstressed, free state, avoiding distortion and the risk of ozone attack.
Large rings should never be hung on pegs.
TEMPERATURE
Finished components should be stored below 30C and preferably below 25C.
Extended exposure to higher temperatures in air can accelerate ageing effects and cause distortion,
hardening, elongation loss and impairment of low temperature flexibility.
If inadvertent freezing has occurred, the apparent hardening effect can be reversed by warming to
normal ambient temperatures.
OXYGEN AND OZONE

Superior O rings are supplied in sealed polythene bags which prevent exposure to circulating air and
atmospheric impurities.
We recommend that O rings are kept in these bags until required it is the combined effect
of atmospheric oxygen and temperature that promotes the problems encountered above.
LIGHT
Ozone is present in low concentrations in the atmosphere and at much higher levels near some
Sunlight and intense artificial light can cause
electrical equipment. It will attack rubber components based upon particular elastomers when they
surface deterioration of rubber components.
are stretched or distorted. This appears as cracks at right angles to the direction of distortion.
In extreme cases, this is manifested as

shallow crazing.
We recommend that storage of such parts
Of all common O ring elastomers, only nitrile (NBR) is significantly prone to ozone attack.
Once again, storage in the original sealed polythene bags in dark or very low-intensity artificial
light conditions offers full protection.
should take place in dark or very low-intensity

artificial light conditions.
SHELF LIFE
HUMIDITY
It is practically impossible to define a specific maximum shelf life for finished elastomeric products.
You should avoid conditions where condensation

may occur prior to assembly/installation.
CONTAMINANTS
Airborne contaminants deposited on the surface
of O rings prior to installation can promote
surface attack. Examples include cutting oil
mists, powders and active chemicals used in
production processes.
To achieve the best results, always rotate stock and store as recommended.
The following table of suggested shelf life is for guidance only.
3 years
7 years
Superior FN
Superior EP
Superior WN
Superior SIL
5 years
Superior LN
Superior MN
Superior HN
Superior PA
Superior TH
Superior VA
Superior VF/VB/VP
In the case of particulates, such contamination

can create a leakage path when in service.
As far as is possible, O rings should be kept
These storage times are more conservative than those proposed in BS 3574, 1989,
Controlled storage and packaging of vulcanised rubber and rubber products.
in their sealed delivery bags until required

for installation.
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THE SUPERIOR WAY
+44 (0)1202 854300
G O I N G F O RWA R D
We are fiercely proud of our place in the world of engineering.

We are also aware of the constant challenges that face us in
order to maintain this position and to fulfil current and future
obligations to our customers.
We continually monitor our performance, sharpen our technical expertise and tighten response
times, enabling us to reinforce our added value.
This publication gives an overview of our philosophy and what we are capable of.
If you would like to learn more about how Superior can contribute to your business success,
we would be pleased to answer your questions and welcome you to Ferndown, meet our people,
see our facility and discuss your needs.
Superior Seals Limited

Nimrod Way
Ferndown Industrial Estate
Wimborne, Dorset BH21 7SH, UK.
Tel: +44 (0)1202 854300
Fax: +44 (0)1202 854313
Email: sales@superiorltd.com
Superior Specials Limited

Nimrod Way
Ferndown Industrial Estate
Wimborne, Dorset BH21 7SH
Tel: +44 (0)1202 891180
Fax: +44 (0)1202 894468
Email: specials@superiorltd.com
All technical information included in this document is provided free of charge for guideline purposes only and is based on technical data which
Superior believes to be reliable.
This information is intended for use by suitably skilled and qualified persons entirely at their own discretion and risk. As the end use of our
product is beyond our control, we make no warranties express or implied and no liability can be accepted in connection with the use of this
information, which is subject to revision without prior notice as additional knowledge and experience are gained.
COPYRIGHT V2.082010 SUPERIOR SEALS LIMITED
Design: Orbital | www.orbital.co.uk
www.superiorltd.com

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TECHNICAL GUIDE

FOR PRECISION MOULDED SEALS

DESIGN. DEVELOP. IMPROVE.

THE SUPERIOR TECHNICAL GUIDE

We believe that this latest edition of the guide will become an

THE SUPERIOR TECHNICAL GUIDE

THE SUPERIOR TECHNICAL GUIDE

20 Bespoke Seal Design

Precision Mouldings / Bespoke Seals

Development of a Seal Profile

O ring Size Range Standards

Materials Reference Guide

Special Moulding Tolerances

O ring Stretching for Assembly

Preparation of Housing/Mating Parts

SUPERIOR TECHNICAL SERVICE

25 Assembly, Care and Storage

+44 (0)1202 854300

RESEARCH, DEVELOPMENT AND PARTNERSHIP

RESEARCH, DEVELOPMENT AND PARTNERSHIP:

Customer Service lies at the heart

Our philosophy is based upon three

Material Science & Technology

The combination of these 3 factors

THE SUPERIOR TECHNICAL GUIDE

At Superior we are able to develop and manufacture the

for each elastomer type. We have

developed particular compounds

which exhibit improved upper or lower

will recover full physical properties during the warm-up period.

temperature performance. Please consult

SUPERIOR TECHNICAL SERVICE

+44 (0)1202 854300

MEDIA COMPATIBILITY RATING

We are able to develop and provide a

Virtually all elastomers exhibit a physical or chemical change

comprehensive range of elastomers

EN549, EN682 Compliance

the elastomer absorbs a medium creating a volume increase or swell;

Food & Beverage Industry:

a base constituent (such as plasticiser) is extracted creating a volume decrease or shrinkage.

FDA, AAA, NSF51

The degree of volume change is dependant upon:

the media type;

Please consult our Technical Department

the geometric shape of the seal (section thickness);

THE SUPERIOR TECHNICAL GUIDE

MATERIALS REFERENCE GUIDE

Superior Elastomer Code

MN, LN, HN, WN, FN

Hardness Range (IRHD)

Mineral Oil (low aromatic)

Data not available

SUPERIOR TECHNICAL SERVICE

It should be noted that the parameters

+44 (0)1202 854300

THE SUPERIOR TECHNICAL GUIDE

To fully specify and select a compound, the most relevant

SUPERIOR TECHNICAL SERVICE

+44 (0)1202 854300

original height recovered height

Heat ageing tests are widely used to record

changes in property of an elastomer.