4

Seal Types &

Gland Design

Major Classifications

Internal Pressure

All O-ring seal applications are categorized in terms

of relative motion. In situations involving little or no
motion relative to the seal, the O-ring application is
STATIC. In situations involving reciprocating, rotating,
or oscillating motion relative to the seal, the O-ring
application is DYNAMIC.

Static Seal Types

Static seals are categorized as either AXIAL
or RADIAL, depending upon the direction in which
squeeze is applied to the O-rings cross section.

STATIC AXIAL SEALS

A static axial seal acts similar to a gasket in that
it is squeezed on both the top and bottom of the
O-rings cross section. This type of seal is typically
employed in the face (flange) type applications,
depicted in Illustration 4.1.
When used as a face seal involving either internal
or external pressure, the O-ring should always be
seated against the low pressure side of the groove
(as shown in Illustration 4.1 & Illustration 4.2) so the
O-ring is already where it needs to be as a result of the
pressure.
Static axial seals tend to be easier to design than
static radial seals. Since there is no extrusion gap,
there are fewer design steps and you can control the
tolerances easier.

Illustration 4.1

Y Min. = O-Ring Mean O.D. - 1% UP TO .060

Y Max. = O-Ring Mean O.D.

External Pressure
X

Static Axial Seal Gland Dimensions:

Table B, p. 18-29, lists SAE recommended
dimensions for static axial seal glands by ascending
AS-568* O-ring numbers.
X Min. = O-Ring Mean I.D.

X Max. = O-Ring Mean I.D. + 1% UP TO .060

Illustration 4.2

*Note: The current revision of the Standard is C but it changes periodically.

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STATIC RADIAL SEALS

Static Radial Seals are squeezed between the inner
and outer surfaces of the O-ring. They are typically
employed in cap and plug type applications, as
depicted in Illustration 4.3.

Static Crush Seal

4
45

Static Radial Seal Gland Dimensions:

Table C, p. 30-41, lists SAE recommended
dimensions for static radial seal glands by ascending
AS-568* numbers.
Note: Recommended dimensions for static radial seal
glands listed in Table C are based on an application
pressure limit of 1500 psi. For higher pressure
requirements reference Section 5, Illustration 5.1 or
contact Apple Rubber for technical assistance.

Radial Seal

Illustration 4.4

STATIC SEALS WITH DOVETAIL GLANDS

O-rings are sometimes employed in static or
slow moving dynamic situations calling for specially
machined dovetail glands. Because of the angles
involved, controlling the tolerances in these glands may
be difficult. The purpose of these glands is to securely
hold the O-ring in place during machine operation
and/or maintenance disassembly. A typical valve seat
application is shown in Illustration 4.5.

Dovetail Gland
O-Ring

Illustration 4.3
Valve
Movement

STATIC CRUSH SEALS

In crush seal applications, the O-ring is completely
confined and pressure deformed (crushed) within a
triangular gland made by machining a 45 angle on the
male cover. Squeezed at an angle to the O-rings axis,
crush seals are used in such simple applications as the
one depicted in Illustration 4.4.
Static Crush Seal Gland Dimensions:
Table D, p. 42, lists SAE recommended dimensions
for static crush seal glands by ascending AS-568*
numbers.

Illustration 4.5

Rule
of
Thumb

For a static crush seal application, it is

recommended that the O-ring volume does not
exceed 95% of the gland void.

*Note: The current revision of the Standard is C but it changes periodically.

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O-Ring

12

Seal Types & Gland Design

In this application, O-ring squeeze is primarily axial

in direction (valve operation exerts force on top and
bottom seal surfaces). To avoid tearing or nicking,
the use of O-ring lubrication is recommended while
installing the O-ring into the dovetail gland. Because of
the difficulty in creating the groove and tight tolerances
required, this type of seal application should only be
used when necessary.
Dovetail Gland Dimensions:
Table E, p. 42, lists SAE recommended dimensions
for dovetail glands by ascending AS-568* numbers.

Dynamic Seal Types

This classification of seals is used in situations
involving reciprocating, rotating or oscillating motion.
Dynamic seal performance may be substantially
affected by a number of operating environmental
factors.
Such factors include seal swell in fluids, surface
finish of hardware components, lubrication, system
pressure, thermal cycling, O-ring squeeze, O-ring
stretch, and friction. Since many of these factors are
interrelated, it is important to consider ALL of them in
dynamic sealing situations.
In discussions of individual dynamic seal types,
therefore, mention will be made of the most critical
operating environmental factors to consider.
More detailed information on Critical Operating
Environmental Factors is found in Section 5.

RECIPROCATIING SEALS
Reciprocating seals, as depicted in Illustration 4.6,
are used in situations involving a moving piston and a
rod. These seals constitute the predominant dynamic
application for O-rings.
For optimum performance of reciprocating seals,
careful consideration of the following factors is
required:
Compound Selection for Thermal Cycling:
Thermal cycling from high (100F and above) to low
(-65F and below) temperatures may cause O-rings
to take a compression set at elevated temperatures
and fail to rebound enough at low temperatures to
provide a leak-proof seal. Such O-ring leaks are
especially prone to occur in low pressure, reciprocating
applications. Therefore, when extreme operating
thermal cycles are anticipated, it is recommended that
you specify a seal compound that exceeds, rather than
merely meets, desired temperature range, compression
set, and resilience needs.
Control Over Pressure Shocks:
With sudden stopping and holding of heavy loads,
hydraulic components can create system pressures far
in excess of seal extrusion resistance capabilities. To
prevent extrusion and eventual O-ring failure, pressure
shocks should be anticipated and effectively dealt with
in both seal selection and system design. As required,
mechanical brakes or pressure relief valves may have to
be built into the hydraulic system.

Reciprocating Seals
Piston Seal

Bore
Diameter
Piston
Diameter

Rod Seal

Piston
Groove
Diameter

Rod Diameter

Rule
of
Thumb

Illustration 4.6

For reciprocating seals passing O-rings

over ports is not recommended. Nibbling and
premature wear and seal failure will result.

*Note: The current revision of the Standard is C but it changes periodically.

13
Bore
Diameter

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 The use of back-up rings or increased seal durometer

may also be necessary to prevent O-ring extrusion.
For more information on the effects of pressure, see
Illustration 5.1 in Section 5 of this guide.

The most important factors to consider in designing

rotary seal glands are application temperature limits,
frictional heat buildup, O-ring stretch, squeeze, and
shaft and glandular machining.

Squeeze:

Application Temperature Limits:

Listed in Table A, p. 17, under Gland Design

at the end of this section are the recommended
squeeze values for O-rings employed in reciprocating
applications. Lower squeeze than that shown in Table
A will reduce friction, but at a cost of possible leakage
in low pressure situations. Greater squeeze than that
shown will increase friction and sealing capability, but
at a cost of difficult assembly, faster seal wear, and the
increased potential for spiral failure.

Rotary shaft seals are not recommended for

applications with operating temperatures lower than
-40F, or higher than +250F. The closer the application
is to room temperature, the longer the O-ring can be
expected to effectively seal.

Stretch:
When the I.D. of an O-ring is stretched, the O-rings
cross section is reduced. In such instances, be sure
to consider that the O-rings reduced cross section
maintains the correct percentage of seal squeeze. The
percentage of stretch should not exceed 5% in most
applications.

% Stretch

Groove Diameter
-1 100
O-Ring ID

ROTARY SEALS
As shown in Illustration 4.7, O-rings may be used
as seals for rotating shafts, with the turning shaft
protruding through the I.D. of the O-ring.

Rotary Seal
O-Ring

Frictional Heat Buildup:

As the generation of frictional heat is inevitable with
rotary seal applications, it is suggested that O-rings
be composed of compounds featuring maximum heat
resistance and minimum friction generating properties.
Internally lubricated compounds are typically used for
rotary applications.
Stretch:
In this application, I.D. stretch must be eliminated
by using shaft diameters no larger than the free state
(relaxed) I.D. of the O-ring. Shaft seals for rotary or
oscillating applications should be designed with
no stretch over the shaft. When an elastomer is
stressed in tension and the temperature is increased,
it contracts instead of expands which increases the
heat and additional contracting until seal failure.
This contraction of an elastomer due to increased
temperature is known as the Joule effect.
Squeeze:
In most rotational shaft applications, O-ring
squeeze should be kept to as little as 0.002" by
using an O-ring with an O.D. of about 5% larger than
the accompanying gland. Once installed, peripheral
compression puts the O-rings I.D. in LIGHT CONTACT
with the turning shaft. This design minimizes frictional
heat buildup and prolongs seal life.
Rotary Seal Gland Dimensions:
Table G, p. 48-53, lists the recommended
dimensions for rotary seal glands.

Illustration 4.7

Rule
of
Thumb

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The closer the application is to room temperature,

the longer an O-ring can be expected to effectively
seal.
14

Seal Types & Gland Design

OSCILLATING SEALS

Surface Finishes

Oscillating Seal Gland Dimensions:

Oscillating Seals

Surface finishes as rough as 64 to 128 micro-inches

RMS can be tolerated. However, a finish of 32 microinches RMS is preferred.
0o to 5o
(Typ.)

Static Gland Detail

Surface finish: S
32 for liquids
16 for vacuum and gases
Finishes are RMS values

63

Oscillating seal gland dimensions are the same as

those used for reciprocating applications (see Table F).

STATIC GLANDS

63

In an oscillating O-ring application, the shaft moves

in an arc within the gland, and in contact with the I.D.
of the seal. Because there is a tendency for the shaft
to twist, self-lubricated O-rings with a hardness of 80
to 90 durometer are most often employed. Caution
should be used, however, with graphite-containing
compounds as they tend to pit stainless steel alloys.

Illustration 4.9

DYNAMIC GLANDS
Reciprocating Seals
A highly polished surface is not desirable because
it will not hold lubricant. The most desirable metal
surface roughness value for dynamic seal applications
is from 10 to 20 micro-inches. A shot-peened or
electro-polished surface is ideal, because it provides
many small pockets in the metal for entrapment of
lubricants. The best surfaces are honed, burnished or
hard chrome plated. Softer metallic surfaces, such as
aluminum or brass, should generally not be used for
dynamic applications.

Illustration 4.8

Machining

Rotary Seals

To preclude premature wear and seal failure,

the metal surfaces which contact O-rings during
installation and system operation must be properly
prepared. Preparation consists of appropriate selection
of materials, as well as machining for optimum surface
finish.

Shaft composition should be of a relatively hard

metal and be within 0.0005" TIR. Additionally, it is
recommended that shaft surfaces be finished to
16 RMS (for smooth, non-abrasive running), with gland
surfaces finished to a rougher 32 RMS (to discourage
O-ring movement within the gland).

Rule
of
Thumb

15

Avoid using graphite-loaded compounds with

stainless steel, as they tend to pit the stainless steel
surface over time.

0o to 5o
(Typ.)

Dynamic Gland Detail

Finishes are RMS values

32

16

32

To prevent O-ring extrusion or nibbling, rectangular,

straight-sided, glandular grooves are best. For
pressures up to 1,500 psi, 5 sloping sides are
acceptable and easier to machine. Break all sharp
corners by at least 0.005" to avoid unnecessary cutting
or nicking of O-rings during assembly and operation.

32

Illustration 4.10

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O-Ring Installation
An O-ring may be easily damaged by improper
handling and may fail for this reason alone. Prior to
O-ring installation, make sure that ALL glandular
surfaces are free of all debris. If necessary, clean
these surfaces with an appropriate solvent THAT IS
COMPATIBLE WITH THE O-RING BEING INSTALLED.

Note: The tables that follow represent a compilation

of data from various sources to aid in the design of an
effective seal. Because each sealing application
is unique, the presented data should be
referred to as a proper initial step, with more
specific design criteria on the following
pages.

Before installation, make sure to lightly coat the

O-ring with a lubricant that is compatible with the
O-ring being installed, as well as compatible with
system chemicals.
In piston applications, avoid stretching the O-ring
more than 100% during installation (stretch should not
exceed 5% in the application). Also, be sure to stretch
it uniformly. Cones, or mandrels, are often used to
assist in these installations. Once the O-ring has been
installed, make certain to remove any twists.
When the piston is pushed into the cylinder, push
it straight in. DO NOT TURN OR TWIST PISTONS
INTO CYLINDERS AS THIS MAY BUNCH OR CUT
O-RINGS!
In installations where the O-ring must pass over
threads or other sharp edges, cover these edges with
tape or a plastic thimble prior to O-ring installation.
As necessary, O-rings may be folded into internal
grooves, but excessive twisting should again be
avoided.
In hydraulic systems, it is recommended that
glandular surfaces be washed with hydraulic fluid,
then cleaned with a LINT-FREE cloth.
In all cases of O-ring installation, try to avoid
excessive twisting, turning, rotating, or oscillating of
glandular components relative to the O-ring. Also try
to avoid O-ring contact with any sharp surfaces,
including fingernails.

Rule
of
Thumb

Before installation, make sure to lightly coat the

O-ring with a lubricant that is compatible with the
O-ring material, as well as with system chemicals.

Please Note the Following:

The applications, suggestions and recommendations

contained in this book are meant to be used as a professional
guide only. Because no two situations or installations are the
same, these comments, suggestions, and recommendations are
necessarily general AND SHOULD NOT BE RELIED UPON BY
ANY PURCHASER WITHOUT INDEPENDENT VERIFICATION
BASED ON THE PARTICULAR INSTALLATION OR USE. We
strongly recommend that the seal you select be rigorously tested
in the actual application prior to production use.

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16