Although there are some factors in the operating conditions that can speak in favor of a larger or smaller cord thickness, the most important factor is the interaction of the O-ring with the installation space.

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Sufficient radii are particularly important to prevent damage to the O-ring. There is also a half trapezoidal groove version.

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1. Groove depthThe distance between the inner and outer surface, groove depth and cord thickness of the O-ring interact to produce the compression of the sealing element. It must lie within a target range that depends on the sealing material.

5. Insertion chamfersJust as important as limiting the maximum elongation is protecting O-rings from contact with sharp workpiece edges. With piston and rod seals, insertion chamfers are used for this purpose. If they are long enough, the inner and outer parts can be positioned neatly in relation to each other during installation.

The arrangement of the groove depends on the type of installation. There are additional design options for the shape of the groove.

2. Trapezoidal grooveDue to the more complex production process, a trapezoidal groove is only used when the installation space must have special properties.

3. Triangular grooveThe triangular groove is an option for flange and cover seals. Due to the shape of the groove, the O-ring presses against three contact surfaces when deformed.

This refers to the grooves in which the O-ring is installed. The shape, depth and width of the groove are the most important parameters.

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4. Sealing gapAlso primarily in connection with the operating pressure is the sealing gap is decisive. The distance between the two sealing surfaces defines this gap dimension.

2. Groove widthFirst and foremost, the width of the groove channel must be wide enough to accommodate an O-ring with the appropriate cord thickness.

The absolute minimum is 6 percent. With a piston seal, the groove depth should be selected so that the O-ring is stretched approx. 1 to 6 percent over the groove base diameter.

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4. StretchingPiston seal example: O-rings must be stretched during assembly in order to snap into the installation space. It is important that the maximum elongation of the O-ring is not exceeded. Split grooves can prevent excessive elongation and are particularly suitable for O-rings with low elasticity.

For example, the dovetail shape can hold the O-ring in position when the sealing surfaces are separated for maintenance. Important detail: The groove width is measured before the radii are attached to the edges.

2. GroutingEnsuring minimum compression and taking account of static or dynamic use: these are decisive criteria for calculating the groove. The ideal dimension for compression also depends on the O-ring material.

Designers note that the O-ring deforms elliptically due to the compression and takes up more space in the groove. For pressurized applications a sufficient groove width should also ensure that the pressurized medium can enter the installation space.

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In addition to the dimensional ratios of the inner and outer sealing surfaces, the depth of the groove and the thickness of the O-ring are also decisive factors.

Especially when pressure is applied to the O-ring, it is pressed against the upper edge of the groove. If it is sharp, material can be sheared off very easily.

The lateral surface of the piston must be sealed against the cylinder running surface. This is done by the O-ring, which sits in a groove in the piston.

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Back-up rings are therefore also used for particularly stressed seals. If the sealing gap is already reduced to the technically and economically feasible minimum, they provide additional safety.

1. Type of sealingWith the piston seal, the O-ring is stretched over the groove base diameter. The other way round with the rod seal: Here, the groove in the outer part should be made so that the O-ring has an oversize on the outer diameter.

Grooves are the installation space for O-rings. Let’s think of a piston seal: Here, a piston slides over the running surface in the cylinder.

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In many cases, the installation space can only be adapted to changing requirements with some additional effort. This makes it all the more important to consider as many influencing factors as possible when designing the groove.

The compression therefore acts in an axial direction. The groove is arranged accordingly. The necessary pressure is created by screwing on a lid.

With a rod seal, on the other hand, the O-ring must have an oversize of approx. 1 to 3 percent compared to the outer diameter of the installation space. This must also be taken into account when determining the groove depth.

1. Rectangular grooveRectangular grooves are the standard case for installation spaces for O-rings. They are manufactured by turning or milling into metallic components. The simple geometric rectangular shape makes this a particularly economical option.

The groove depth has the most direct effect on the compression of the O-ring. However, there are other parameters that can have just as much influence on the long-term durability of a seal.

For static seals, the compression should be between 15 and 30 percent of the cross-section. In contrast, the maximum value in dynamic use is 20 percent, which is intended to limit frictional stress.

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7. TemperatureO-rings subjected to expansion contract under the effect of heat. This happens, for example, with a piston seal where the O-ring is stretched beyond the groove base diameter. This potentially increasing elongation should be taken into account when dimensioning the groove.

1. Flange gasketA flange gasket is used for mostly stationary connections such as pipe joints or inspection openings and closures.

Temperature and pressure differences between the two areas in the cylinder must be maintained, as must the separation of different media. In addition to the piston seal, this also applies to other types of installation.

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3. Rod sealAs with the piston seal, the groove of the rod seal is designed so that the O-ring is pressed along the radius. However, the groove is not located in the inner part of the groove (piston seal), but in the outer part.

If the O-ring and groove are optimally matched, low wear, reliable compression and secure installation can be achieved. And these are key factors for a permanently durable seal.

As a general rule, the sealing gap should be smaller as the pressure increases. Depending on the tolerances, this can push the manufacturability of the components to their limits.

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This behavior is part of the damage pattern of gap extrusion. It directly impairs the sealing effect because the lost material reduces the compression.

2. Piston sealWith this type of installation, the O-ring sits in a groove that extends over the outer diameter of the piston. On the one hand, the groove creates space for the sealing element and, on the other hand, ensures the sealing effect effect via the correct elastic compression between the contact surfaces.

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6. System pressure and sealing gapA smaller sealing gap requires tighter manufacturing tolerances, but pays off under high system pressure. Designers should therefore take the pressure conditions into account when designing the installation space and provide additional support rings if necessary.

3. Groove fillingO-rings can swell in contact with certain media. The groove must provide sufficient space so that the O-ring does not swell out. This would increase the compression and thus increase friction.

This ensures an even pressure load on the O-ring. However, a groove that is too wide is particularly disadvantageous when pressure conditions change. As a result, the O-ring always moves to the edge of the groove facing away from the pressure and can suffer mechanical damage.

One disadvantage of this groove shape is that it can result in varying compression. However, it is suitable for confined spaces.

3. Groove radiusEdges that are touched by the O-ring during assembly and when installed must be rounded. Otherwise they pose a major risk of mechanical damage.