Failure Analysis of a Novel Ceramic-Coated Floating Oil Seal Considering O-Ring Initial Assembly Deformation

The floating oil seal (FOS) is a critical component in coal mining machinery, where frictional wear and high stress on the O-ring can lead to oil leakage and eventual FOS failure, significantly impairing equipment performance. To address this issue, this study proposes a novel ceramic-coated floating oil seal (NCCFOS) composite structure that enhances wear resistance without modifying the existing sealing cavity configuration. A two-dimensional axisymmetric finite element model of the NCCFOS was developed based on the Mooney-Rivlin constitutive model, considering the O-ring assembly process for improved accuracy. The model was analyzed under oil pressure loading, with parametric studies examining the influence of oil pressure, assembly clearance, and material hardness on O-ring stress, contact pressure, and frictional stress distribution in the floating seal ring. The results demonstrate that accounting for the assembly process yielded more realistic stress predictions compared to conventional modeling approaches. The NCCFOS design effectively mitigated stress concentrations, reduced O-ring wear, and extended fatigue life, offering a practical solution for enhancing the reliability of coal mining machinery seals.