Oil leakage and power loss from radial shaft seals used in automotive power transmission systems

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Radial shaft seals are frequently used in power transmission systems to prevent oil leakage. The importance of these components for operational reliability provides a great challenge for the industry. Pertinent design and standardisation of key surface parameters such as surface texture and machine lead angle or shaft lead are paramount. The former is an inherent property of any surface, which is also commonly referred to as surface roughness whilst the latter is formed during manufacture of the shafts.The often contradictory objectives of efficiency, effective sealing and reliability require a combined numerical and experimental approach. A numerical model accounting for surface interactions and hydrodynamic flow in the mixed regime of lubrication will be created. The numerical model will be used to understand the underlying physics and inform design. In parallel, a component level test rig will be created to experimentally validate the numerical model and to benchmark new components designs. Additionally, new standards will be created to characterise the waviness and roughness of the contact surfaces measured using optical interferometers.