saej1236v002

__________________________________________________________________________________________________________________________________________SAETechnicalStandardsBoardRulesprovidethat:“ThisreportispublishedbySAEtoadvancethestateoftechnicalandengineeringsciences.Theuseofthisreportisentirelyvoluntary,anditsapplicabilityandsuitabilityforanyparticularuse,includinganypatentinfringementarisingtherefrom,isthesoleresponsibilityoftheuser.”SAEreviewseachtechnicalreportatleasteveryfiveyearsatwhichtimeitmaybereaffirmed,revised,orcancelled.SAEinvitesyourwrittencommentsandsuggestions.Copyright©2007SAEInternationalAllrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystemortransmitted,inanyformorbyanymeans,electronic,mechanical,photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofSAE.TOPLACEADOCUMENTORDER:Tel:877-606-7323(insideUSAandCanada)Tel:724-776-4970(outsideUSA)Fax:724-776-0790Email:CustomerService@sae.orgSAEWEBADDRESS:http://www.sae.orgJ1236REV.OCT2007SURFACEVEHICLERECOMMENDEDPRACTICEIssued1972-02Revised2007-10SupersedingJ1236MAY1995CastIronSealingRings(Metric)RATIONALEThisdocumenthasbeenupdatedforimprovedclarificationandalsotoreflectnewreferencestandards.1.SCOPEThepurposeofthisSAERecommendedPracticeistoestablishguidelinesfortheautomatictransmissionandhydraulicsystemsengineertodesigncastironsealingringsandselectacceptablewidth,thickness,coatings,andotheraccepteddesigndetails.2.REFERENCES2.1ApplicablePublicationsThefollowingpublicationsformapartofthisspecificationtotheextentspecifiedherein.Unlessotherwiseindicated,thelatestissueofSAEpublicationsshallapply.2.1.1SAEPublicationAvailablefromSAE,400CommonwealthDrive,Warrendale,PA15096-0001,Tel:877-606-7323(insideUSAandCanada)or724-776-4970(outsideUSA),www.sae.org.SAEJ1590InternalCombustionEngines—PistonRings—MaterialSpecificationsSAEJ2310RectangularCrossSectionPolymericSealingRings(Metric)2.1.2ASTMPublication(AmericanSocietyforTestingandMaterials)AvailablefromASTM,100BarrHarborDrive,WestConshohocken,PA19428-2959,Tel:610-832-9585,www.astm.org.ASTMA247-67StandardTestMethodforEvaluatingtheMicrostructureofGraphiteinIronCastingsSAEJ1236RevisedOCT2007-2-3.MATERIALSCastironsealingringsaregenerallymadefromgraycastironpistonringmaterial.Graycastironpistonringmaterialisusedforgeneralautomotiveapplication.Graycastironpistonringsaremadewithahighcarbonequivalentironandwithcastingtechniquesthatpromote,inthesmallsectioncastings,themostdesirablegraphiteandmatrixmicrostructuralconditionsforwearresistanceandadequatemechanicalandphysicalproperties.ThechemicalelementrangesshowninTable1representtypicalchemicalcompositionsforgraycastironpistonrings.ReferencealsoSAEJ1590Class10Subclass12.TABLE1-CHEMICALELEMENTRANGESElements%Totalcarbon3.50–3.95Silicon2.20–3.10Manganese0.40–0.80Phosphorus0.30–0.80Sulfur0.13max3.1CompositionAlloyingelementssuchaschromium,copper,molybdenum,vanadium,tin,etc.,maybeaddedtoenhancethematerialpropertiesorimprovethematerialforspecialapplications.3.2HardnessRockwellB95–107orequivalent.3.3MicrostructureGraycastironpistonringsaremadetopresentanabrasionresistantmatrixcombinedwiththebestgraphiteattainableingrayironformechanicalandphysicalproperties.Thematrixisessentiallycompletelypearliticorsorbiticwithaminimumoffreeferriteandmassivecementite.Thephosphorusconstituent,steadite,isuniformlydistributedinnonmassiveparticles.ThegraphitewillconsistprincipallyofrandomlyorientedflakesthatareasdescribedinASTMA247-67.ThegraphiteparticleswillnormallybeofASTMsizes4through8.4.APPLICATIONDESIGNDATA4.1SurfaceFinishandCoatingsSealingringsareusuallyphosphateoroxidecoated.Occasionally,theyareuseduncoatedorcoveredwithaflashoftinorothermetallicplating.Ringsidefinishtobe0.90μmRamaximumbeforecoating.ODistobesmooth-turned(seeFigure1).SAEJ1236RevisedOCT2007-3-FIGURE1-SEALRINGDESIGN4.2AxialWidth(W)ThewidthsshowninTable2areconsidered"common"sizes.Otherwidthsmaybenecessaryforspecialapplications.Theminimumsealingringwidthtolerancehashistoricallybeen0.025mmforuncoatedandphosphatedringslessthan127mmindiameterand0.038mmforringsmorethan127mmindiameter.Consultaringmanufacturerfortolerancingofplatedrings.ThegeneralfailuremodeofahookjointsealingringisthatitspinsintheboreandwearsontheOD.Whenthehooksengage,duetotheODwear,theylimitthetravelandtheringfailstosealontheOD.Thistypicallyresultsinnotenoughpressureattheclutch.BasedonsideversusODtorqueonthesealingring,thenominalwidthshouldbeapproximately1.4timestheradialthickness.Consultaringmanufacturerifthewidthislessthan1.2timestheradialthickness.(SeeFigure1andFigure2).TABLE2-AXIALSEALINGRINGWIDTHMaximumSealingRingWidthNominalWidth2.00mm1.99mm2.39mm2.38mm3.00mm2.99mm3.16mm3.15mm3.97mm3.96mm4.00mm3.99mm4.75mm4.74mm5.00mm4.99mm6.00mm5.99mm6.34mm6.33mmSAEJ1236RevisedOCT2007-4-4.3RadialWallThickness(T)Itisrecommendedthatsealingringradialwallthicknessesbe0.030to0.040timesgagediameter.Ifasomewhatthinnersectionisdesiredtominimizegroovedepthsandoptimizeshaftdiameters,aringmanufacturershouldbeconsultedsothataradialwallthicknesscanberecommendedthatwillstillgivegoodsealingcharacteristicsalongwiththereducedthickness.(SeeFigure1.)However,otherconsiderationsinradialthicknesssizingareincludedlaterinthisstandard.4.4EndClearanceorCompressedGap(G)Thisdocumentappliestobuttjointandhookjointrings.Thetolerancerequiredformanufactureincreasesastheringdiametersgetlarger.Thesmallestrecommendedclearanceis0.05mm,whichshouldbemeasuredattheODoftheringinagageofminimumborediameterasillustratedinFigure1andFigure2.Consultaringmanufacturerfortheupperlimitsincethisdimensionconsiderablyaffectscostandperformance.4.5HookJointDetailsHookjointringsareusedwhenassistanceisneededinblindassemblyoperations.ThedirectionofthehooksisoptionalasshowninFigure2.Alsoshownaretheothernecessaryhookdimensions.FIGURE2-HOOKJOINTDETAILS(TOPVIEW)SAEJ1236RevisedOCT2007-5-4.6GroovingRecommendationsTheringgroovemustbedeepenoughsothattheringwillnotbottominthegrooveatextremeconditions.Thegrooverootdiameter(GRD)maybecalculatedbyusingtheformulashowninFigure3.NotethataddingIDchamferstotheringwouldallowtheringtonestintothegrooveradiusandmakeGRDmaxlargerandhelpreducehang-down(HMAXinEquation1).AlsonotethatreducingringradialthicknesstoleranceandGRDtolerancewouldalsohelpreducehang-down.Thegroovesidesshouldbecutperpendiculartotheaxisoftheshaftwithin0.02mmmaximum.Thegroovesidesshouldbeflatwithin0.025mmmaximumin360degreesand0.0065mmmaximumin90degrees.Thesurfacefinishonthegroovewallsshouldbe1.3μmmaxRa.FIGURE3-GROOVEDIAMETERANDSIDECLEARANCESAEJ1236RevisedOCT2007-6-5.SAMPLECALCULATION5.1LoadingChamferDiameterCalculationInordertoproperlyinstallthecarrierandringassemblyinthebore,withoutaringcompressor,achamferofsufficientdiameterisrequiredtoallowfortheringbottominginthegrooveononesideandtheringhangingoutontheothersideasillustratedinFigure4.Theminimumradialdimensionofthechamferisequaltothemaximumhang-downandcanbecalculatedusingEquation1:⎟⎟⎠⎞⎜⎜⎝⎛−++−=MAXMINMINMINMAXMAXET2CGRDZH(Eq.1)TheminimumdiameterofthechamfercanbecalculatedusingEquation2:MAXMAXMINH2BX+=(Eq.2)FIGURE4-LOADINGCHAMFERDETAILSSAEJ1236RevisedOCT2007-7-5.2ExampleCalculationforSealingRingApplicationSeeFigure1throughFigure4.Given:B=50.52–50.54C=50.29–50.42E=0.065maxF=0.25maxT=2.03–2.29Z=53.98maxCheck:BMIN-CMAX≥0.1050.52-50.42=0.10GRDMAX=CMIN-2(TMAX+EMAX+FMAX)=50.29-2(2.29+0.065+0.25)=50.29-5.21GRDMAX=45.08GRDMIN=GRDMAX-0.25=45.08-0.25GRDMIN=44.83HMAX=53.98-49.525HMAX=4.46XMIN=BMAX+2HMAX=50.54+8.92XMIN=59.466.NOTES6.1MarginalIndiciaThechangebar(l)locatedintheleftmarginisfortheconvenienceoftheuserinlocatingareaswheretechnicalrevisionshavebeenmadetothepreviousissueofthereport.An(R)symboltotheleftofthedocumenttitleindicatesacompleterevisionofthereport.PREPAREDBYTHESAEAUTOMATICTRANSMISSIONANDTRANSAXLESTANDARDSCOMMITTEE<</ASCII85EncodePagesfalse/AllowTransparencyfalse/AutoPositionEPSFilestrue/AutoRotatePages/All/Binding/Left/CalGrayProfile(DotGain20%)/CalRGBProfile(sRGBIEC61966-2.1)/CalCMYKProfile(U.S.WebCoated\050SWOP\051v2)/sRGBProfile(sRGBIEC61966-2.1)/CannotEmbedFontPolicy/Warning/CompatibilityLevel1.3/CompressObjects/Tags/CompressPagestrue/ConvertImagesToIndexedtrue/PassThroughJPEGImagestrue/CreateJDFFilefalse/CreateJobTickettrue/DefaultRenderingIntent/Default/DetectBlendstrue/DetectCurves0.1000/ColorConversionStrategy/LeaveColorUnchanged/DoThumbnailsfalse/EmbedAllFontstrue/EmbedOpenTypefalse/ParseICCProfilesInCommentstrue/EmbedJobOptionstrue/DSCReportingLevel0/EmitDSCWarningsfalse/EndPage-1/ImageMemory1048576/LockDistillerParamstrue/MaxSubsetPct100/Optimizetrue/OPM1/ParseDSCCommentstrue/ParseDSCCommentsForDocInfotrue/PreserveCopyPagetrue/PreserveDICMYKValuestrue/PreserveEPSInfotrue/PreserveFlatnesstrue/PreserveHalftoneInfofalse/PreserveOPICommentstrue/PreserveOverprintSettingstrue/StartPage1/SubsetFontstrue/TransferFunctionInfo/Preserve/UCRandBGInfo/Preserve/UseProloguefalse/ColorSettingsFile()/AlwaysEmbed[true]/NeverEmbed[true]/AntiAliasColorImagesfalse/CropColorImagestrue/ColorImageMinResolution300/ColorImageMinResolutionPolicy/OK/DownsampleColorImagestrue/ColorImageDownsampleType/Bicubic/ColorImageResolution300/ColorImageDepth-1/ColorImageMinDownsampleDepth1/ColorImageDownsampleThreshold1.50000/EncodeColorImagestrue/ColorImageFilter/DCTEncode/AutoFilterColorImagestrue/ColorImageAutoFilterStrategy/JPEG/ColorACSImageDict<</QFactor0.15/HSamples[1111]/VSamples[1111]>>/ColorImageDict<</QFactor0.15/HSamples[1111]/VSamples[1111]>>/JPEG2000ColorACSImageDict<</TileWidth256/TileHeight256/Quality30>>/JPEG2000ColorImageDict<</TileWidth256/TileHeight256/Quality30>>/AntiAliasGrayImagesfalse/CropGrayImagestrue/GrayImageMinResolution300/GrayImageMinResolutionPolicy/OK/DownsampleGrayImagestrue/GrayImageDownsampleType/Bicubic/GrayImageResolution300/GrayImageDepth-1/GrayImageMinDownsampleDepth2/GrayImageDownsampleThreshold1.50000/EncodeGrayImagestrue/GrayImageFilter/DCTEncode/AutoFilterGrayImagestrue/GrayImageAutoFilterStrategy/JPEG/GrayACSImageDict<</QFactor0.15/HSamples[1111]/VSamples[1111]>>/GrayImageDict<</QFactor0.15/HSamples[1111]/VSamples[1111]>>/JPEG2000GrayACSImag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