Shaft roughness effect on elasto-hydrodynamic lubrication of rotary lip seals: Experimentation and numerical simulation

Numerical analyses of the isothermal elasto-hydrodynamic lubrication (EHL) have made considerable advances in order to identify the most important features in the successful operation of rotary lip seal, and the results have shown a good agreement with experiments. Most of the models previously published are capable of predicting the combined effects of thin film through deformed lip and rotating shaft, but they assume a smooth surface of the shaft. Although this assumption is only verified for shaft roughness much smaller than that of the seal lip, it is the best solution to avoid a transient model. First, the present study describes an experimental work that provides a basis upon which a numerical EHL model of rotary lip seal is constructed by taking into account both the shaft and lip roughness. After confirming the validity of the current model by comparing experimental with numerical results, simulations have been performed and have underlined the effect of shaft roughness amplitude and profile on the rotary lip seal performance. It is shown that for shaft roughness beyond half of the lip roughness, the seal may leak. •Experiments are performed on rotary lip seals. Isothermal elastohydrodynamic model was performed.•Friction torque and film temperature measurements were taken for each rotational shaft speed.•The validity of the current model was confirmed by comparing experimental with numerical results.•Simulations have underlined the effect of shaft roughness amplitude and profile on the rotary lip seal performance.•It is shown that for shaft roughness beyond half of the lip roughness, the seal may leak.