Abstract

The European Union’s regulatory mandate requirements for vehicular components include the integrity of sealing performance, mitigating leaks from fuel tanks and transmission systems in order to guard against environmental pollution. Non-compliance can result in significant costs for the OEM and their supplier base. The majority of the reported research regarding leakage from radial lip seals focuses on static analysis of leakage under a given set of laboratory conditions. However, in practice, seal conjunctions are often subjected to significant excitations due to vehicular vibration. In the current study, the case of a front-wheel drive vehicle, equipped with three-axle accelerometers and subjected to a comprehensive road test, is used as the basis for the development of a realistic representative test rig. The test rig is developed using bespoke components from the vehicle under investigation to assess the impact of the encountered natural frequencies on sealing performance in controlled laboratory conditions, when the system is subjected to controlled excitation. Experiments are conducted to evaluate leakage at the transmission interface, focusing specifically on the sealing system’s performance. The influence of driveshaft manufacturing processes using corundum grinding and subsequent surface topography upon leakage performance are also considered. Identified modal response frequencies are imposed upon the test rig using a shaker, whilst the seal leakage is measured. The importance of shaft roughness characteristics, such as topographical skewness upon seal leakage rate under various resonant conditions, are ascertained. The results indicate potentially significant leakage rates under excitation conditions, with a non-optimised shaft roughness profile.