Design and development of a high-performance device for sealing ring fatigue and friction characterization

Purpose This study aims to present the design and validation of a novel high-precision device for characterizing fatigue and friction behavior of sealing rings under realistic operating conditions, addressing critical gaps in existing experimental systems. Design/methodology/approach The modular device integrates a servo-driven motion stage with a ball screw mechanism for precise displacement control (resolution: 1 µm, speed error <0.3%), paired with high-fidelity sensors (force resolution: 0.03 N, nonlinearity: 0.01%, hysteresis: 0.05%) for real-time friction and displacement measurement. Adjustable fixtures enable testing of full-ring specimens without segmentation. Polyurethane O-rings were subjected to reciprocating fatigue tests (2,450 cycles) and variable speed-displacement experiments to validate system performance. Findings Results demonstrated the system’s capability to capture dynamic friction mechanisms, including stick-slip phenomena and elastic rebound. Maximum static friction increased with reciprocating speed (81.4–153.1 N at 1,000–5,000 µm/s), while fatigue tests revealed stabilization of static friction after initial wear-in phases. The device achieved exceptional repeatability, with displacement control accuracy within 3 µm after error compensation. Originality/value This work advances sealing technology by introducing a standardized platform that uniquely combines full-ring testing, micro-displacement analysis and direct friction measurement under configurable motion parameters. The system overcomes limitations of prior setups, such as indirect force estimation and segmented specimen requirements, offering insights into seal degradation and performance optimization for industrial applications.