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Sealing Failure Mechanism and Finite-Element Analysis of O-Ring Sealing-Behavior in a Core-Barrel Roller-Cone Bit Bearing

Yachao Ma, Jinmao Yang, Jie Li, Bing Deng, Wei Zhang, Jianhui Yu
Vol.8, No.6, pp.40-54, 2026 DOI: 10.62051/ijmee.v8n6.05 September 21, 2026
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Abstract: Core-drilling roller-cone bit bearings operate under high pressure, solids-laden drilling fluid, and dynamic loading. HNBR O-rings isolate the lubricated bearing cavity from the external environment; their failure can cause rapid bearing wear and cone seizure. This study investigates the failure mechanism and sealing behavior of HNBR O-rings through uniaxial tensile testing, macroscopic observation, scanning electron microscopy (SEM), and nonlinear finite element analysis (FEA). The HNBR material exhibited an ultimate tensile strength of 17.24 MPa, an elastic modulus of 8.73 MPa, and an elongation at break of 342.24%. The third-order Yeoh model fitted the tensile response more accurately than the Mooney-Rivlin model and was adopted for FEA. Macroscopic and SEM observations revealed circumferential grooves and abrasion on the inner surface, abrasive wear, spalling, and particle adhesion on the outer surface, and laminar tearing with profile distortion on the lateral surface. A two-dimensional axisymmetric nonlinear contact model was used to evaluate the effects of compression ratio (11.5%-17.5%) and fluid pressure (1.0-1.5 MPa) on contact pressure, von Mises stress, and effective contact area. As the compression ratio increased from 11.5% to 17.5%, the maximum Contact Stress increased from 2.7712 MPa to 4.9585 MPa and the maximum von Mises stress increased from 1.2905 MPa to 2.0492 MPa. Contact Stress exceeded fluid pressure under all simulated conditions. Sealing surface 3, between the O-ring upper surface and the groove top face, exhibited the lowest Contact Stress and effective contact area and was identified as the weakest sealing region. A compression ratio of 14.5%-16% is recommended within the investigated range to balance sealing reliability and rubber stress. The results provide guidance for O-ring design, assembly control, and failure prevention in core-drilling roller-cone bit bearings.
Keywords: Core-drilling Roller-cone Bit Bearing, HNBR O-ring, Sealing Failure, Hyperelastic Constitutive Model, Finite Element Analysis, Compression Ratio, Contact Pressure
APA Citation: Yachao Ma, Jinmao Yang, Jie Li, Bing Deng, Wei Zhang, Jianhui Yu (2026). Sealing Failure Mechanism and Finite-Element Analysis of O-Ring Sealing-Behavior in a Core-Barrel Roller-Cone Bit Bearing. International Journal of Mechanical and Electrical Engineering, 8(6), 40-54. https://doi.org/10.62051/ijmee.v8n6.05

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