Design
O-Ring Crush Seal Calculator
Evaluate a highly confined crush-groove O-ring seal without hiding over-compression or overfill conditions.
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Calculator guidance and result interpretation
What this calculator solves
Crush seals intentionally deform the ring more than conventional glands. This model checks whether the selected geometry still leaves enough free volume and avoids uncontrolled over-compression.
When to use it
- •Permanent or rarely opened joints
- •Compact static hardware
- •Legacy crush-groove review
Input parameters
- Crush geometry
- Groove width, depth and mating dimensions over their tolerance limits.
- O-ring volume
- Ring cross-section, diameter and tolerances that determine occupied volume.
- Material conditions
- Hardness, temperature and expected swell for the selected compound.
How to read the results
- Compare minimum contact compression with maximum material strain.
- Maximum gland fill is usually the controlling crush-seal result.
- Out-of-window conditions are marked unqualified without preventing report export.
Engineering considerations
- High calculated compression can shorten life through permanent set or material damage.
- Thermal expansion and media swell are critical in a nearly full gland.
- Prototype assembly force and disassembly condition should be checked.
Related tools and engineering resources
Frequently asked questions
Is a crush seal the same as a normal face seal?
No. A crush design intentionally uses a more confined gland and often greater deformation, so fill and material strain need separate attention.
Why can a crush seal pass contact but still be risky?
The ring may have ample contact pressure while having too little free volume for tolerance, heat or swell, creating excessive stress.