🧮 Design Calculator 📐 Groove Design 🔍 Failure Analysis 🔧 Installation 🧪 Material Selection

O-Ring Size Calculator

Calculate groove dimensions, compression ratios, and design parameters with ±0.002" precision while staying aligned with inventory and material guidance.

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Groove Dimension Calculator

Calculate optimal groove dimensions for static and dynamic O-ring applications based on AS568 standards.

Calculated Groove Dimensions

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Compression & Stretch Calculator

Calculate compression ratio, stretch percentage, and stress factors for optimal sealing performance.

Calculated Compression & Stretch

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Engineering Guidelines

Static Applications

  • Compression: 15–25%
  • Stretch: 1–5%
  • Fill Ratio: 70–85%
  • Surface Finish: 16–32 μin Ra

Dynamic Applications

  • Compression: 10–20%
  • Stretch: 2–8%
  • Fill Ratio: 65–80%
  • Surface Finish: 8–16 μin Ra

High Pressure

  • Compression: 20–30%
  • Back-up rings recommended >1500 PSI
  • Extrusion gap: 0.003–0.005"
  • Shore A durometer: 75–90

High Temperature

  • Reduced compression: 10–18%
  • FFKM materials recommended >400°F
  • Increase clearances for expansion
  • Consider thermal cycling effects
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O-Ring Failure Mode Engineering

Extrusion Failure

Maximum Gap Formula

G = 0.1 × P^0.5
G (mm), P (MPa)

10 MPa → 0.32mm; 50 MPa → 0.70mm; pair 90A + PTFE backup rings to reduce extrusion.

Compression Set

  • Dynamic squeeze 10–20%, static 15–25%.
  • For ≥200°C choose FKM/FFKM; steam service prefers EPDM/FFKM.
  • Use assembly lubricant and smoother surfaces to avoid scarring.
  • Add PTFE backup rings for long high-pressure cycles.

Calculator usage & submission guide

These modules explain how the calculator connects to inventory, material guidance, and packaging traceability so engineering and sourcing stay aligned.

Calculator connected to live inventory

This calculator is the same engine we use when matching your dash lists to the 430M+ o ring inventory across NBR, FKM, EPDM, silicone, HNBR, PTFE, and FFKM. Inputting actual IDs, ODs, and cross-sections tells us instantly which kits can ship without molding.

When you plug in dimensions and application modes the script checks them against AS568 and metric data, flagging when squeeze or stretch leaves the safe window so we can recommend alternate dash numbers or materials.

Because the tool lives inside WordPress, your inputs flow straight into our service queue—no spreadsheet cleanup or duplicate typing.

Step-by-step workflow

Step one: gather ID/OD/CS, groove width and depth, media, pressure, and temperature notes. The hero area links back to the materials and technical hubs so you can verify assumptions before typing.

Step two: run the groove and compression calculators, capturing the recommended squeeze, fill, and stretch percentages plus unit selections. If something looks off, adjust the inputs and re-run; every iteration is logged.

Step three: submit the results via the quote form or email the exported table. We reply within one to three business days with specific o ring kits, backup rings, and packaging approaches aligned with your calculations.

Material and groove intelligence

Each calculation references our material database with compression set, swell, and maximum extrusion gap data so we can suggest whether NBR, HNBR, Viton, EPDM, silicone, PTFE, or FFKM suits the job.

Toggling between static, dynamic rod, or dynamic piston updates groove width and squeeze automatically, keeping the conversation grounded in test results.

Guideline cards below the calculator summarize compression limits, gap equations, and practical notes so engineers and technicians follow the same playbook.

Submission, documentation, and traceability

Every calculation can be exported as a PDF or screenshot and attached to your quote ticket. We store it alongside shipment logs so compliance teams always know which numbers drove the decision.

When you open a quote we add the calculation ID to the packing slip so maintenance crews can match delivered o rings to the assumed groove and squeeze values.

Technicians can scan the packaging QR code to reopen the calculator with the original inputs, accelerating field adjustments.

Packaging and verification support

Once the numbers check out we prep the physical kits. Low-MOQ lots ship with labels showing dash numbers, material codes, and compression targets pulled from your calculator output.

We photograph every box—especially when shipments include backup rings, PTFE spacers, or QA documentation—and keep those images tied to this calculator page for reference.

Historical data stays available so you can compare previous repairs with today’s calculations and confirm whether groove wear or temperature shifts require new materials.