Enhancement of the Service Life of Hydraulic Cylinders through Optimization of Sealing Element Parameters

Peer-reviewed article deposited for open archiving and discovery (librarian deposit; author: Taras Veherinskyi). Original publication: Veherinskyi T.I. (2025). Enhancement of the Service Life of Hydraulic Cylinders through Optimization of Sealing Element Parameters. Frontiers in Emerging Engineering & Technologies (FEET), Vol. 2, No. 10 (2025), pp. 1-7. Published 04 October 2025. Article page: https://irjernet.com/index.php/feet/article/view/294 Issue archive: https://irjernet.com/index.php/feet/issue/view/91 Abstract: In this work a comprehensive investigation aimed at increasing the service life of hydraulic cylinders by tuning the parameters of their sealing components is carried out. The significance of the study is determined by the economic losses incurred during downtime and major overhauls of heavy construction and mining machinery, in which hydraulic cylinders often constitute the primary vulnerable elements. The objective of the research is to propose and substantiate a methodology for selecting and optimizing seals capable of improving wear resistance and, consequently, extending the overall lifespan of the hydraulic cylinder. The methodological foundation of the work includes a review of recent publications in the fields of materials science and seal tribology, a detailed study of the physicochemical and mechanical wear mechanisms, as well as a synthesis of data on the refurbishment of hydraulic cylinders under operational loads. As baseline information, the results of repair and modernization of machines of the Caterpillar and Komatsu brands are utilized. The findings of the study consist in the systematization of factors determining the wear intensity of sealing elements and the creation of an algorithm for their selection with regard to various operating modes. A comparative analysis of the operational characteristics of seals made of polyurethane (PU), polytetrafluoroethylene (PTFE) and their composite modifications is presented. The scientific novelty of the work lies in the proposal of an integrated approach combining the selection of the optimal sealing material, its geometric configuration and mating surface parameters with advanced restoration technologies, which ensures maximal extension of the hydraulic cylinder life cycle. The practical significance of the results is that they can be employed by designers, service specialists and managers of enterprises operating complex hydraulic equipment.HAL open archive record: https://hal.science/hal-05855803 (hal-05855803)