Open Access

Matthias Graf, Tobias Lankenau, Kathrin Ottink, Thomas Ebel

• Additive manufacturing (AM) methods are finding more and more applications in the manufacturing of machine parts. One consequence of this method is that generated surface qualities are typically lower than in other processes. This becomes especially relevant when the surface quality is critical for the mechanical function: This is the case in dynamic sealing technologies, for example, in seals between a moving rod and a hydraulic cylinder. Between the seal lip and the polished rod, a thin lubrication film is established with the goal of minimal leakage. How well this goal is reached depends on the surface quality of the seal. For spare part production of seals, we investigate AM methods, which have a surface defined by layers from fused filament fabrication (FFF). We apply a coupled model for fluid–structure interaction of the elastic seal and the film flow. This model provides information on flow field and pressure distribution. Results change when the ‘ideal’ seal lip is replaced by the seal lip geometry from FFF. The continuous loss of solid body contact is replaced by a stepwise loss of contact for the FFF surface.