Metric O-Ring Stretch, Squeeze, and Fill for female o-ring groove dimensions.
1/16/13
STOCK O-RING TOLERANCES:
Cross Section Tol.
0.00 to 1.80 = +/- 0.08mm
1.81 to 2.65 = +/- 0.09
2.66 to 3.55 = +/- 0.10
3.56 to 5.30 = +/- 0.13
5.31 to 7.00 = +/- 0.15
INSIDE DIA. TOL.
1.80   to 2.50   = +/- 0.13mm
2.51   to 4.50   = +/- 0.14
4.51   to 6.30   = +/- 0.15
6.31   to 8.50   = +/- 0.16
8.51   to 10.00 = +/- 0.17
10.01 to 11.20 = +/- 0.18
11.21 to 14.00 = +/- 0.19
14.01 to 16.00 = +/- 0.20
16.01 to 18.00 = +/- 0.21
18.01 to 20.00 = +/- 0.22

REQUIRED:     
Find the Stretch, squeeze and o-ring groove Fill for the o-ring and groove dimensions given w/ tolerances.  
GIVEN:  
O-Ring body Dial. (cs):   

O-Ring I.D. (id): 

Plug Dia. (B):   

Bore Dia. (D):   

Groove O.D. Dia. (A-1):    

Groove Width (G):   

ASSUME:
SOLUTION:
Dimension Limits O-Ring (calculated):  

Dimension Limits Groove Geometry (calculated):  

PERCENT O-RING STRETCH (0 - 5%):    

smallest o-ring

largest o-ring
Observed Reduced Dia in percent due to Stretch (0 - 3%):   
Observed Reduced Dia in percent due to Stretch (3 - 25%)
This reduced diameter reduces the squeeze on assembly and may need to be accounted for.  

Percent Reduced diameter (due to stretch):  
(0-3% or 3-25%)

(0-3% or 3-25%)

(0-3% or 3-25%)

Reduced diameter in radial direction due to stretch (mm):  

O-RING % SQUEEZE (7% - 30%):   
(Mxx_d), Thickness dimension thru the o-ring; Stretched (scs), or un-stretched (cs):   
Max:    

Nom:  

Min:  

O-RING GROOVE % FILL (60% - 85%):  
O-ring Groove Sectional Area:  

Volume of Stock O-Ring:  

Assume:  Stretched o-ring is an Elipse: Area = π*a*b