A novel finite element model for the flare joint contact status at the seal ring with multiscale factors during assembly

Abstract

The sealing performance of a hydraulic system is determined by the joint’s interfacial contact status, which is impacted by unavoidable assembly errors and joint manufacturing deviations on multiple scales. A novel geometric analysis model was heuristically developed for incorporating the macroscopic and mesoscopic topographies into the accurate estimation of the contact surfaces' initial relative assembly position. The microscopic contact model is subsequently constructed using the reverse reconstruction method based on the measured characteristics of rough surfaces. In conjunction with the relative contact position, a multiscale finite element contact model of the interface in the assembly was generated. The simulated indentation results are then compared to experimental data for selected typical circumferential angles, while the impact of topography at each scale is investigated. The findings show the variation in the seal formation tendencies and illustrate how effectively the model can predict the contact status at the seal ring. The influence of the macroscopic mating angle is mostly apparent in the distribution of plastic deformation along the circumferential direction. The mesoscopic flare angle is mostly reflected in the width and depth of the interfacial depression, and the radial circular runout impacts the seal ring formation process by altering the contact phase.