Fluid pressure penetration for advanced FEA of metal-to-metal seals

This numerical study investigates the behaviour of the contact faces in the metal-to-metal seal of a typical pressure relief valve in the commercial FE-package ANSYS. The valve geometry is simplified to an axisymmetric problem, which comprises a simple representative geometry consisting of only three components. A cylindrical nozzle, which has a valve seat on top, contacts with a disk, which is preloaded by a compressed linear spring. Analysis considerations include the effects of the Fluid Pressure Penetration (FPP) across the valve seat which exists at two different scales. In-service observations show that there is certain limited fluid leakage through the valve seat at operational pressures about 90% of the set pressure, which is caused by the fluid penetrating into surface asperities at the microscale. At the macroscale, non-linear FE-analysis using the FPP technique available in ANSYS revealed that there is also a limited amount of fluid penetrating into gap, which is caused primarily by the global plastic deformation of the valve seat. Accurate prediction of the fluid pressure profile over the valve seat is addressed in this study by considering the FPP interaction on both scales. The shape of this pressure profile introduces an additional component of the spring force, which needs to be considered to provide a reliable sealing