Modelling of leakage on metal-to-metal seals

Surfaces in a typical seal exhibit both waviness and roughness. The influence of the interaction between these two scales on the leakage behaviour is expected to be relevant. Therefore, a model, which can study it, is developed here. The model is composed of state-of-the-art models for the contact mechanics between rough metal surfaces and for the liquid flow through the rough aperture in-between them. Correlation between percentage real contact area and actual contact topology and leak rate was confirmed through numerical analysis. Small changes in relative position between the contacting surfaces showed large deviation in leak rate. The validity of the model was justified by comparing results from numerical simulations using the model and experimental results found in literature qualitatively.