SUMMARY
Rod seals are one of the most critical components of hydraulic systems. However, the fundamental physics of seal behavior is still poorly understood. In pursuit of a comprehensive physics based seal analysis/ design tool, in this work, a multi-scale multi-physics (MSMP) seal model is developed. The model solves the transient problem involving macro-scale viscoelastic deformation mechanics, macro-scale contact, micro-scale two phase fluid mechanics, micro-scale asperity contact mechanics and micro-scale fluid-structure interaction. A finite element-finite volume-statistical mechanics hybrid computational framework is developed which solves these governing equations in a strongly coupled manner. Surface characterization coupled with wavelet transform based adaptive signal extraction method is performed to accurately estimate the surface parameters needed by MSMP model. Intelligent constrained optimization algorithm is developed, which coupled with dynamic mechanics analysis, provides the macro-scale viscoelastic moduli and relaxation time scales spanning broad frequency spectrum of molecular motions. Atomic force microscopy is used to characterize the micro/nano-scale viscoelastic response of the surface asperities. MSMP framework developed is used to analyze a variety of high frequency sealing applications and to design novel seals incorporating smart materials. MSMP computational framework developed in this study has a strong potential to be used as a stand-alone seal analysis/design software.