Concave Contact Geometry for Enhanced Sealing and Structural Integrity in Ultra-High Pressure Hydrogen Solenoid Valves
Ultra-high-pressure hydrogen solenoid valves face a fundamental design challenge of operating across a wide pressure range from 2 MPa to 87.5 MPa. To address the conflicting requirements of effective sealing at low pressures and structural integrity at high pressures, this study proposes a novel con...
Saved in:
| Main Authors: | , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2025-05-01
|
| Series: | Applied Sciences |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2076-3417/15/11/6184 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| Summary: | Ultra-high-pressure hydrogen solenoid valves face a fundamental design challenge of operating across a wide pressure range from 2 MPa to 87.5 MPa. To address the conflicting requirements of effective sealing at low pressures and structural integrity at high pressures, this study proposes a novel concave contact geometry based on Hertzian contact theory. Finite element analysis examines the mechanical relationships between plunger curvature radius (<i>R<sub>ₚ</sub></i>), seat curvature radius (<i>Rₛ</i>), and eccentricity (<i>e</i>). Optimization utilizing Latin hypercube sampling and kriging metamodeling yields an optimal design (<i>Rₚ</i> = 5.73 mm, <i>Rₛ</i> = 4.68 mm, <i>e</i> = 0.95 mm) with an <i>Rₚ/Rₛ</i> ratio of 1.22. The optimized concave contact geometry achieves 23.7% higher contact pressure at 2.0 MPa and 42.7% lower maximum equivalent stress at 87.5 MPa compared to conventional rectangular geometry. Experimental validation confirms the concave contact geometry seals at 1.7 ± 0.2 MPa, below the AIS-195 standard requirement of 2.0 MPa and 69.6% lower than the rectangular design (5.6 ± 0.7 MPa). Structural analysis after 87.5 MPa high-pressure exposure reveals no measurable deformation in the concave design, while the rectangular design exhibits permanent deformation of 0.0580 ± 0.007 mm. This integrated methodology provides a framework for optimizing contact geometries in fluid control components operating under extreme pressure conditions, successfully reconciling contradictory requirements across the entire pressure range. |
|---|---|
| ISSN: | 2076-3417 |