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...
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2025-05-01
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| author | Jaeseong Choi Hwayoung Kim |
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| description | 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. |
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| institution | Kabale University |
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| spelling | doaj-art-8db80026be0446f7b8f8a8be35c9c12f2025-08-20T03:46:48ZengMDPI AGApplied Sciences2076-34172025-05-011511618410.3390/app15116184Concave Contact Geometry for Enhanced Sealing and Structural Integrity in Ultra-High Pressure Hydrogen Solenoid ValvesJaeseong Choi0Hwayoung Kim1School of Mechanical Engineering, Pusan National University, Busan 46241, Republic of KoreaSchool of Mechanical Engineering, Pusan National University, Busan 46241, Republic of KoreaUltra-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.https://www.mdpi.com/2076-3417/15/11/6184ultra-high-pressure hydrogen valvesconcave contact geometryHertzian contact theorysealing performancestructural integritycontact mechanics |
| spellingShingle | Jaeseong Choi Hwayoung Kim Concave Contact Geometry for Enhanced Sealing and Structural Integrity in Ultra-High Pressure Hydrogen Solenoid Valves Applied Sciences ultra-high-pressure hydrogen valves concave contact geometry Hertzian contact theory sealing performance structural integrity contact mechanics |
| title | Concave Contact Geometry for Enhanced Sealing and Structural Integrity in Ultra-High Pressure Hydrogen Solenoid Valves |
| title_full | Concave Contact Geometry for Enhanced Sealing and Structural Integrity in Ultra-High Pressure Hydrogen Solenoid Valves |
| title_fullStr | Concave Contact Geometry for Enhanced Sealing and Structural Integrity in Ultra-High Pressure Hydrogen Solenoid Valves |
| title_full_unstemmed | Concave Contact Geometry for Enhanced Sealing and Structural Integrity in Ultra-High Pressure Hydrogen Solenoid Valves |
| title_short | Concave Contact Geometry for Enhanced Sealing and Structural Integrity in Ultra-High Pressure Hydrogen Solenoid Valves |
| title_sort | concave contact geometry for enhanced sealing and structural integrity in ultra high pressure hydrogen solenoid valves |
| topic | ultra-high-pressure hydrogen valves concave contact geometry Hertzian contact theory sealing performance structural integrity contact mechanics |
| url | https://www.mdpi.com/2076-3417/15/11/6184 |
| work_keys_str_mv | AT jaeseongchoi concavecontactgeometryforenhancedsealingandstructuralintegrityinultrahighpressurehydrogensolenoidvalves AT hwayoungkim concavecontactgeometryforenhancedsealingandstructuralintegrityinultrahighpressurehydrogensolenoidvalves |