Study on structural deformation-induced hydrodynamic modulation in composite micro-grooved sealing ring

Purpose Micro-grooved seals are extensively used in rotating machinery. Current studies frequently neglect the elastohydrodynamic coupling effects arising from structural deformation, leading to an imbalanced pressure equilibrium between hydrodynamic and operational oil pressures. This study aims to investigate deformation-induced hydrodynamic performance degradation in composite micro-grooved seals for vehicle transmissions. Design/methodology/approach A bidirectional fluid-structure interaction framework is developed to resolve the interdependencies among structural compliance, hydrodynamic pressure redistribution and leakage modulation. The model incorporates multiphysics interaction at fluid-solid interfaces to systematically analyze the mechanistic interplay between structural deformation and hydrodynamic pressure redistribution. Experimental validation using a sealing performance test rig confirmed the framework’s predictive accuracy. Findings Results demonstrate that seal deformation reduces hydrodynamic pressure, thereby lowering opening forces and leakage, with mean reductions of 16.3% and 14.4%, respectively, when seal deformation is not considered. The average deviations of calculated and experimental values are found to be 5.4% for leakage rate and 9.6% for friction torque. Originality/value This study provides mechanistic insights into the tribodynamic behavior of micro-grooved face seals. The framework advances deformation-aware sealing system design, offering actionable guidelines for groove geometry optimization in high-pressure fluid applications.