Gasket joint sealing behavior prediction using simplified FEA approach.

Gaskets are used widely for sealing of a bolted joint. This paper focuses on Rubber over metal (ROM) gaskets which are widely used in automotive industry. Finite Element Analysis (FEA) of ROM gasket is complex and involves material (hyperelastic), contact and geometric nonlinearity. Gasket could be flat or have one or multiple beads. Analytical approaches are available in literature for flat gaskets without bead patterns. This paper focuses on analysis of ROM gaskets with beads used in automotive axle differential carrier housing and cover pan. Instead of modelling ROM gaskets using three dimensional (3-D) elements, this work suggests an innovative methodology which uses one- and two-dimensional elements with derived attributes for gasket joints. This problem can be viewed as displacement controlled because the gasket is compressed up until the limiter height subjected to bolt preload. 3-D FEA results are used to validate the results of this approach. This method successfully predicts contact width, contact pressure values and the results are consistent with 3-D FEA. While maintaining the accuracy of the results, this approach provides a significant improvement in the FE models creation, computational efficiency and lowers the barriers to solution convergence brought on by material hyperelasticity and large deformation. The suggested method may be applied to both normal evaluations of ROM gasket bolted joints as well as DOE studies to identify the transfer function between input/output parameters and evaluate joint sealing behavior.