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Reinforced Elastomers for High Pressure Seals
Plate Array - Mesh & Fiber - Lattice
Design for an extreme-expansion frac-cup using a plate array for support.
There is a large large diameter difference between the seal OD and shoulder OD. This allows the seal to flex, and one seal can cover a large range of sizes. But, that same diameter difference means the seal will see large forces due to pressure, and supporting it is an engineering challenge.
We are experts at complicated FEA simulations and non-linear analysis. We solve problems that are difficult (or impractical) to simulate - and sometimes can't be simulated directly.
We specialize in hard-to-simulate non-linear problems such as:
-hyper-expansion of reinforced elastomers
-multi-stage reinforcement of elastomers and composites under elasto-plastic flow
-metallic/ceramic composites and laminates with creep
-controlled hyper-plastic deformation of metals
-statically indeterminate structures
such as lattice structures, etc.
-crack growth cross boundaries such as lattice structures, composites, and 3D prints
We use specialized FEA software that go beyond what common simulation packages are capable of.
Ultra-compact designs can be achieved with multi-stage mechanisms. Additionally, combined machine elements can be integrated to serve a dual purpose plus contribute to the mechanism. This creates designs that are unusually capable for their size.
As counter-intuitive as it is, sometimes the best tool to design a mechanism is a series of vector diagrams in 2D CAD software. For statically-indeterminate mechanisms (such as cycloids), this may even be the only option.
For ultra-light-weight applications, lattice structures and sandwich structures are a great option. But they are statically indeterminate and highly dependent on the boundary conditions of the simulation - which requires good judgment. These structures can be used to tune the input response, vibration curves, and physical performance, meaning you don't need to add those extra parts to the design.
We have experience in advanced concepts:
-Creating reinforced seals for high-temp and extreme deformation conditions (reinforcement with fiber, mesh, lattice, plate array, etc),
-Composite material matrixes with special considerations such as electrical conductivity, heat dissipation, crack growth, partial delamination, etc.
-Combined machine elements that drastically reduce space (but behave in unpredictable ways and must be analyzed).
-Ultra-compact assemblies with extreme loads, using advanced concepts such as localized plastic yielding to produce a final shape, arc stabilized components, controlled elastic-plastic deformation to produce a desired harmonic response, etc.
Analysis of a pipe extrusion with a hot-forging process.
Sealing of a pipeline tubular using a double seal. Pressure comes from the right. The first elastomer is 70-duro (low-pressure seal). The second elastomer is 90-duro (high pressure seal). Supported in place by a flex backing plate.
Application requires that the firm elastomer is undersized, so it needs a large expansion to start sealing.
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