This paper presents an overview of a numerical method developed to allow one-way structure-fluid interaction of a scanned representative surface of a Pressure Relief Valve (PRV) measuring 100 um by 100 um to be incorporated into a coupled finite element and computational fluid dynamics model to investigate gas leak rates through micro-gaps in full size metal-to-metal contacting components. The virtual representative surface is created via a real scan using a 3D micro coordinate and surface roughness measurement system. The scan of the physical surface is converted to a CAD format and a finite element model generated which is deformed for a given loading condition. The micro-gaps of the deformed FEA model are extracted and imported into the CFD solver to find the resulting volumetric/mass flow rate for the same set of pressure conditions. This coupled approach allows the leakage rate to be found based on only the surface roughness of metal-to-metal sealing surfaces. This methodology can now be expanded to understand the behaviour and response of metal-to-metal deformable contacting surface components under pressure. Thereafter, the design objective is to minimise or eliminate component leakage.
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