Numerical modelling of the thermomechanical behaviour of a polymer seal for an automotive cabin
DOI:
https://doi.org/10.15282/ijame.23.1.2026.17.1015Keywords:
FEM, Car door seals, Coupled thermal-mechanical behavior, NonlinearityAbstract
Automotive door seals play a critical role in ensuring cabin tightness, acoustic comfort and thermal insulation, yet their performance is strongly influenced by temperature-dependent material behaviour. The objective of this study is to develop and validate a comprehensive nonlinear coupled thermo-mechanical finite element model capable of predicting the stiffness, deformation and heat-transfer characteristics of a T4-type elastomer seal under realistic operating conditions. A temperature-dependent Mooney–Rivlin hyperelastic formulation was implemented, with material coefficients calibrated using an inverse-fitting procedure based on manufacturer specification data. The model incorporates transient heat conduction, contact interactions and the effect of trapped air within the seal geometry. Quantitative results demonstrate that increasing temperature from −8°C to 34°C reduces peak contact stresses by approximately 38%, increases total displacement by more than 50%, and enhances heat flux from 10 W/m² to 57 W/m² due to improved thermal conformity. The findings highlight the significant impact of coupled thermo-mechanical effects on seal performance and provide a robust numerical framework for virtual prototyping and optimisation of sealing systems in modern vehicles, including EVs with stringent thermal management requirements.
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