<div class="section abstract"><div class="htmlview paragraph">In an air brake system, compressed air is used as an energy medium for braking applications, ensuring a good seal between the components is critical. The sealing performance of gaskets are significant for the product with joint features as it affects functionality and can cause a breakdown of the entire system; hence, finite element simulation of the sealing performance of gaskets is important for any product development. To simulate fluid interacting with gasket, a fluid-structure interaction (FSI) simulation is necessary by co-simulating a computation fluid dynamics (CFD) and finite element analysis (FEA) solvers to capture complex behavior of seal deformation under dynamic conditions during leakage, but it is a time-consuming process. In this article, the sealing performance of gaskets is studied in detail only till the start of leakage. It is not necessary to simulate the dynamic behavior of the seal beyond leakage to validate the sealing performance; hence, static nonlinear analysis is performed in FEA to capture the seal behavior. But instead of simulating the interaction of fluid as a normal pressure load, a new technique called pressure penetration load is applied. This new technique can not only simulate the normal pressure on the seal and body but also simulate the penetration of fluid through the seal. The intensity of penetration depends on the contact pressure and exists at the interface between the seal and body, due to bolt torque. If the contact pressure is less, the fluid pressure can penetrate and open the contact. This method can predict the possibility of leakage efficiently, and the computation cost is less compared to FSI simulations involving two solvers. The contact pressure developed during the assembly process is simulated and confirmed with the Fuji film test—a pressure-indicating sensor film. Using pressure penetration load, the sealing performance is analyzed to ensure no leakage during extreme conditions. With this methodology, the gasket groove volume, number of bolts, bolt torque, and bolt locations can be optimized. This paper also discusses the sensitivity of various FEA parameters like element size, element type, and dependence of bolt modelling for the current simulation to reduce computation time. This methodology can be applied to validate various products with face-sealing gaskets. A design optimization study is done using this method to convert a metal cover into plastic material with topology optimization to save weight and overall cost of the product.</div></div>

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