Utilization of FEA based Fluid Pressure Penetration Technique for understanding Fluid Leakage Phenomenon from Mechanical Fittings

In demanding automotive coolant applications characterized by extreme pressure and temperature conditions, a variety of Mechanically Attached Fittings (MAFs) are offered by multinational corporations (MNCs). These engineered fittings have been designed to meet the rigorous requirements of various industries, providing a cost-effective and reliable means to seal coolant hose joints. Mechanical fitting assemblies are critical in various engineering systems and are used for connecting various fluid-carrying locations. Understanding leakage phenomena from MAFs is essential for ensuring their reliability and efficiency. This study explores the deployment of Fluid Pressure Penetration Technique (FPPT) available in Abaqus FEA software to comprehensively analyze leakage paths in mechanically joined fittings. The FPPT offers a systematic approach to model fluid penetration behavior within fitting joints under many loading conditions. By utilizing Abaqus software, a powerful finite element analysis tool, with FPPT, a detailed understanding of leakage paths, stress distributions, and failure modes can be achieved. This paper introduces the FPPT methodology and details the FEA model setup utilized in the simulation of mechanical fitting carrying fluid. Furthermore, preliminary results demonstrating the effectiveness of the FPPT coupled with Abaqus software in identifying leakage sources, its comparison with physical test and predicting potential failure locations are discussed. The outcome of this study presents significant benefits for optimizing mechanical fitting designs, enhancing system performance, and mitigating leakage risks in aerospace, electrical and mobility engineering applications, where zero leakage is the primary Critical to Quality (CTQ) factor.