Multi-Field Coupling Numerical Analysis and Experimental Validation of Surface-Textured Metal Seals in Roller Cone Bits

Metal seals play a crucial role in ensuring the dependable functioning of the bearing system in roller cone bits. Due to the intricate nature of downhole conditions, the microstructure design of sealing end faces, specifically the surface texture, is rarely used in metal seals. This study focuses on examining the applicability of surface texture technology in metal seals for cone bits to enhance the lubrication characteristics and friction and wear properties of liquid film between end faces. A multi-field coupling model of surface-textured metal seals was established and experimentally verified. The liquid film carrying the capacity and sealing performance of five different shapes of surface-textured end faces (circle, ellipse I (horizontal), ellipse II (vertical), triangle, and chevron) were investigated under varying rotational speeds and environmental pressures. The influences of texture parameters, including depth and area ratio, on the lubrication characteristics and friction reduction effects of surface-textured metal seals were investigated, and the microscopic wear morphology characteristics of the sealing end faces were analyzed. The results show that surface textures can effectively improve the liquid film state and comprehensive performance of metal seals. Specifically, triangle textures significantly enhance the hydrodynamic pressure effect and weaken the abrasive wear and adhesive wear of the end faces. However, when the environmental pressure is p >= 30 MPa, the surface textures gradually lose the advantages of dynamic lubrication but can still reduce friction. The proper texture depth and area ratio can achieve zero leakage (obtained theoretically) and minimal friction in metal seals.