Numerical Analysis of Thermal–Structural Coupling for Subsea Dual-Channel Connector

In deep-sea oil and gas development scenarios, deep-sea dual-channel connectors often face the risk of seal failure due to internal and external temperature difference loads. To address this issue, this paper systematically establishes equivalent heat transfer models for the key parts of the connector based on the third-type boundary condition. On this basis, the quantitative correlation between the equivalent thermal conductivity, composite heat transfer coefficient and temperature of each part is explored. Using the finite element numerical simulation method, the transient temperature field of the connector under three working conditions (heating, cooling and temperature shock) is simulated and analyzed, revealing the temperature distribution characteristics and temperature change trends of the maximum temperature difference of each key component of the connector; combined with thermal–structural coupling simulation, the temperature field is converted into static load, to determine the behavior of the contact stress on the sealing surface under different temperature–pressure coupling working conditions; in addition, by placing the test prototype in a high-low temperature cycle chamber, the seal performance tests under pressurized and non-pressurized working conditions are carried out to verify the reliable sealing performance of the connector under variable temperature conditions. The results of this paper provide comprehensive theoretical support and an experimental basis for the thermodynamic optimization design of deep-sea connectors and the improvement of the reliability of the sealing system.