Fatigue life prediction of safety valve seal based on orthogonal test

In response to the frequent fatigue failure of seals in hydraulic support safety valves under high-pressure, high-flow conditions with water-based media, this study aims to improve the service life of the seal by optimizing its structure. Using ABAQUS and a combined seal fatigue life prediction model, the influence of key structural parameters on fatigue life was investigated. Orthogonal experiments and range analysis were conducted, revealing the order of influence as follows: groove chamfer, relief hole diameter, O-ring compression ratio, and sealing clearance. After optimization, the fatigue life of the seal increased by 2.01 times. The proposed analysis method and model provide a useful reference for the reliability-based design of safety valves in hydraulic supports under high-pressure environments.