Multi-Condition Wear Simulation and Parametric Analysis of VL-Type Seals for Aviation Hydraulic Actuators

To elucidate the wear evolution and failure mechanisms of VL-type composite seals in aviation hydraulic actuators under multiple operating conditions, a two-dimensional plane-strain finite element model was developed for a VL seal consisting of a PTFE L-ring and an NBR O-ring. The model incorporated the Mooney–Rivlin hyperelastic constitutive law and the Archard wear model. The effects of O-ring compression ratio, hydraulic pressure, sliding velocity, and temperature on cumulative wear, wear rate, and contact state were systematically investigated. The results show that the compression ratio has a nonlinear influence on wear. Within 8–16%, the peak wear increases approximately linearly with compression ratio; above 16%, the peak wear reaches a plateau and a secondary wear zone appears, indicating a transition from single-contact to multi-contact sealing. Hydraulic pressure promotes wear over the range of 4–28 MPa, and at 28 MPa the opposite lip edge of the L-ring comes into contact with the cylinder wall, weakening the sealing effectiveness. Within 0.1–0.3 m/s, wear increases approximately linearly with sliding velocity. However, under high velocity and insufficient hydraulic pressure, the L-ring may undergo inversion, resulting in complete seal failure. Temperature exhibits a non-monotonic effect: material softening reduces local contact stress and wear from −55 to 80 °C, whereas excessive softening at 135 °C causes the peak wear rate to increase again. A parametric analysis scheme involving an increased L-ring height and thickness, a reduced O-ring cross-section diameter, and reserved deformation space raises the critical compression ratio for stable single-contact sealing from 16% to above 20%. These findings clarify the contact-stress/contact-area competition mechanism governing VL seal wear and provide guidance for the design of aviation hydraulic actuator seals.