The reduction or elimination of leakage of hydraulic fluid from fluid power systems is considered a fundamental prerequisite for the expanded use of fluid power. There is also a need to reduce seal friction to both reduce energy dissipation and eliminate control problems. These seals are developed through empirical means at the present time, since the fundamental physics of seal operation has been unclear. This research develops numerical models for analyzing reciprocating hydraulic rod seals with various rod surfaces. These models consist of coupled fluid mechanics, contact mechanics and deformation analyses. Both flooded and starved lubrication boundary conditions are applied. For seals with a smooth rod and a plunge-ground rod, the model combines a 1-D finite volume Reynolds equation solver with a 2-D axisymmetric finite element deformation and static contact mechanics analyses, and a Greenwood-Williamson contact mechanics analysis with rod motion. Leakage and friction, along with sealing zone details with the plunge-ground rod are compared with those with the smooth rod. The influence of rod surface finish on seal performance is investigated and explained, under both flooded and starved conditions For seals with a micro-patterned rod, the model consists of finite volume Reynolds equation solver, finite element deformation and static contact mechanics analyses and a Greenwood-Williamson dynamic contact mechanics analysis. This model is able to handle rod surface pattern with 3-dimensional geometrics. Simulations with different micro-pattern geometries are performed to analyze the fundamental mechanism of surface pattern effects on seal operation. Again, both flooded and starved conditions are applied and the results for both cases are compared and analyzed.

La grande diversité des applications, dans tous les domaines industriels, des plus simples aux plus complexes, que ce soit pour un usage quotidienne ou pour des applications high-tech, nécessite la conception continue de systèmes d'étanchéité de plus en plus performants. Les vérins pneumatiques sont des éléments fondamentaux de l'automatisation dans des domaines industriels très variés : les dispositifs de levage, la robotique, l'aérospatial, les systèmes respiratoire, etc. Cependant, un dysfonctionnement d'étanchéité conduit à des performances plus faibles et même à des disfonctionnements. Inversement, une meilleure connaissance des phénomènes aux interfaces, permettra l’amélioration du rendement, la prolongation de la durée de vie et de la fiabilité des différentes applications pneumatiques.Ce travail de thèse est focalisé sur l'étude expérimentale et numérique des systèmes d'étanchéité par joints pneumatiques. Un banc d'essais modulable a été conçu et réalisé pour permettre l'investigation expérimentale de différents types de joints pneumatiques, pour une large gamme de conditions de fonctionnement, en termes de vitesse linéaire, pression pneumatique et solutions constructives. Il permet principalement de caractériser le frottement des joints mais aussi la visualisation des phénomènes physiques au niveau de la zone d'étanchéité et de son environnement.En parallèle, un modèle théorique ElastoHydroDynamique, incluant la prise en compte des conditions de lubrification mixte et le comportement rhéologique non-newtonien de lubrifiant (graisse) a été développé. Il est basé sur le couplage d'un logiciel de calcul non-linéaire (permettant la prise en compte du comportement mécanique hyperélastique des joints) et un modèle d'écoulement en film mince. Les comparaisons de mesures expérimentales avec les prédictions numériques ont permis de valider le modèle théorique ainsi que d'améliorer la compréhension des conditions de fonctionnement et d'alimentation de la zone d'étanchéité. / The great diversity of applications in all industrial fields, from the simplest to the most complex, whether for everyday use or for high-tech applications, requires the continuous design of increasingly efficient sealing systems. Pneumatic cylinders are fundamental elements of automation in a wide variety of industrial fields: lifting devices, robotics, aerospace, respiratory systems, etc. However, a sealing failure leads to lower performance and even malfunctions. Conversely, a better knowledge of the phenomena at the interfaces will allow the improvement of efficiency, the extension of the service life and of the reliability of the various pneumatic applications.This thesis work focuses on the experimental and numerical study of pneumatic seal systems. A modular test bench has been designed and built to allow the experimental investigation of different types of pneumatic seals, for a wide range of operating conditions, in terms of linear velocity, pneumatic pressure and constructive solutions. It mainly allows to characterize the friction of the joints but also the visualization of physical phenomena at the level of the sealing zone and its environment.In parallel, an ElastoHydroDynamic theoretical model, including the consideration of mixed lubrication conditions and the non-Newtonian rheological behaviour of lubricant (grease) has been developed. It is based on the coupling of a non-linear comercial software (allowing the modelling of the hyperelastic mechanical behaviour of the joints) and a thin film flow model. Comparisons of experimental measurements with numerical predictions validated the theoretical model and improved the understanding of the operating and supply conditions of the sealing area.