Elastomeric Components Research Articles

Flexible force‐bearing liquid crystalline elastomer component toward a dynamic braille platform

AbstractLiquid Crystalline Elastomers (LCEs) are elastomeric actuators capable of reversible shape change under external stimulation such as heat or light. This ability makes them prime candidates for use in the field of soft robotics, with examples of explored applications ranging from heart patches to active yarn. Here, we apply LCE actuation to the field of dynamic Braille displays, with the small Braille pins capable of being either flat or protruding on demand. We demonstrate that the complex and numerous moving parts of a dynamic Braille device could be replaced by a single sheet of LCEs embossed with small actuating bumps. A simple molding procedure produces a surface patterned with at‐scale Braille bumps, as a result of a precise and complex internal organization within the elastomer sample that emerges during polymerization. Unlike in previous attempts to use LCEs for Braille technology, our millimeter‐scale protruding features are generated out of the bulk of the material, resulting in structural integrity, and high resistance to compression force. The localized bump‐to‐flat reversible actuation occurs on a timescale of seconds. The potential of this development for application into a complete Braille dynamic display are discussed.

Experimental investigation of suspension-type abrasive water jet machining of nitrile rubber for positive displacement motor applications

The lightweight elastomers (such as nitrile rubber) frequently used in the Positive Displacement Motor (PDM) stator assembly are subjected to harsh environmental conditions. These elastomeric components are manufactured by primary casting/shaping methods, followed by secondary manufacturing/machining processes. The production of intricate shapes/sizes in single or batch-size elastomeric components using primary casting methods requires a customized mould to fulfil the requirement of sudden breakdown conditions, which is uneconomical. It necessitates an alternate production method that can satisfy the need for the elastomeric component at the stage of failure. The current research focuses on the possibility of producing nitrile rubber components using a non-conventional machining method, Suspension-type Abrasive Water Jet Machining (AWJM), suitable for batch production with better dimensional stability and versatility in shape/size. This work presents the experimental investigation of Suspension-type AWJM of nitrile rubber specimens (15 mm thick) using a custom-designed Tungsten Carbide (WC) nozzle under room-temperature condition. The top surface of the machined slot is analyzed to determine the mineral composition and abrasive particle embedding through Energy Dispersive Spectroscopy (EDX) and Backscatter Electron (BSE) detector. The Taguchi Orthogonal Array (OA) is employed to study the effect of the process parameters (Water Jet Pressure (WJP), Traverse rate (Vf), and Stand-Off Distance (SOD)) on the performance parameters (Kerf Taper Ratio (KTR), and Material Removal Rate (MRR)). The Analysis of Variance (ANOVA) is applied to check the statistical significance and percentage contribution of each process parameter on the performance of Suspension-type AWJM. The uniformity in the geometry of the machined slot is analyzed by the waviness patterns observed in the profile images of the cut specimen. The analysis of the EDX results reveals the presence of Manganese (Mn) and an increased percentage of Silicon (Si) particles near the top surface of the machined slot. The SOD influences KTR the most, whereas Vf highly influences MRR. It is observed that the waviness pattern is minimal at high WJP experimental runs. The outcome of this research work provides a quick and economical method of producing the PDM bushings instead of the casting/moulding method.

New methodology to predict operational limit of hydrogenated acrylonitrile butadiene rubber packer element for downhole application in energy industry

AbstractHydrogenated acrylonitrile butadiene rubber (HNBR) has been widely used in many products that serve as sealing components for downhole operations in the energy industry, especially downhole permanent packers. A reliable methodology needs to be developed to predict operational limits for the elastomer during various tool deployments and operations. These operational limits are mostly based on laboratory life prediction tests derived from industry standards meant for material selection or screening. However, the conventional life prediction method cannot capture the effect of size/shape/stress and adequately predict the sealing performance of an actual elastomeric component under downhole operations. To fill this gap, a lifetime prediction methodology for a downhole HNBR packer was developed based on fundamental material behavior such as viscoelasticity, hyperelasticity, chemical/physical degradation from laboratory aging tests, and finite element analysis. Thereafter, the proposed methodology was used to develop an operational limit for the downhole packer in completion brine, calcium bromide. The results showed that the proposed methodology was not limited to the size or shape of the elastomeric product and can be readily extended to develop a successful operational limit for various elastomeric components in the energy industry.

Thermomechanical Properties of Cross-Linked EVA: A Holistic Approach

Cross-linked ethylene–vinyl acetate (EVA) is used in technically demanding applications ranging from solar cell encapsulants exposed to years of harsh environments to athletic shoes exposed to countless impact recovery cycles. The thermomechanical properties of this versatile material represent the combined responses of semicrystalline and elastomeric components. To fully describe structure–property relations of cross-linked EVA, it is necessary to explore the combined effects of vinyl acetate content, molecular weight, and chain topology on the thermomechanical properties. The interdependent effects of these factors influence both the amount of crystallinity and the size of the crystallites within the material. Subsequent cross-linking of EVA reduces crystallinity relative to the un-cross-linked starting materials. By controlling the properties of the un-cross-linked starting materials and the degree of cross-linking, it is possible to tune the performance properties of the cross-linked EVA. Understanding these effects enables material selection and property adjustment to meet the demands of existing and emerging applications.

Lightweight and High Impact Toughness PP/PET/POE Composite Foams Fabricated by In Situ Nanofibrillation and Microcellular Injection Molding.

Polypropylene (PP) has become the most promising and candidate material for fabricating lightweight products. Microcellular injection molding (MIM) is a cost-effective technology for manufacturing porous plastic products. However, it is still challenging to fabricate high-performance PP microcellular components. Herein, we reported an efficient strategy to produce lightweight and high impact toughness foamed PP/polyethylene terephthalate (PET)/polyolefin-based elastomer (POE) components by combining in situ fibrillation (INF) and MIM technologies. First, the INF composite was prepared by integrating twin-screw compounding with melt spinning. SEM analysis showed PET nanofibrils with a diameter of 258 nm were achieved and distributed uniformly in the PP due to the POE's inducing elaboration effect. Rheological and DSC analysis demonstrated PET nanofibrils pronouncedly improved PP's viscoelasticity and crystal nucleation rate, respectively. Compared with PP foam, INF composite foam showed more stretched cells in the skin layer and refined spherical cells in the core layer. Due to the synergistic toughening effect of PET nanofibrils and POE elastic particles, the impact strength of INF composite foams was 295.3% higher than that of PP foam and 191.2% higher than that of melt-blended PP/PET foam. The results gathered in this study reveal potential applications for PP based INF composite foams in the manufacturing of lightweight automotive products with enhanced impact properties.

Physical–mechanical properties of multifunctional thermoplastic elastomers based on polyolefins and styrene-butadiene elastomer

The article presents the results of a study of the effect of the content of styrene-butadiene elastomer on the change in ultimate tensile stress, tensile yield strength, elongation at break, flexural strength, enthalpy and melting temperature, Vicat softening temperature, and melt flow rate of polymer blends based on a wide range of thermoplastic polyolefins: high-density polyethylene, low-density polyethylene, polypropylene, ethylene-hexene-1 copolymer, polypropylene random copolymer, and block copolymer of ethylene with propylene. Nanoparticles of technical carbon (TC), aluminum, and calcium stearate were used as fillers. It has been shown that, depending on the type of polyolefin used and the specific concentration of elastomer, the polymer mixture can acquire the properties of a thermoplastic elastomer (TPE). In high-density polyethylene and an ethylene-hexene-1 copolymer, the properties of TPE appear at an elastomer concentration of 30 wt %; in low-density polyethylene, this effect occurs at its 20 wt % content. In polypropylene, polypropylene random copolymer, and ethylene-propylene block copolymer, TPE properties appear at 40 wt % concentration of the elastomeric component. This was confirmed by the results of scanning electron microscopy, X-ray diffraction analysis, differential scanning calorimetry, as well as the “stress–strain” dependence of polymer mixtures. To achieve technological compatibility and miscibility of non-polar polyolefins with polar elastomer, compatibilizers based on high-density polyethylene and polypropylene modified with maleic anhydride were used. It is shown that the equality of the values of the ultimate tensile stress and the tensile yield strength is a consequence of the occurrence of phase inversion in the polymer mixture, that is, change of the dispersed medium to the dispersed phase and vice versa.

Sterilizable and Reusable UV-Resistant Graphene-Polyurethane Elastomer Composites.

Shortages of personal protective equipment (PPE) at the start of the COVID-19 pandemic caused medical workers to reuse medical supplies such as N95 masks. While ultraviolet germicidal irradiation (UVGI) is commonly used for sterilization, UVGI can also damage the elastomeric components of N95 masks, preventing effective fit and thus weakening filtration efficacy. Although PPE shortage is no longer an acute issue, the development of sterilizable and reusable UV-resistant elastomers remains of high interest from a long-term sustainability and health perspective. Here, graphene nanosheets, produced by scalable and sustainable exfoliation of graphite in ethanol using the polymer ethyl cellulose (EC), are utilized as UV-resistant additives in polyurethane (PU) elastomer composites. By increasing the graphene/EC loading up to 1 wt %, substantial UV protection is imparted by the graphene nanosheets, which strongly absorb UV light and hence suppress photoinduced degradation of the PU matrix. Additionally, graphene/EC provides mechanical reinforcement, such as increasing Young's modulus, elongation at break, and toughness, with negligible changes following UV exposure. These graphene/EC-PU composites remain mechanically robust over at least 150 sterilization cycles, enabling safe reuse following UVGI. Beyond N95 masks, these UVGI-compatible graphene/EC-PU composites have potential utility in other PPE applications to address the broader issue of single-use waste.

A fluidic relaxation oscillator for reprogrammable sequential actuation in soft robots

A fluidic relaxation oscillator for reprogrammable sequential actuation in soft robots

A comparative study of 85 hyperelastic constitutive models for both unfilled rubber and highly filled rubber nanocomposite material

Nonlinear finite element analysis is widely used for structural optimization of the design and the reliability analysis of complex elastomeric components. However, high-precision numerical results cannot be achieved without reliable strain energy functions (SEFs) of the rubber or rubber nanocomposite material. Although hyperelastic constitutive models have been studied for nearly 80 years, selecting one that accurately describes rubber's mechanical response is still a challenge. This work reviews 85 isotropic SEFs based on both the phenomenological theory and the micromechanical network theory proposed from the 1940s to 2019. A fitting algorithm which can realize the automatic fitting optimization and determination of the parameters of all SEFs reviewed is developed. The ability of each SEF to reproduce the experimental data of both the unfilled and highly filled rubber nanocomposite is quantitatively assessed based on a new proposed evaluation index. The top 30 SEFs for the unfilled rubber and the top 14 SEFs for the highly filled rubber nanocomposite are presented in the ranking lists. Finally, some suggestions on how to select an appropriate hyperelastic constitutive model are given, and the perspective on the future progress of constitutive models is summarized.

Heat Build-Up and Rolling Resistance Analysis of a Solid Tire: Experimental Observation and Numerical Simulation with Thermo-Mechanical Coupling Method.

The hysteresis of rubber materials due to deformation and viscoelasticity is the main reason for the heat build-up (HBU) and rolling resistance (RR) of the rolling tire. It is important to realize the high precision prediction of HBU and RR of tire for the optimal design of high-performance fuel-saving tire. In this work, a thermo-mechanical coupling method based on Endurica and Abaqus co-simulation was used to predict the steady-state temperature distribution and RR of three finite element models (Lagrangian–Eulerian model, Lagrangian model, and Plane Strain model) of the solid tires under different loads and rotating speeds. The simulation results were compared with the experimental results. The Kraus self-heating model was utilized in the thermo-mechanical coupling method, which realized the quantitative relationship between the dynamic loss modulus of rubber and the loading conditions (temperature, strain, and strain rate). Special attention was paid to the determination of the material parameters in the Kraus self-heating model. The comparison between simulation results and experimental results shows that the Lagrangian model had the highest prediction accuracy, and the average prediction errors of the steady-state surface temperature and RR under three loading conditions were 3.4% and 7.9%, respectively. The Lagrangian–Eulerian model came in the second with average errors of 9.7% and 11.1%, respectively. The Plane Strain model had the worst prediction accuracy, with the average errors of 21.4% and 44.6%, respectively. In terms of the simulation time, the Plane Strain model had the lowest cost, and the average calculation time was 1143 s. The Lagrangian–Eulerian model took the second place, with an average calculation time of 2621 s. The Lagrangian model had the highest computation cost, with an average time of 5597 s. The comparison between the simulation results and the experimental results verified the effectiveness of the thermo-mechanical coupling analysis method. The methods of three finite element models of the solid tires in this work can provide some reference for the optimization design of elastomeric components (Lagrangian model), pneumatic tires (Lagrangian–Eulerian model), and non-pneumatic tires (Plane Strain model).

Under-extrusion challenges for elastic filaments: the influence of moisture on additive manufacturing

The applicability of Additive Manufacturing for operational parts expands with the availability of new materials with specific properties. For elastomeric components produced with Fused Filament Fabrication, challenges associated with the printing process due to the nature of the material are faced. This paper investigates the effect of under-extrusion in this process regarding the feeding system and, predominantly, the moisture for thermoplastic polyurethanes with 3D printing experiments and thermomechanical testing. In particular, the filament flow control with a Bowden extruder provides a challenge. A microscopic analysis reveals the signs of under-extrusion, along with the influence of material drying to reduce the moisture content. The drying may depend not only on time and temperature, but also on mass and surface effects. Water uptake measurements exhibit absorptions up to 1.89% in weight, most of which take place during the first 24 h of the experiments. Tensile tests performed on samples with different moisture contents show their influence in the ultimate stresses. The moisture in the material causes under-extrusion induced failures. Those failures are less likely to happen at lower moisture levels, resulting in occasional higher tensile strengths. Overall, the importance of proper storage of the material throughout printing is verified, even under moderate humidity conditions due to its hygroscopic nature.

Hyperelastic modelling of rubber with multi-walled carbon nanotubes subjected to tensile loading

This study thoroughly examined the application of inverse FE modelling and indentation tensile tests to identify nanotubes' rubber material properties. Carbon nanotubes with various percentages of multi-walled carbon nanotubes exposed to high tensile stress were used to enhance the mechanical qualities of natural rubber (NR). In this work, carbon nanotubes have been added to natural rubber. By using a solvent casting technique, toluene was used to make nanocomposites. 0.2%, 0.4%, 0.6%, 0.8%, and 1%. In this article, rubber and multi-walled carbon nanotubes interact in practical ways. Mechanical features of carbon nanotubes in NR have been researched. The results will lead to rubber products with improved mechanical qualities compared to present nanocomposite rubber containing various percentages of multi-walled carbon nanotubes exposed to large tensile test loading. The relative fitness error for significant stresses is reasonable with a second or third-order deformation model in numerical results. Non-linear finite element analysis is widely used to optimise complicated elastomeric components' design and reliability studies. However, accurate numerical results cannot be achieved without using rubber or rubber nanocomposite materials with reliable strain energy functions. The indentation tensile tests of rubber samples have been simulated and confirmed using a parametric FE model. An inverse materials parameter identification algorithm was used to calculate the hyperelastic material properties of rubber samples evaluated in uniaxial tensile. Using ABAQUS FE software, material parameters and force-displacement data may be automatically updated and extracted. The numerical data for the inverse method of material property prediction has been successfully established by developing simulation spaces for various material characteristics. The force-displacement curve can be represented using technical methods. The results demonstrate that the inverse FE modelling process might be simplified by using these curve fitting parameters and plot equations to build a mathematical link between curve coefficients and material properties. The first, second, and third-order deformation models were tested using FE simulations for the tensile test.

Test data improve material modelling – enhancing design quality of elastomer components

The results of virtual simulation of elastomer parts often differ significantly from the real behaviour of components. A possible reason for this is that only data from unidirectional tensile tests are taken into account. Research workers in Germany report that they have improved known test specifications for biaxial tensile tests. According to scientists at Fraunhofer Institute for Structural Durability and System Reliability LBF, implemented three-dimensional (3D) optical measurement during loading enables the mechanical response of elastomer sheets to be measured precisely. The data from the new test improve material modelling – enhancing design quality of elastomer components.

Gamma Radiation Processed Polymeric Materials for High Performance Applications: A Review.

The polymeric properties are tailored and enhanced by high energy radiation processing, which is an effective technique to tune the physical, chemical, thermal, surface, and structural properties of the various thermoplastic and elastomeric polymeric components. The gamma and electron beam radiation are the most frequent radiation techniques used for crosslinking, compatibilizing, and grafting of various polymer blends and composites systems. The gamma radiation-induced grafting and crosslinking are the effective, rapid, clean, user-friendly, and well-controlled techniques for the polymeric materials for their properties improvement for high performance applications such as nuclear, automobile, electrical insulation, ink curing, surface modification, food packaging, medical, sterilization, and health-care in a different environment. Similarly, electron beam radiations crosslinking has been a well-known technique for properties development and has economic benefits over chemical crosslinking techniques. This review focuses on the development of polymeric multi component systems (functionalized polymer, blends, and nanohybrids), where partially nanoscale clay incorporation can achieve the desired properties, and partially by controlled high energy radiations crosslinking of blends and nanocomposites. In this review, various investigations have been studied on the development and modifications of polymeric systems, and controlled dose gamma radiation processed the polymer blends and clay-induced composites. Radiation induced grafting of the various monomers on the polymer backbone has been focused. Similarly, comparative studies of gamma and electron beam radiation and their effect on property devlopment have been focused. The high energy radiation modified polymers have been used in several high performance sectors, including automotive, wire and cable insulation, heat shrinkable tube, sterilization, biomedical, nuclear and space applications.

Phase-field modeling of fracture in strain-hardening elastomers: Variational formulation, multiaxial experiments and validation

Elastomeric sealing and rubber-like materials find applications in a variety of industrial domains. Understanding the behavior of such materials and description of fracture in elastomeric components is therefore decisive in the choice of materials for realizing newer concepts and product designs. Over the years, phase-field modeling of fracture has proven to be a capable tool in handling arbitrary cracks and their propagation in an adequate manner. Nevertheless, a large number of associated models are based either on small-strain assumptions or focus on phenomenological hyperelastic models, both of which are seldom of interest to industrial-grade rubbers. In this work, we present a way to perform phase-field fracture simulation in conjunction with the renowned Gent model of hyperelasticity, wherein the singularity issue near the limit of chain stretch is handled adequately. An extension of an existing model is proposed to describe crack propagation in multiaxial loading cases. The salient features of the model are demonstrated by suitable numerical examples. Furthermore, we perform material characterization experiments on an industrially relevant silicone material and use the above framework to determine the model parameters of this elastomeric adhesive. Additionally, the ability of the model to predict stress–strain response and crack path in different deformation modes is demonstrated.

Advanced Characterisation of Soft Polymers under Cyclic Loading in Context of Engine Mounts.

The experimental investigation of viscoelastic behavior of cyclically loaded elastomeric components with respect to the time and the frequency domain is critical for industrial applications. Moreover, the validation of this behavior through numerical simulations as part of the concept of virtual prototypes is equally important. Experiments, combined measurements and test setups for samples as well as for rubber-metal components are presented and evaluated with regard to their industrial application. For application in electric vehicles with relevant excitation frequencies substantially higher than by conventional drive trains, high-frequency dynamic stiffness measurements are performed up to 3000 Hz on a newly developed test bench for elastomeric samples and components. The new test bench is compared with the standard dynamic measurement method for characterization of soft polymers. A significant difference between the measured dynamic stiffness values, caused by internal resonance of the bushing, is presented. This effect has a direct impact on the acoustic behavior of the vehicle and goes undetected by conventional measurement methods due to their lower frequency range. Furthermore, for application in vehicles with internal combustion engine, where the mechanical excitation amplitudes are significantly larger than by vehicles with electric engines, a new concept for the identification of viscoelastic material parameters that is suitable for the representation of large periodic deformations under consideration of energy dissipation is described. This dissipated energy causes self-heating of the polymer and leads to the precocious aging and failure of the elastomeric component. The validation of this concept is carried out thermally and mechanically on specimen and component level. Using the approaches developed in this work, the behavior of cyclically loaded elastomeric engine mounts in different applications can be simulated to reduce the time spent and save on the costs necessary for the production of prototypes.

Plastics in robots: a degradation study of a humanoid skin mask made of soft urethane elastomer

Understanding the degradation of plastic materials is a big challenge for curators, conservators and conservation scientists in museums worldwide aiming to preserve their collections due to the variety of formulations of synthetic polymers and pigments. The conservation of polyurethane (PUR) based objects is challenging because they can suffer from extensive degradation. Particularly PUR elastomers can degrade shortly after their production, as occurred to the mask of the Japanese robot SAYA, which within 8 years suffered from two large tears, discoloration and stickiness. This research aims at studying the degradation phenomena of the androids’ synthetic skin. Better knowledge of the chemical composition of the mask and the chemical and physical decay will contribute to planning a suitable stabilization treatment. Within a multi-analytical approach, colorimetric and microscopic investigations highlighted discolored areas, which showed further color changes within a five months monitoring campaign, confirming the instability of the material likely due to ongoing degradation. Raman microscopy allowed the identification of Pigment White 6 (titanium dioxide TiO2) in the anatase form, known to promote the photosensitivity of PUR substrates towards ultraviolet (UV) light. Attenuated total reflectance Fourier transform infrared (ATR-FTIR) spectroscopy identified the PUR composition of the mask, the presence of phthalates as plasticizers and suggested the formation of quinone chromophores in the polymer structure as a result of photo-oxidation, possibly responsible for the mask yellowing. Evolved gas analysis-mass spectrometry (EGA-MS) and double-shot-gas chromatography/mass spectrometry (TD/Py–GC/MS) analyses support the characterization of the formulation of the mask as being made of methylene diphenyl diisocyanate (MDI) PUR ether elastomer. Plasticizers in high concentration, mainly diisononyl phthalate (DINP) and bis(2-ethylhexyl)phthalate (DEHP), and the UV stabilizer Tinuvin 328 were also detected. In addition, the presence of styrene-acrylonitrile (SAN) could also contribute to the mask’s chemical instability. More amount of UV stabilizer and phthalates were detected at the surface (contributing to its stickiness) than in the inner core. The degradation of the mask results from the light susceptibility of MDI PUR ether and SAN, as well as the higher photochemical activity of anatase. The mask was transferred on to a mannequin and placed in the storage area to prevent light exposure and photo-oxidation. As loose edges had to be stabilized, tests were conducted and adhesive stripes glued with a PUR dispersion were selected for keeping the head’s shape. The novelty of this study is the implementation of conservation science on the study of androids with PUR elastomeric components in robotic collections, which are becoming increasingly popular in technical museums, however still seldomly studied.

Numerical studies on the heat dissipation process in elastomers under rotating loading direction

Elastomeric components such as car bearings and vibration dampers are subjected to dynamic loads with various amplitudes and loading directions during operation. To better understand the lifetime expectancy of these components it is required to implement a material model that sufficiently accounts for the material thermo-mechanical behaviour. This paper implements a finite viscoelastic model which includes heat dissipation and addresses the effect of inelasticity on the self-heating and the applied loading conditions. The material model is implemented in a user subroutine and finite element calculations are carried out on a simple shear loading with rotating directions. The self-heating effect and the resulting variation of the dissipation induced forces are shown and discussed. With the aid of the presented material model, thermo-mechanically coupled simulations can be performed. Based on the results, the required loading limits and boundary conditions for the mechanical fatigue tests can be defined to minimise the thermal fatigue effects.

Nondimensional translational characteristics of elastomer components

Elastomer components are used in both primary and secondary spring stages in bogies of rail vehicles. The design of spring components of a bogie requires knowledge of the calculation of the elastic properties of these components. An elastomer spring component is typically analyzed in the dimension to be investigated. Calculated force-displacement curves are directly related to the material and dimension of the component itself. The objective of this paper is to establish generalized or, in other words, universally valid force-displacement characteristics by breaking the entanglement with component size. The advantage of this approach is the extended validity of the results for a specific spring shape of any size. The simulations are performed only once for each shape and may be converted to any other size using the proposed methodology. A numerical study of a layer spring with rectangular cross-sectional area and fixed edges on both top and bottom sides serves as a reference example.

Operational envelope prediction of fluoroelastomer seals for downhole operation in the oil and gas industry

AbstractThe energy industry for downhole operation needs a reliable methodology to develop an operation envelope for elastomer performance used in various service/permeant tools. These operation envelopes are mostly based upon the laboratory life prediction tests derived from Industry standard meant for “materials selection/screening.” However, the above life prediction method is limited, as it cannot capture the effect of size/shape and adequately predict the sealing performance of the actual elastomeric component under downhole operating conditions. To bridge this gap, for the first time in this article, we have developed a new lifetime prediction methodology for elastomers using fundamental material behavior such as viscoelasticity, hyper‐elasticity, chemical degradation combined with laboratory tests, and finite element analysis. Thereafter, the proposed methodology is used to develop an operation envelop for an actual size fluoroelastomer (FKM) O‐ring in the hydraulic fluid. This clearly shows that the proposed methodology is not limited to a particular O‐ring size and can be readily extended to develop a successful operation envelope for various elastomer‐sealing applications in the energy industry.