Rubber seals undergo large deformation, hyperelastic near-incompressible behavior, and changing contact and friction conditions, factors linear analysis cannot capture. A blog by Ioannis Tsavlidis on SimScale explains how nonlinear finite element analysis, using the Hexagon Marc solver, addresses this through calibrated hyperelastic and elastoplastic material models, multi-step assembly and pressure loading, refined meshing, and defined result controls for contact pressure, plastic strain, and contact force. Using a bidirectional rod seal, it shows how engineers assess sealing performance, permanent deformation, and rod loading, while flagging pitfalls like volumetric locking and mesh distortion. Overall, it offers a practical reference for accurate seal simulation.
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