An integral FEA model and a nonlinear contact algorithm were emplyed for the double-cone seal structure, which were applied on the large-sized double-cone seal structure under internal pressure. The stress distribution of double-cone ring and gasket under pre-tightening and working conditions, as well as the influence of pre-tightening force and internal pressure on the gasket stress, double-cone ring strain and radial clearance, were obtained. If the radial clearance was designed according to g⩾0.1% D1, the material of double-cone ring would yield globally. Meanwhile, If the radial clearance was designed according to g⩽0.05%D1, the sealing performance in the pressurizing process would not be ensured. A radial clearance g=(0.075%∼0.1%)D1 is recommended.

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