###### Abstract  
The dynamic response of pump valve motion directly influences the volumetric efficiency of drilling pumps and serves as a critical factor in performance enhancement. This study presents a coupled fluid-structure interaction (FSI) analysis of a novel secondary cushioned pump valve for drilling systems. A validated 3D transient numerical model, integrating piston-valve kinematic coupling and clearance threshold modeling, was developed to resolve the dynamic interactions between reciprocating mechanisms and turbulent flow fields. The methodology addresses critical limitations in conventional valve closure simulations by incorporating a geometrically adaptive mesh refinement strategy while maintaining computational stability. Transient velocity profiles confirm complete sealing integrity with near-zero leakage (<0.01 m/s), while a 39.3 MPa inter-pipeline pressure differential induces 16% higher jet velocities in suction valves compared to discharge counterparts. The secondary cushioned valve design reduces closure hysteresis by 22%, enhancing volumetric efficiency under rated conditions. Parametric studies reveal structural dominance, with increases in cylindrical spring stiffness lowering discharge valve lift by 7.2% and velocity amplitude by 2.74%, while wave spring optimization (24% stiffness enhancement) eliminates pressure decay and reduces perturbations by 90%. Operational sensitivity analysis demonstrates stroke frequency as a critical failure determinant: elevating speed from 90 to 120 rpm amplifies suction valve peak velocity by 59.87% and initial closing shock by 129.07%. Transient flow simulations validate configuration-dependent performance, showing 6.3 \(\pm\) 0.1% flow rate deviations from theoretical predictions (Q\({}_{\text{L}\max}\) = 40.0316 kg/s) due to kinematic hysteresis. This study establishes spring parameter modulation as a key strategy for balancing flow stability and mitigating cushioning-induced oscillations. These findings provide actionable insights for optimizing high-pressure pump systems through hysteresis control and parametric adaptation. s 2025 15 5431 12 April 2025 8 May  
rapid advancements in drilling technologies, the requirement for enhanced discharge pressure and flow capacity has intensified. Although increasing stroke frequency and stroke length are effective approaches to enhancing displacement and efficiency, such intensification accelerates valve failure mechanisms [1,2]. This technical contradiction necessitates urgent solutions for enhancing pumping efficiency while extending valve service life. The dynamic behavior of pump valves constitutes a critical factor influencing both drilling pump performance and valve failure mechanisms. Previous investigations have extensively investigated pump performance and valve dynamics, encompassing valve motion analysis, experimental measurements, flow field characteristics within pump chambers, and valve impact dynamics [3, 4, 5, 6, 7, 8, 9]. Owing to the geometric complexity of the pump's hydraulic end, and the coupled motion between pistons and valves, establishing precise mathematical models for valve dynamics presents significant challenges [7, 8, 9]. Bench testing, combined with numerical simulations, enables more accurate determination of valve motion characteristics [10, 11, 12, 13, 14, 15, 16, 17]. Particularly during new product development phases, numerical methods serve as cost-effective approaches to rapid prototype performance evaluation, effectively reducing development costs and cycle times. The authors' investigation reveals that current research on drilling pump performance inadequately addresses the kinematic coupling characteristics among pistons, suction valves, and discharge valves [18, 19, 20, 21, 22, 23]. Prevailing methodologies predominantly employ separate modeling approaches for suction and discharge stroke valve dynamics.