The gap between two mating surfaces has a direct influence on sealing performance. However, traditional surface metrology rarely characterizes the gap between two mating surfaces. To solve this problem, a novel concept of surfaces complementarity is proposed in this paper. Surfaces complementarity measures how well two rough surfaces fit into each other. To make this concept applicable in engineering practices, a virtual assembly algorithm is developed. The automatic virtual assembly algorithm aligns the mating surfaces by maximizing the overlap ratio of the surface masks. Then, a sum surface which is complementary to the surface gap is constructed to represent the mating states. The top surface of a cylinder block and corresponding cylinder head surface measured by high definition metrology is mated by the virtual assembly algorithm. The differences of functional parameters between the mating surfaces and the sum surface are discussed thoroughly. Due to surfaces complementarity, parameters of the sum surface has a certain deviation from expected combined parameters from two individual surfaces. A case of square surface shows the practical application potential of the virtual assembly algorithm to optimize the sealing performance of the mating surfaces.

两个配合表面之间的间隙直接影响密封性能。然而，传统的表面计量很少能表征两个配合表面之间的间隙。为了解决这个问题，本文提出了一种新的表面互补概念。曲面互补性可衡量两个粗糙曲面相互配合的程度。为了使该概念适用于工程实践，开发了虚拟装配算法。自动虚拟装配算法通过最大化表面蒙版的重叠率来对齐配合表面。然后，构造与表面间隙互补的和表面以表示配合状态。虚拟装配算法将通过高清计量技术测得的气缸体顶面和相应的气缸盖表面配对。彻底讨论了配合面和合面之间的功能参数差异。由于曲面的互补性，和曲面的参数与两个单独曲面的预期组合参数有一定偏差。正方形表面的情况显示了虚拟装配算法在优化配合表面的密封性能方面的实际应用潜力。