Effects of Four Types of Pre-swirls on the Leakage, Flow Field, and Fluid-Induced Force of the Rotary Straight-through Labyrinth Gas Seal

The labyrinth seal in turbomachinery is a key element that restricts leakage flow among rotor-stator clearances from high-pressure regions to low-pressure regions. The fluid-induced forces on the rotor from seals during machine operation must be accurately quantified to predict their dynamic behavior effectively. To understand the fluid-induced force characteristics of the labyrinth seal more fully, the effects of four types of pre-swirls on the leakage, flow field, and fluid-induced force of a rotary straight-through labyrinth gas seal (RSTLGS) were numerically investigated using the proposed steady computational fluid dynamics (CFD) method based on the three-dimensional models of the RSTLGS. The leakage, flow field, and fluid-induced force of the RSTLGS for six axial pre-swirl velocities, four radial preswirl angles, four circumferential positive pre-swirl angles, and four circumferential negative pre-swirl angles were computed under the same geometrical parameters and operational conditions. Mesh analysis ensures the accuracy of the present steady CFD method. The numerical results show that the four types of pre-swirls influence the leakage, flow field, and fluid-induced force of the RSTLGS. The axial pre-swirl velocity remarkably inhibits the fluid-induced force, and the circumferential positive pre-swirl angle and circumferential negative pre-swirl angle remarkably promote the fluid-induced force. The effects of the radial pre-swirl angle on the fluid-induced force are complicated, and the pressure forces and viscous forces show the maximum or minimum values at a specific radial pre-swirl angle. The pre-swirl has a negligible impact on the leakage. The four types of pre-swirls affect the leakage, flow field, and fluidinduced force of the RSTLGS to varying degrees. The pre-swirl is the influence factor affecting the leakage, flow field, and fluid-induced force of the RSTLGS. The conclusions will help to understand the fluid-induced force of labyrinth seals more fully, by providing helpful suggestions for engineering practices and a theoretical basis to analyze the fluid–structure interaction of the seal-rotor system in future research.

Effect and sensitivity analysis of the rotational speed on the fluid-induced force characteristics of the straight-through labyrinth gas seal

The effects of the rotational speed on the fluid-induced force characteristics of a straight-through labyrinth gas seal( STLGS) are numerically investigated using the steady computational fluid dynamics( CFD) method based on a three-dimensional model of the STLGS. The fluid-induced force characteristics of the STLGS for five rotational speeds at a pressure drop of △P = 5000 Pa with and without eccentricity are computed. The grid density analysis ensures the accuracy of the present steady-CFD method. The effect and sensitivity analysis show that the changes in rotational speed affect the pressure forces,viscous forces and total pressure distributions on the rotor surface,velocity streamlines,leakage flow rates,and maximum flow velocities. The results indicate that the rotational speed inhibits the pressure forces,leakage flow rates and maximum flow velocities and promotes the viscous forces and total pressure on the rotor surface.

Investigation and Improvement of the Staggered Labyrinth Seal

Recent studies on staggered labyrinth seals have focused on the effects of different parameters,such as the pressure ratio and rotational speed on the leakage flow rate.However,few investigations pay sufficient attention to flow details and the sealing mechanism,which would be of practical importance in designing seals having higher performance.This paper establishes a theoretical model to study the seal mechanism,thus revealing that leakage is determined by the pressure ratio and geometric structure.Numerical simulation is implemented to illustrate details of the flow field within the seal structure.Viscous dissipation is used to quantitatively investigate the contribution that each location makes to the seal performance,revealing that orifices and stagnation points are the most important positions in the seal structure,generating the most dissipation.The orifice is carefully studied by using the theoretical model.Experiments for different pressure ratios are conducted and the results match well with those of the theoretical model and numerical simulation,verifying the theoretical model and analysis of the seal mechanism.Three new designs,based on a good understanding of the seal mechanism,are presented,with one reducing leakage by 24.5%.

Numerical Analysis of Labyrinth Seal Performance for the Impeller Backface Cavity of a Supercritical CO_(2) Radial Inflow Turbine

For a radial inflow turbine(RIT),leakage flow in impeller backface cavity has critical impacts on aerodynamic performance of the RIT and axial force acting on the RIT impeller.In order to control this leakage flow,different types of labyrinth seals are numerically studied in this paper based on a supercritical carbon dioxide(S-CO_(2))RIT.The effects of seal clearance and cavity outlet pressure are first analyzed,and the impacts of seal design parameters,including height,number and shape of seal teeth,are evaluated.Results indicate that adding labyrinth seal can improve cavity pressure and hence adequately inhibits leakage flow.Decreasing the seal clearance and increasing the height of seal teeth are beneficial to improve sealing performance,and the same effect can be obtained by increasing the number of seal teeth.Meanwhile,employing seals can reduce leakage loss and improve RIT efficiency under a specific range of cavity outlet pressure.Finally,the influences of seal types on the flow field in seal cavity are numerically analyzed,and results demonstrate that isosceles trapezoidal type of seal cavity has better sealing performance than triangular,rectangular and right-angled trapezoidal seal cavities.

ANALYSIS OF COUPLING INFLUENCES OF LABYRINTH SEAL PARAMETERS ON CROSS COUPLED STIFFNESS AND DIRECT DAMPING COEFFICIENT

Labyrinth seal can cause steam-exciting, the structural and operating parameters of labyrinth seal have effect on stability of rotor-system. For investigating the coupling influences of the structure and operating parameters of labyrinth seals on dynamic coefficients, a model of calculating dynamic coefficients of labyrinth seals is presented using a two control volume model. The coupling influences of parameters on cross-coupled stiffness and direct damping of labyrinth seal are discussed. In the conclusion, a reference of preventing steam-exciting vibration and optimum determination of design parameters of labyrinth seals are provided.

Labyrinth Seal Design Optimization Based on Quadratic Regression Orthogonal Experiment

The influence of labyrinth seal structure parameters and their interaction on the characteristics of leakage amount are numerically investigated by conducting a quadratic regression orthogonal experiment. To determine the optimal structure parameters of the steam seal for minimizing the leakage amount, a reliable regression equation that does not lack of fit is established. The flow characteristics of the fluid in the labyrinth seal are analyzed in detail. Results show that the leakage amount is greatly influenced by seal cavity depth, convex platform height, seal tooth thickness, and tooth tip clearance, with the tip clearance having the most significant effect. The interaction among the four items exerts a certain impact on the leakage amount. The proposed regression equation exhibits a good significance and does not lack of fit. After optimization, the labyrinth seal demonstrates increased entropy and energy dissipation at the tip of the seal tooth, as well as decreased speed and inertia effect in the cavity, suggesting that the resistance leakage performance of the optimized labyrinth seal is improved.

Nonlinear dynamic characteristics model of labyrinth seal based on Muszynska model

An accurate seal forces model is the foundation to analyze the rotor-seal systems. In this paper, the Navier-Stokes equation and energy equation are solved to simulate the interior flow field in the labyrinth seal gap. The leakage rate is compared with the experimental results in the literatures. The ：4maximum error is 4% , which proves that the method of employing CFD to simulate the interior flow field of labyrinth seal gap is reliable. Based on this, the interior flow field and fluid exciting force of stage teeth labyrinth seal are studied. By coupling with the Muszynska model, the method of defining the experience loss parameters in Muszynska model is proposed. The results indicate that the experience parameters obtained by the proposed method can depict the nonlinear exciting force of labyrinth seal better.

Labyrinth seal leakage and dynamics characteristics analysis based on Black Model

One of the important problems to be tackled in turbo machines is the leakage dynamics characteristics of labyrinth seals. In this paper we analyzed the effect of labyrinth seal structure and the change in fluid flow pressure on the leakage characteristics of seal. Computational fluid dynamics (CFD) model for 3D labyrinth seal was built which provides a basis for reducing steam flow excitation. The streamline pattern and the pressure drop characteristics for leakage of steam through a labyrinth seal was investigated. Simulations of internal flow and leakage characteristics had been performed by CFD software and Black-Child model. The results showed that the amount of leakage is directly proportional to the tooth gap and inlet pressure and inversely proportional to the cavity depth and outlet pressure. The proposed CFD model provides a feasible method to predict the leakage characteristics of labyrinth seal in response to the structure of seal and the change in inlet-outlet pressures.

高速篦齿碰摩对封严环裂纹萌生与扩展影响研究

篦齿封严结构碰摩是航空发动机空气系统工作中存在的普遍问题,由于实际碰摩中难以观察到封严环上裂纹萌生与扩展的过程,采用有限元方法进行数值仿真能够对裂纹萌生与扩展过程和机理有更加深入的认识。建立碰摩后带磨损槽的封严环模型,考虑了封严环表面对流换热、碰摩力和碰摩温度,采用扩展有限元法(XFEM)对封严环碰摩温度场、应力场以及裂纹的萌生与扩展进行数值研究,并将仿真分析结果与碰摩试验裂纹结果进行对比。结果表明:数值仿真所得到的裂纹萌生位置及扩展方向均与碰摩试验中实际产生的裂纹基本一致,揭示了裂纹产生的机理,证明了该模型能够较好地模拟碰摩所导致的裂纹萌生与扩展过程。

具有前置凸台防旋板的汽轮机交错齿迷宫密封动力学特性研究

为提高汽轮机多级轴端迷宫密封动力学性能,针对汽轮机两级轴端交错齿迷宫密封,开展了具有前置凸台的新型防旋板结构方案设计和止旋抑振性能评估。首先,针对两级轴端交错齿迷宫密封,设计了一级和两级传统防旋板、一级和两级前置凸台新型防旋板等动密封防旋板结构方案,并建立了具有“虚拟旁路边界”的有、无防旋板多级交错齿迷宫密封动力学计算模型,实现了对多级动密封进口压力场和高预旋速度场的精准模拟;然后,采用基于多频椭圆轨迹涡动模型的动密封气流激振动力学特性(CFD)摄动数值预测方法,对比分析了无防旋板、传统防旋板和新型前置凸台防旋板作用下,两级交错齿迷宫密封泄漏特性和气流激振动力学特性;最后,通过分析不同防旋板结构方案下,两级交错齿迷宫密封腔室旋流发展、腔室速度场和动态压力分布、转子面气流激振力,阐明了防旋板的止旋抑振机制。结果表明:无防旋板的迷宫密封具有最低的泄漏量,一级传统防旋板或一级前置凸台防旋板的设置会使密封齿数减少,导致密封泄漏量增加约4.5%;相比于一级防旋板,具有两级防旋板的迷宫密封泄漏量增加约5.5%;相比于传统防旋板,前置凸台防旋板可减小交叉刚度、增大有效阻尼;相比于一级防旋板,两级防旋板可减小高涡动频率下的交叉刚度、增大直接阻尼,进而提高密封的有效阻尼;在传统防旋板的基础上设置前置凸台可提升防旋板的止旋性能,且两级防旋板可有效抑制密封下游区域的旋流发展,能显著提升迷宫密封动力学性能、抑制汽轮机轴系振动失稳。

分流通道对台阶型篦齿封严性能影响研究

为提高涡轮级间篦齿的封严性能,设计了一种带分流通道的台阶型篦齿封严结构,研究了不同压比与转速下分流通道对篦齿封严泄漏特性和传热特性的影响规律,并与光滑篦齿进行对比。结果表明:在衬套上增设一个分流通道后,处于通道出口处的气流在离心力作用下被卷吸进通道,增强了篦齿的封严效果;分流通道的周向间隙率β越大,封严效果越佳,当周向间隙率β为3时,绝热壁面流量系数为13.47%,绝热壁面风阻温升为48.7 K;分流通道数量增加,篦齿的泄漏加剧;随着压比增加,密封泄漏量增大,分流通道可以引导核心射流回流,故泄漏量增速逐渐变缓而绝热壁面风阻温升增速加剧;当转速从3×10^(3)r/min增加到2.1×10^(4)r/min,气流摩擦耗散加剧,篦齿绝热壁面流量系数逐渐降低,绝热壁面风阻温升逐渐升高,分流通道对高转速下篦齿的封严效果提升显著。

进口防旋板对汽轮机交错齿迷宫密封泄漏特性和动力学特性影响研究

为提高汽轮机高压缸和中压缸之间过桥汽封的气流激振动力学性能、抑制汽轮机轴系振动失稳,针对交错齿迷宫密封,开展了进口防旋板结构方案设计和动力学性能评估研究。首先,建立了具有“虚拟旁路边界”的交错齿迷宫密封动力学计算模型,实现了对动密封进口压力场和高预旋速度场的精准模拟;然后,采用基于多频椭圆轨迹涡动模型的非定常计算流体动力学(CFD)摄动数值方法,对比分析了进口预旋(预旋比为0、0.3、0.5)对无防旋板结构的迷宫密封的动力特性系数的影响规律;最后,详细评估了不同进口防旋板结构方案的止旋抑振性能,比较分析了防旋板倾角和数量对迷宫密封的泄漏量、动力特性系数和周向旋流比分布的影响规律。研究结果表明:迷宫密封泄漏量对防旋板倾角和数量变化不敏感(泄漏量变化小于0.5%);进口预旋会导致迷宫密封交叉刚度和有效阻尼穿越频率增大、有效阻尼减小,易诱发轴系失稳;进口防旋板能够显著减小迷宫密封的交叉刚度(约为53%)和有效阻尼穿越频率(约为24 Hz)、增大有效阻尼,使密封泄漏量略有增加(约为4.5%);相较于直防旋板,45°倾角斜防旋板使密封交叉刚度进一步降低约14%,有效阻尼穿越频率变化较小;当防旋板数由36增加到72时,密封交叉刚度降低约24%,有效阻尼穿越频率减小约5 Hz;而当防旋板数由72增加到144时,密封的转子动力特性对防旋板数变化不敏感;综合考虑加工成本和止旋抑振性能,具有72个直防旋板的迷宫密封进口防旋板结构方案最优。研究结果可为交错齿迷宫密封防旋板设计提供参考。

基于能量法的篦齿封严环气弹稳定性数值研究

针对航空发动机篦齿封严环气弹稳定性问题,采用基于三维插值及非定常动网格技术的能量法,建立了篦齿封严环气弹稳定性数值求解模型。在验证数值方法准确性的基础上,研究了供气压力、转速和进气畸变对篦齿封严环气弹稳定性的影响,分析了篦齿封严环气动力、气动功分布特性,揭示了进气畸变对篦齿封严环气弹稳定性的影响机理。研究表明:在本文研究中,外篦齿封严环相对于内篦齿封严环更易发生气弹失稳;随供气压力增加,外篦齿封严环气弹稳定性呈现降低趋势,当供气压力为0.55 MPa和0.7 MPa时,外篦齿封严环存在气弹失稳的风险;转速2000 r/min和4000 r/min相对于6000 r/min具有更大的气弹失稳风险。相比于360°圆周进气,90°圆周进气的外篦齿封严环气动力存在相互抵消的耦合作用,所以90°圆周进气的外篦齿封严环具有较高的气弹稳定性。篦齿封严环在发生气弹失稳时,齿腔底部做功占总气动功百分比会显著增加,故在进行结构优化时,可改变齿腔底部的结构参数以对篦齿封严环气弹稳定性进行改善。

周向进气畸变对篦齿封严环气弹稳定性影响研究

针对航空发动机篦齿封严环在周向进气畸变状态下的气弹稳定性问题,采用三维插值和非定常动网格技术,建立了基于能量法的篦齿封严环气弹稳定性求解模型,在验证求解模型准确性的基础上,研究了对称进气与非对称进气、进气畸变程度对篦齿封严环气弹稳定性的影响规律,分析了气动功在齿腔不同区域分布特性,揭示了周向进气畸变对篦齿封严环气弹稳定性影响机理。研究表明,周向进气畸变可改变气动阻尼比,对篦齿封严环气弹稳定性影响较大。非对称进气时,篦齿封严环气弹稳定性随畸变度的增加先降低后增加再降低。对称进气时,篦齿封严环气弹稳定性随畸变度的增加先增加后降低,相对于非对称进气畸变,对称进气方式对气弹稳定状态影响较小。篦齿封严环在发生气弹失稳时,周向进气畸变对气动功影响最大的区域位于首级篦齿迎风区域,是流场周向压力均匀性最差的区域,周向进气畸变的影响随相对距离增加而降低;篦齿封严环所有齿腔底部的总气动功受周向进气畸变影响较大,在进行结构设计时可改变齿腔底部尺寸、形状等,以降低周向进气畸变对篦齿封严环气弹稳定性的影响。

偏置量影响的超超临界汽轮机转子密封动力特性

超超临界汽轮机运行时不平衡的汽流冲击力会引发汽流激振,以某1000MW汽轮机超高压缸隔板迷宫密封为研究对象,采用改进的涡动方程控制转子实现多频涡动,分析了不同偏置量对密封动力特性的影响。结果表明:直接刚度k_(yy)随涡动频率的增加而增加,直接阻尼c_(yy)在30Hz以前先降低后不变。随着压比的增加,有效阻尼增大,转子的稳定性提高。各偏置量下直接刚度k_(yy)朝着正方向增大,c_(yy)随频率的增加先大幅度减小最后近似不变,偏置量引起的密封气动特性变化在高压区域较强。

基于CFD的双侧迷宫密封结构气缸侧密封齿优化

针对压缩机迷宫密封内部流场与泄漏量问题,对双侧迷宫密封结构中的气缸侧密封齿展开优化研究。设计三角形、矩形、摆线形3种气缸侧密封齿结构,选用不同的气缸与活塞侧密封齿的齿高、齿宽、密封齿间隙的几何比例(1∶2、1∶3、1∶4、1∶5、1∶6),建立不同结构的双侧密封齿密封模型,对其密封性能进行CFD动网格瞬态模拟,并与单侧密封齿密封结构进行了比较。结果表明:双侧密封齿密封结构的泄漏量相比单侧密封齿密封结构下降了25.8%~56.0%;3种不同形状的气缸侧密封齿密封性能由高到低依次为三角形、矩形、摆线形;不同几何比例的气缸侧密封齿模型中,密封性能从强到弱排列为1∶4、1∶5、1∶2、1∶6、1∶3。气缸侧与活塞侧迷宫齿几何比例为1∶4的三角形气缸侧密封齿结构的密封性能最优,相比单侧密封齿密封结构泄漏量下降了56%。

基于瞬态有限元的齿轮箱迷宫密封泄漏研究

针对某高速列车齿轮箱迷宫密封的润滑油泄漏问题,基于ANSA软件建立齿轮箱及迷宫密封结构的有限元模型,并采用FLUENT软件对其进行多相流瞬态仿真分析,研究迷宫密封结构的相对啮合深度、节流齿厚、径向间隙、回油孔直径及个数、齿与台阶距离、齿宽、密封间隙对润滑油泄漏量的影响。结果表明:当相对啮合深度大于0.5时,润滑油泄漏量与相对啮合深度呈负相关;润滑油泄漏量与节流齿厚、回油孔直径、回油孔数量呈负相关;润滑油泄漏量与径向间隙、齿宽、齿与台阶距离、密封间隙呈正相关。根据研究结果对迷宫密封结构进行改进,改进后的迷宫密封结构润滑油泄漏量降低为原始泄漏量的3.6%。

基于反旋流的密封气流激振抑制方法及结构参数设计

梳齿密封因其结构简单、方便维修及使用寿命长等特点被广泛应用于各类透平机械,反旋流装置可通过影响密封腔室内周向流动,减弱螺旋形效应引起的气流激振问题,提高密封系统稳定性。建立反旋流梳齿密封三维数值模型,计算分析不同结构参数下反旋流喷嘴对密封动力学特性影响。结果表明:反旋流喷嘴倾斜角度越小,系统阻尼越大、稳定性越高,当倾斜角度为30°时,有效阻尼为垂直角度入射时的4倍;反旋流喷嘴形状对密封动力特性及流动特性影响较小,2种喷嘴孔型交叉刚度均为负值且低频下二者交叉刚度差值约为5 k N/m、高频下约为1~2 k N/m;喷嘴数目越多,越能够抑制转子周向流动,利于系统稳定。

进口预旋下三种典型迷宫密封转子动力特性研究

为探讨考虑进口预旋的迷宫密封转子动力特性,基于Murphy小位移涡动理论建立气流激振力与转子涡动位移的控制方程,采用用户自定义函数建立多频椭圆涡动模型,利用FLUENT动网格技术数值求解直通齿式迷宫密封(SLS)、倾斜齿式迷宫密封(ILS)和阶梯式迷宫密封(STLS)在不同预旋比下的激振力,通过快速傅里叶变换得到整机运行时的密封动力特性系数,并对转子稳定性和密封的泄漏量进行分析。结果表明:在40~180 Hz涡动频率范围内3种密封结构的直接刚度系数呈先减小后增大的趋势,表现出很强的频率相关性,而密封结构与进口预旋对阻尼系数的影响可以忽略;阻尼系数随涡动频率增加缓慢减小至负值并趋于平稳,其中STLS的阻尼系数最小,稳定性最差,ILS的稳定性最好;增加进口预旋比会降低有效阻尼系数,并导致泄漏量降低;STLS在不同预旋条件下的密封性能均最佳,相比于SLS与ILS的泄漏量分别减少了15%和7%;在研究的20~200 Hz涡动频率范围内3种类型迷宫密封的交叉刚度由负值增大为正值,而有效阻尼减小为负值,此时迷宫密封转子系统稳定较差,可能会诱发转子失稳。

梳齿汽封泄漏特性实验研究

通过建立梳齿汽封三维数值计算模型研究了在不同背压阀门开度、转速和进口压力下梳齿汽封泄漏量的变化规律,设计并搭建了梳齿汽封泄漏特性密封实验台,并将模拟值与实验值进行对比。研究表明:梳齿汽封实验值与模拟值吻合较好;同一背压阀门开度下,梳齿汽封泄漏量随着进口压力增大而增加,且近似呈线性关系,而随着转速升高,梳齿汽封泄漏量缓慢下降且近似保持恒定;保持进口压力和转速恒定,汽封泄漏量随着背压阀门开度的变大而增加,且汽封泄漏量在背压阀门开度为1.0时最大。