Test Results for Leakage and Rotordynamic Coefficients of Floating Ring Seals in a High-Pressure,High-Speed Turbopump

Test results are presented for short floating ring seals (D = 53.0 mm, L/D = 0.15) using a smooth surface and a round-hole pattern defined as a damper floating ring seal (h/C_r = 3, γ = 0.34: the ratio of hole area to surface area) for supplied pressures of 3.0, 5.0, and 7.0 MPa, respectively, with the shaft operating speed up to 24,800 rpm. The measured data includes leakage, attitude angle, eccentricity ratio, and rotordynamic coefficients such as stiffness, damping, and inertia. When the floating ring seals are locked up, the eccentricity ratio of the smooth surface floating ring seal is lower than that of the damper floating ring seal. The attitude angle increases linearly with the operating speeds. The damping coefficients of the damper floating ring seal are higher than those of the floating ring seal. Whirl frequency ratios of the floating ring seal are lower than the damper floating ring seal with high eccentricity ratio at low operating speed range. The design parameters determined from these test results will be used for high-pressure and high-speed turbopump seals in a liquid rocket engine system.     

Numerical simulation of rotordynamic coefficients for eccentric annular-type-plain-pump seal using CFD analysis

Annular seals are primarily used to control the leakage in turbomachinery, such as pumps. Consequently, annular seals substantially affect the stability of turbomachinery. Designing the annular seals of high performance pumps require the accurate prediction of the seal’s leakage flow rate and rotordynamic coefficients. The bulk-flow model is the traditional means for leakage flow rate analysis and predictions. Bulk-flow analysis is based on the Hirs’ lubrication equation, which simplifies the Navier-Stokes equation. However, the analysis of the bulk-flow model requires a great amount of time to develop an analysis code. Furthermore, the code possesses many constraints for analyzing seals with complicated shapes. 3D CFD simulations provide faster and less expensive estimates of the flow field for a wide variety of operating parameters and flow conditions. In this study, the flow field and the rotordynamic coefficients of a plain-eccentricannular seal were simulated with circular whirl orbits using 3D CFD code. A relative coordinate system was defined to calculate the 3D velocity profile and the dynamic pressure distribution of the seal clearance for each rotor whirling speed. The rotordynamic coefficients were determined by reaction forces of seal fluid, which were calculated by integrating the dynamic pressures to the whole area of seal. The results from our analyses were compared to existing theoretical calculations as well as compared to results acquired from experiments. The present 3D CFD results of leakage and rotordynamic coefficients of K and C showed better improvement in prediction.     

可倾气封与固定气封性能试验比较分析

提出一种新型可倾气封。与传统固定式气封相比,可倾气封块在气流力作用下可以绕支点作自适应摆动,当气封块达到平衡位置时,切向激振力减小,从而提高稳定性。试验采用不平衡同频激励法测定可倾气封的动力特性,研究和比较了可倾气封和传统固定式气封的动静态性能。试验结果表明,两种气封泄漏量相当,可倾气封内产生的切向气流力比固定气封小。低压比下两种气封动力特性系数相近,随着压比的增大,动力特性系数差异逐渐增大。以气流力对气缸的做功量大小为综合评判依据,发现可倾气封做功量明显小于固定气封,压比越大,做功量差异也越大,可倾气封的稳定性较高。对于大型旋转机械而言,气封进出口压比很大,两种气封动力特性的差异将会更大。     

迷宫密封三维流场动力学特性计算及研究

迷宫密封气动特性对转子动力学特性的作用明显。应用计算流体动力学技术建立迷宫密封模型,利用计算流体动力学软件Fluent中旋转流场计算方法,对迷宫密封流场进行数值计算,该方法可以将非稳定流场计算转变成稳定流场,从而降低密封流场的计算量。讨论流场参数对其动力学特性的影响。通过对流场计算结果分析发现,气流流速在跨音速时,迷宫密封气动力系数和泄漏量都有较大的变化。因此在工程设计和操作时,要考虑密封中气流流速对转子动力学特性的影响。     

反旋流对密封静力与动力特性影响的理论与试验研究

设计加工无/有反旋流共4种密封结构,从理论与实验两个方面研究反旋流对密封静力与动力特性的影响规律。建立反旋流密封静力特性CFD模型,理论分析反旋流对密封间隙流体切向速度、周向压力分布以及泄漏特性的影响;设计搭建反旋流密封动力特性试验台,试验测试无/有反旋流密封的泄漏特性,应用不平衡同频激励法试验研究反旋流对密封动力特性的影响。研究结果表明:反旋流可减小密封间隙流体的切向速度,进而降低密封间隙流体的周向压力差,且密封间隙流体周向压差随切向速度的减小而降低,这是反旋流抑制密封气流激振力的主要原因;密封的泄漏量随进出口压比的增加而增大,两者近似呈线性关系;与无反旋流密封相比,反旋流密封增加了密封的泄漏量,且随着进出口压比的增加,两者泄漏量差异增大;密封的动力特性系数的随密封进出口压比与转速的增加而增大。在相同工况下,主刚度大于交叉刚度约一个数量级,主阻尼与交叉阻尼数量级相同,且主阻尼大于交叉阻尼;反旋流可有效降低密封的等效刚度,增加密封的等效阻尼,提高密封的稳定性。     

用双控制体模型计算直通式篦齿密封的动特性系数

用双控体模型计算直通式篦齿密封动特性系数,介绍单控体模型。通过理论计算与试验结果的对比,说明采用的双控体模型方法是可行的;分析了密封间隙、转速等对密封动特性系数的影响;用实例比较单控体模型和双控体模型的结果,得出一些有意义的结论。     

基于相似原理的环瓣式石墨密封泄漏流动特性求解模型

环瓣式石墨密封因其泄漏通道尺寸微小，导致其建模、网格划分以及计算困难。基于相似原理方法建立环瓣式石墨密封泄漏通道求解模型，采用方程分析法推导环瓣式石墨密封泄漏通道内流体流动相似准则，获得遵循几何相似和力学相似的映射模型，并采用建立的泄漏通道映射模型分析环瓣式石墨密封的泄漏流动特性，并与实际模型计算结果进行比较。研究结果表明：泄漏通道内气体流动相似性可综合采用弗劳德、欧拉、雷诺相似准则表征；映射前后模型相同结构位置处流体压力、速度分布具有较好的一致性。通过映射模型求解的泄漏量与实际模型求解的泄漏量相对误差在误差允许范围内，验证了推导的泄漏通道流体流动相似准则和映射方法的可靠性，为研究环瓣式石墨密封微小泄漏通道泄漏流动特性提供新方法。     

The effects of thermoelastic and wear on the leakage of compressible gases in shaft seals

Analysis are presented for a compressible gas flow across shaft seals. The leakage flow rate is developed analytically for a sealing gap due to eccentricity, misalignment of a shaft, sinusoidal wavy surfaces for both bodies, thermoelastic deformation on the edge of the body, and wear on the mating surfaces. A pressure distribution is determined as a power series based on the simplified nonlinear Reynolds equation. The restriction to exclude the thermoelastic effects was presented. Analytical results indicate that the thermoelastic distortion may dominate the seal performance when the eccentricity is large and width of the seal small at high speeds.     

大型水泵导轴承梳齿迷宫密封研究

推导了大型水泵油润滑导轴承梳齿迷宫密封泄漏量计算公式。通过实例计算了梳齿迷宫密封的泄漏量及各密封段的压降,分析了各段对密封效果的影响。比较了梳齿迷宫密封与端面密封的密封效果,分析了油润滑导轴承浸水的可能原因,指出了梳齿迷宫密封的适用性。结果表明:在水泵导轴承梳齿迷宫密封中O形密封圈的磨损量对泄漏量影响很大,O形密封圈必须选用耐磨性能好的材料,并控制泵轴摆度以减小O形密封圈的磨损量;在正常运行情况下梳齿迷宫密封的泄漏量远大于端面密封,因此要保证足够的排漏水能力,以免因排漏水不畅造成导轴承浸水。     

Numerical prediction of rotordynamic coefficients for an annular-type plain-gas seal using 3D CFD analysis

Annular-type gas seals in many types of compressors and turbines are designed to reduce leakage and enhance the vibrational stability of the turbo machinery. Many researchers have attempted precise theoretical evaluation of the leakage and the rotordynamic coefficients from reaction forces of small seal gaps. The Bulk-flow model, which is based on Hirs’ lubrication equation, is a general method with advantages of simplicity and short computing time. However, due to the disadvantage of the long time required to develop analysis code, and constraints from complicated seal shapes, CFD analysis is currently preferred. In the present, the method for determining the rotordynamic coefficients of an annular plain-gas seal, which is the simplest shape of gas seals, is suggested by extending the analysis of an annular plain-pump seal. A relative coordinate system for steady-state simulation is defined to calculate the compressible flow field and dynamic pressure distribution of the seal gap. The present analysis is verified by comparison with results acquired from Bulk-flow analysis code and published experimental results. The 3D CFD rotordynamic coefficients results of direct stiffness(K) and cross coupled stiffness(k) show better improvements in prediction.     

Parametric Study of Spiral Groove Gas Face Seals

A finite element analysis for the isothermal flow in spiral groove gas face seals is detailed along with a successive approximation method for the iterative solution of the nonlinear Reynolds equation. Zeroth- and first-order pressure fields are calculated for evaluation of the seal opening force and leakage and the axial stiffness and damping force coefficients, respectively. A parametric study shows the static and dynamic force behavior of a baseline SGFS operating with a large pressure ratio. The recommended geometric parameters presented ensure large static stiffness and damping force coefficients while still allowing for low seal leakage rates. A reduction in the power loss and a significant increase in the seal static stiffness coefficient are unique features of thin seal dams.     

Pressure dam influence on the performance of gas face seals

The introduction of grooves, micropores, and other forms of surface geometric modifications onto the mating seal plates has been performed to enhance the gas face seal performance. Reducing fluid leakage through the seal surface has been the main motivation for the development of efficient sealing technology for industrial turbomachinery. Pressure dams are generally etched on the seal inner and outer radii to improve even more the seal capability of reducing the gas leakage to atmosphere. This paper presents a finite element analysis carried out to determine the opening force, the flow leakage and the dynamic force coefficients of flat gas face seals with pressure dams operating under stringent conditions. Several curves of steady-state and dynamic seal performance characteristics depict the influence of the pressure dam position and width on the seal performance and efficiency.     

新型涡流槽密封泄漏特性与动力特性研究

提出一种密封入口周向均匀设置有涡流槽的新型密封结构,建立了传统迷宫密封与新型涡流槽密封泄漏特性及动力特性求解模型,在实验验证数值计算方法准确性的基础上,通过比较分析了传统迷宫密封与新型涡流槽密封在不同进出口压比、预旋比工况下的泄漏特性与动力特性,研究了新型涡流槽结构对密封泄漏特性及动力特性的影响机理。研究结果表明：随着涡流槽数量的增加,涡流槽密封的泄漏量逐渐降低;在同一压比下,不同涡流槽数新型密封的泄漏量之间差值随着压比的增大而增大。当压比为6时,64涡流槽的新型密封较传统迷宫密封,泄漏量下降了3.37%;在高预旋比的工况下,不同涡流槽数量密封的切向气流力均与转子涡动方向相反,起到抑制转子涡动的作用,且随着涡流槽数量的增加,切向气流力也随着增大;随着转子涡动频率的增大,三种不同涡流槽数量密封的交叉刚度先减小到负值然后增大到正值。涡流槽密封的有效阻尼均高于传统迷宫密封,新型涡流槽密封可以提高转子系统的稳定性。     

Estimation of the leakage for compressible gases in high-speed shaft seals

A comprehensive analytical work to estimate the leakage rate is presented for compressible fluid flow across shaft seals. The sealing gap for this study includes geometric terms such as eccentricity, misaligned shaft, and sinusoidal waviness of the mating surfaces. A temperature distribution across the sealing gap is developed using a temperature dependent viscosity. A pressure distribution in polynomial form is solved based on the simplified nonlinear Reynolds equation using the approximate power series expansion. It was found that the seal performance is largely influenced by the eccentricity and width of the seal at high speeds (greater than about 150m/s).     

空化对低温浮动环密封流场和密封特性的影响

为探究典型工况下单相和两相空化流动的流场及密封特性,对考虑过渡段的低温浮动环密封进行数值仿真,对比分析转子面、密封间隙轴向及周向的压力分布特点,并探究单相和两相流动条件下进口压力、进口温度、转子偏心率以及转子转速对泄漏量、进口损失系数、密封力和偏位角的影响.研究结果表明:同心状态下,单相流和两相流的流场均具有对称性;偏...     

接触式机械密封端面泄漏模型的研究进展

泄漏率是评定机械密封性能的主要参数。接触式机械密封端面泄漏过程复杂,影响因素较多,且泄漏率是一个与运行时间相关的变量,而非稳态参数,因此其泄漏模型的建立是机械密封研究领域的难点。国内外的学者对接触式机械密封端面泄漏模型进行了大量的研究,相继提出了经验公式和数值计算模型。本文介绍了边界摩擦状态和混合摩擦状态的泄漏率经验公式;分析了包含密封端面间的液膜压力、微凸体接触比压、液膜厚度和载荷平衡方程的泄漏率数值计算模型,对不同作者在不同假设条件下采用数值计算模型得出的泄漏率计算结果进行了比较分析;探讨了经验公式和数值计算模型存在的问题。     

迷宫和薄叶气封结构与气动特性的对比分析

数值研究相同条件下迷宫气封和薄叶气封结构特点、气动特性、密封机理及密封效果,比较两种气封的差异。通过与已发表的试验数据的对比,校核所采用的商业计算流体力学软件CFX的可靠性,计算得到的性能曲线与试验数据有较好的一致性,采用的数值模拟方法可行。分别对迷宫气封和薄叶气封内部流场进行数值模拟。通过对两种气封计算结果的对比分析,阐明它们的密封机理,给出各自的封严特性和所产生的摩擦转矩的变化规律。分析结果表明,薄叶气封的径向间隙远小于迷宫气封,漏气量为迷宫气封的1/3,对旋转轴产生的摩擦阻抗力矩低于迷宫气封,从结构运行特点和气动性能两方面说明薄叶气封的优越性,认为在不久的将来薄叶气封有可能替代迷宫气封。     

A novel negative dislocated seal and influential parameter analyses of static/rotordynamic characteristics

This paper proposes a new type of negative dislocated seal (NDS) based on the dislocated bearing theory to investigate the influential parameters of static rotor eccentricity and dislocated ratio on the static and rotordynamic characteristics of an example seal solved with computational fluid dynamics (CFD) the flow field. The rotordynamic characteristics of the NDS were investigated in respect of the effects of rotor whirling frequency on response force, stiffness coefficients, damping coefficients and rotor system stability, by multifrequency elliptical orbit rotor whirling model. Based on the studies, we reached the following conclusions. The circumferential pressure distribution of NDS and conventional labyrinth seal (LS) presents sine periodic variation approximately, while relative to the LS, the NDS has two divergent wedge gaps and reduces the hydrodynamic pressure effects, then the circumferential pressure difference and tangential force on rotor surface decreases by about 40 %~190 %. The leakage of the NDS linearly increases with the rising eccentricity ratio and dislocation ratio approximately, and is larger (about 0.9 %~1.5 %) than the LS. The direct stiffness coefficients of the two seals increase with the rise of rotor whirling frequency, while the absolute values of both the cross-coupled stiffness coefficients and the damping coefficients decrease with raising rotor whirling frequency. Compared with the LS, the NDS has smaller (about 28.8 %~206.2 %) cross-coupled stiffness coefficient, larger (about 26.15 %~60.39 %) effective damping coefficient, and good stability of rotor system. This study has developed a novel seal structure to improve the seal performance of turbomachinery such as aeroengine.     

表面粗糙度对矩形动密封特性的影响

基于耦合了密封圈的弹性变形、流体动力分析和过盈接触的密封性能数值计算流程,利用Matlab 软件编程实现矩形动密封特性的数值计算,得到矩形密封圈的油膜厚度、泄漏量及摩擦力等密封性能参数,分析表面粗糙度对矩形密封圈的润滑状态和泄漏量的影响。结果表明：往复运动速度一定时,随着密封圈粗糙度的增加,密封偶合面的润滑状态由流体润滑转变为润滑润滑状态,密封的泄漏量也呈几何式增加,说明粗糙度对密封圈的工作寿命和密封性能有较大的影响;往复运动速度也是影响矩形密封圈密封性能的关键工作参数之一,密封压力一定时,随着粗糙度的增加,不发生泄漏的临界速度降低。     

Influence of the Mechanical Seals on the Dynamic Performance of Rotor–Bearing Systems

In this paper, to consider the effects of mechanical seals, a lumped-mass model and the transfer matrix method are used to establish the equations for the dynamics performance of rotor bearing system. The general inverted iteration method is also used to solve the eigenvalue problem of these equations. To check the response of the rotor bearing system under unbalance motivation, the Gauss method is used to calculate the dynamic response of the constrained vibration. The results, based on the dynamic properties calculation of a typical mechanical spiral seal, such as stiffness coefficients and damping coefficients, exert the influence of the mechanical seal on the rotor bearing system of the high-speed machinery. Meanwhile, some structure parameters that may affect the dynamic performance and forced vibration under unbalance motivation of the rotor bearing system considering mechanical seals are analyzed in the paper. The analysis results show that the mechanical seal more or less has effects on the rotor bearing system. The mechanical seal has much more effects on the flexible rotor bearing system than on the rigid one. For instance, in a certain case, if the effects of the mechanical seal were taken into account, the system s critical speed may increase by 70 80%.