Study on wear characteristics of brush seal bristle tips based on fluid-structure interaction modeling
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摘要:
随着航空发动机向着高推质比以及低油耗方向发展，刷式密封的工作环境越来越苛刻。特别是在高压、高转速环境下，刷丝尖端极易与转子发生摩擦磨损，进而导致整个密封系统的失效。基于三维稳态刷式密封模型，并结合Archard黏着磨损理论，在考虑刷丝多载荷作用发生变形情况下建立了能够高效求解刷丝尖端摩擦磨损特性的流固耦合研究方法。实际工作过程中转子受热膨胀/径向跳动，与刷丝发生严重干涉，从而加剧刷丝尖端的磨损。因此，详细研究了转子径向位置不变及恢复原位两种情况下的刷丝磨损特性，揭示了刷丝尖端磨损对刷丝受力、变形以及泄漏量的影响规律，并且对比了不同压比和干涉量下的磨损情况。研究结果表明：在转子径向位置变化并恢复原位的情况下，上游区域刷丝所受转子接触力大于下游刷丝，磨损较快。磨损量在前100 min内增长速度最快，300 min后逐渐趋于平稳。在转子在干涉位置保持不变的情况下，刷丝磨损速度比磨损后转子恢复原位的情况下快29.7%，泄漏量的激增主要发生在磨损开始的0～50 min。两种情况下泄漏量激增的原因不同，转子恢复原位的情况下泄漏量由于径向间隙的增大而增大，转子位置保持在干涉位置不变的情况下泄漏量的增长取决于刷丝的排列状态。
Abstract:As aero-engines develop towards higher thrust-to-weight ratios and lower fuel consumption, the operating environment for brush seals has become increasingly harsh. Especially in high-pressure and high-speed environments, the tips of the brush filaments are prone to frictional wear against the rotor, which can lead to the failure of the entire sealing system. Based on a three-dimensional steady-state brush seal model and combined with the Archard adhesive wear theory, a fluid-solid coupling research method that can efficiently solve the frictional wear characteristics of brush filament tips under the condition of deforming brush filaments under multi-load effects was established. During actual operation, the rotor underwent thermal expansion/radial runout, causing severe interference with the brush filaments and thereby exacerbating the wear of the brush filament tips. Therefore, a detailed study was conducted on the wear characteristics of brush filaments under two scenarios: when the rotor’s radial position remained unchanged and when it returned to its original position. It revealed the influence of brush filament tip wear on the force, deformation, and leakage of the brush filaments, and compared the wear conditions under different pressure ratios and interference amounts. The research results showed that when the rotor’s radial position changed and returned to its original position, the contact force exerted by the rotor on the brush filaments in the upstream region was greater than that on the downstream brush filaments, resulting in faster wear. The wear amount increased most rapidly within the first 100 minutes and gradually stabilized after 300 minutes. When the rotor remained in the interference position, the wear rate of the brush filaments was 29.7% faster than when the rotor returned to its original position after wear. The sharp increase in leakage mainly occurred within 0—50 minutes from the start of wear. The reasons for the sharp increase in leakage were different under the two scenarios: in the case where the rotor returned to its original position, the leakage increased due to the enlargement of the radial gap; in the case where the rotor remained in the interference position, the increase in leakage depended on the arrangement state of the brush filaments.
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Key words:
- brush seal /
- wear characteristics /
- fluid-structure interaction /
- adhesive wear /
- Archard model
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图 7 刷丝与转子接触力对比
Figure 7. Comparison of positive pressure between brush filament and rotor
图 8 刷丝磨损过程中转子位置变化情况
Figure 8. Changes in the position of the rotor during the bristle wear process
图 10 不同时间静压分布云图及流线图
Figure 10. Contour and streamline diagram of static pressure distribution at different times
图 18 Z=0.5 mm截面轴向速度分布及流线图
Figure 18. Axial velocity distribution and streamline diagram of Z=0.5 mm section
图 21 两种情况下总磨损体积随时间变化
Figure 21. Variation of total wear volume over time at two conditions
图 23 30 min时不同压比下刷丝接触力
Figure 23. Positive pressure of the brush filament at different pressure ratios at 30 min
图 24 不同压比下刷丝磨损长度随时间变化
Figure 24. Variation of brush filament wear length with time at different pressure ratios
图 26 不同压比下刷式密封摩擦磨损特性随时间变化
Figure 26. Variation of friction wear characteristic of brush seal under different pressure ratios
图 28 30 min时不同压比下刷丝接触力
Figure 28. 30 min at different pressure ratios of the brush filament positive pressure
图 29 不同干涉下刷丝磨损长度随时间变化
Figure 29. Variation of brush filament wear length with time under different interferences
图 31 不同干涉下刷式密封摩擦磨损特性随时间变化
Figure 31. Variation of friction and wear characteristics of brush seal under different interferences
图 32 不同干涉下泄漏量随磨损时间变化
Figure 32. Amount of leakage varies with wear time under different interferences
表 1 刷式密封几何参数
Table 1. Geometric parameters of brush seal
参数 数值 轴向刷丝排数n 10 刷丝与径向倾角φ/（°） 40 刷丝长度l/mm 13.35 悬挂高度h/mm 1.5 刷丝直径d/mm 0.1 弹性模量E/1011 （N/m2） 2.25 刷丝与转子径向间隙Δc/mm 0 
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