Study on wear characteristics of brush seal bristle tips based on fluid-structure interaction modeling
-
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.
-
Key words:
- brush seal /
- wear characteristics /
- fluid-structure interaction /
- adhesive wear /
- Archard model
-
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 
下载: 导出CSV
-
[1] ASLAN-ZADA F E, MAMMADOV V A, DOHNAL F. Brush seals and labyrinth seals in gas turbine applications[J]. Proceedings of the Institution of Mechanical Engineers: Part A Journal of Power and Energy, 2013, 227(2): 216-230. doi: 10.1177/0957650912464922 [2] CONNER K J, CHILDS D W. Rotordynamic coefficient test results for a four-stage brush seal[J]. Journal of Propulsion and Power, 1993, 9(3): 462-465. doi: 10.2514/3.23644 [3] CHUPP R E, GHASRIPOOR F, TURNQUIST N A, et al. Advanced seals for industrial turbine applications: dynamic seal development[J]. Journal of Propulsion and Power, 2002, 18(6): 1260-1266. doi: 10.2514/2.6061 [4] 房友龙, 刘永葆, 余又红, 等. 热和离心力作用下高压涡轮转子的径向变形[J]. 燃气涡轮试验与研究, 2011, 24(2): 31-35. FANG Youlong, LIU Yongbao, YU Youhong, et al. Radial displacement of HPT rotor caused by the centrifugal and heat[J]. Gas Turbine Experiment and Research, 2011, 24(2): 31-35. (in ChineseFANG Youlong, LIU Yongbao, YU Youhong, et al. Radial displacement of HPT rotor caused by the centrifugal and heat[J]. Gas Turbine Experiment and Research, 2011, 24(2): 31-35. (in Chinese) [5] 杜春华, 吉洪湖, 胡娅萍, 等. 刷式封严磨损特性及其对泄漏影响的试验研究[J]. 推进技术, 2017, 38(11): 2597-2605. DU Chunhua, JI Honghu, HU Yaping, et al. Experimental investigation on wearing characteristics and effects on leakage of brush seal[J]. Journal of Propulsion Technology, 2017, 38(11): 2597-2605. (in ChineseDU Chunhua, JI Honghu, HU Yaping, et al. Experimental investigation on wearing characteristics and effects on leakage of brush seal[J]. Journal of Propulsion Technology, 2017, 38(11): 2597-2605. (in Chinese) [6] BAYLEY F J, LONG C A. A combined experimental and theoretical study of flow and pressure distributions in a brush seal[C]// Proceedings of International Gas Turbine and Aeroengine Congress and Exposition. New York, US: ASME, 2015: 404-410. [7] CHEW J W, LAPWORTH B L, MILLENER P J. Mathematical modeling of brush seals[J]. International Journal of Heat and Fluid Flow, 1995, 16(6): 493-500. doi: 10.1016/0142-727X(95)00061-T [8] CHEN L H, WOOD P E, JONES T V, et al. An iterative CFD and mechanical brush seal model and comparison with experimental results[J]. Journal of Engineering for Gas Turbines and Power, 1999, 121(4): 656-662. doi: 10.1115/1.2818522 [9] 孙丹, 刘宁宁, 胡广阳, 等. 考虑刷丝变形的刷式密封流场特性与力学特性流固耦合研究[J]. 航空动力学报, 2016, 31(10): 2544-2553. SUN Dan, LIU Ningning, HU Guangyang, et al. Fluid-structure interaction investigation on the flow field and mechanical characteristic in brush seals with bristle deflections[J]. Journal of Aerospace Power, 2016, 31(10): 2544-2553. (in ChineseSUN Dan, LIU Ningning, HU Guangyang, et al. Fluid-structure interaction investigation on the flow field and mechanical characteristic in brush seals with bristle deflections[J]. Journal of Aerospace Power, 2016, 31(10): 2544-2553. (in Chinese) [10] 刘育心, 董文蕾, 孔晓治, 等. 刷式密封刷丝变形力学特性及周向滑移气动失稳机理研究[J]. 推进技术, 2025, 46(2): 2312008. LIU Yuxin, DONG Wenlei, KONG Xiaozhi, et al. Mechanical characteristics of bristle deflections and mechanism of circumferential slip aerodynamic instability for brush seals[J]. Journal of Propulsion Technology, 2025, 46(2): 2312008. (in ChineseLIU Yuxin, DONG Wenlei, KONG Xiaozhi, et al. Mechanical characteristics of bristle deflections and mechanism of circumferential slip aerodynamic instability for brush seals[J]. Journal of Propulsion Technology, 2025, 46(2): 2312008. (in Chinese) [11] 赵欢, 冯毓钟, 孙丹, 等. 刷式密封刷丝摩擦磨损特性实验研究[J]. 航空动力学报, 2024, 39(4): 20210490. ZHAO Huan, FENG Yuzhong, SUN Dan, et al. Experimental study on friction and wear characteristics of brush seal brush wire[J]. Journal of Aerospace Power, 2024, 39(4): 20210490. (in ChineseZHAO Huan, FENG Yuzhong, SUN Dan, et al. Experimental study on friction and wear characteristics of brush seal brush wire[J]. Journal of Aerospace Power, 2024, 39(4): 20210490. (in Chinese) [12] 冯毓钟. 刷式密封摩擦磨损特性数值与实验研究[D]. 沈阳: 沈阳航空航天大学, 2022. FENG Yuzhong. Study on friction and wear characteristics of brush seals[D]. Shenyang: Shenyang Aerospace University, 2022. (in ChineseFENG Yuzhong. Study on friction and wear characteristics of brush seals[D]. Shenyang: Shenyang Aerospace University, 2022. (in Chinese) [13] 陈春新, 李军, 丰镇平. 刷式密封刷丝束与转子接触力的数值研究[J]. 西安交通大学学报, 2010, 44(7): 23-27. CHEN Chunxin, LI Jun, FENG Zhenping. Numerical investigation into bristle-rotor contact force of brush seals[J]. Journal of Xi’an Jiaotong University, 2010, 44(7): 23-27. (in ChineseCHEN Chunxin, LI Jun, FENG Zhenping. Numerical investigation into bristle-rotor contact force of brush seals[J]. Journal of Xi’an Jiaotong University, 2010, 44(7): 23-27. (in Chinese) [14] 谢晓俊, 康宁. 低泄漏高寿命刷式封严的数值计算[J]. 航空动力学报, 2003, 18(6): 824-826. XIE Xiaojun, KANG Ning. Numerical computation of low leakage and high endurance brush seal[J]. Journal of Aerospace Power, 2003, 18(6): 824-826. (in ChineseXIE Xiaojun, KANG Ning. Numerical computation of low leakage and high endurance brush seal[J]. Journal of Aerospace Power, 2003, 18(6): 824-826. (in Chinese) [15] ZHU Peng, LIU Yuxin, KONG Xiaozhi, et al. Experimental and numerical investigation on leakage flow, bristle deflections, and oscillation characteristics of brush seals[J]. Physics of Fluids, 2025, 37: 015163. doi: 10.1063/5.0249110 [16] AKSIT M F, TICHY J A. Wear of brush seals: background and new modeling approach[J]. Tribology Transactions, 1998, 41(3): 368-374. doi: 10.1080/10402009808983760 [17] STANGO R J, ZHAO H, SHIA C Y. Analysis of contact mechanics for rotor-bristle interference of brush seal[J]. Journal of Tribology, 2003, 125(2): 414-421. doi: 10.1115/1.1510879 [18] DEMIROGLU M, GURSOY M, TICHY J A. An investigation of tip force characteristics of brush seals[C]//Proceedings of the ASME Turbo Expo: Power for Land, Sea, and Air. Montreal, Canada: ASME, 2007. 1249-1260. [19] ARCHARD J F. Contact and rubbing of flat surfaces[J]. Journal of Applied Physics, 1953, 24(8): 981-988. doi: 10.1063/1.1721448 [20] 桂长林. Archard的磨损设计计算模型及其应用方法[J]. 润滑与密封, 1990, 15(1): 12-21. GUI Changlin. The archard design calculation model and its application methods[J]. Lubrication Engineering, 1990, 15(1): 12-21. (in ChineseGUI Changlin. The archard design calculation model and its application methods[J]. Lubrication Engineering, 1990, 15(1): 12-21. (in Chinese) [21] 董书娜, 杜春华, 崔亚辉, 等. 基于Archard模型的刷式密封单边磨损特性[J]. 航空动力学报, 2020, 35(7): 1437-1446. DONG Shuna, DU Chunhua, CUI Yahui, et al. Unilateral wear characteristics of brush seal based on Archard model[J]. Journal of Aerospace Power, 2020, 35(7): 1437-1446. (in ChineseDONG Shuna, DU Chunhua, CUI Yahui, et al. Unilateral wear characteristics of brush seal based on Archard model[J]. Journal of Aerospace Power, 2020, 35(7): 1437-1446. (in Chinese) [22] 袁玮. 刷式密封接触分析及磨损特性的研究[D]. 西安: 西北工业大学, 2004. YUAN Wei. Research on contact analysis and wear characteristics of brush seals[D]. Xi’an: Northwestern Polytechnical University, 2004. (in ChineseYUAN Wei. Research on contact analysis and wear characteristics of brush seals[D]. Xi’an: Northwestern Polytechnical University, 2004. (in Chinese) [23] LIU Yuxin, ZHU Peng, PEKRIS M, et al. Investigation of the dynamic characteristics of brush seals using a transient fluid-structure interaction method[J]. Journal of Engineering for Gas Turbines and Power, 2025, 147(11): 111018. doi: 10.1115/1.4068978 [24] LIU Yuxin, CHEW J W, PEKRIS M J, et al. The effect of inlet swirl on brush seal bristle deflections and stability[J]. Journal of Engineering for Gas Turbines and Power, 2020, 142(7): 071002. doi: 10.1115/1.4046696 [25] DURAN E T. Brush seal contact force theory and correlation with tests[J]. Alexandria Engineering Journal, 2022, 61(4): 2925-2938. doi: 10.1016/j.aej.2021.08.027 -
点击查看大图
计量
- 文章访问数: 506
- HTML浏览量: 271
- PDF量: 44
- 被引次数: 0