Search Results (9)

The windage loss in impeller back gap and labyrinth seal cavities significantly impacts the aerodynamic performances of supercritical carbon dioxide (sCO₂) compressors. To accurately calculate windage loss, essential factors affecting the skin friction coefficients C_f,d (disk-type gap) and C_f,s (shaft-type gap), including Reynolds number Re, pressure ratio π, and radius ratio η, are investigated in this paper. The flow characteristics of the gap are analyzed and prediction models are proposed. The results indicate that both C_f,d and C_f,s decrease with increasing Re and grow with π and η, attributable to expanded high-vorticity regions caused by enhanced flow instability and larger vortices. The leakage flow rate m is unchanged for Re < 10⁶ since the fluid can flow into the impeller back gap, and slightly decreases for Re ≥ 10⁶ due to the centrifugal force and the inhibition effect of the vortices filling inlet regions. Moreover, the m grows with π and η due to a larger pressure difference and through-flow area. Maximal relative deviations of 6.23% and 6.83% can satisfy the requirements for calculating accurate windage loss in the impeller back gap and labyrinth seal cavities, which help the primary design of sCO₂ compressors. Full article

The worldwide concern regarding the harmful effects of old polluting and toxic propellants has led to increased interest in new, green propellants and higher efficiency thrusters. This fact requires that a new generation of turbopumps, fit for these propellants, is developed. This paper focuses on the design of a radial inflow turbine, which was developed to power a single-shaft turbopump system for a 30 kN upper stage expander cycle thruster engine. The objective was to create a high-efficiency, compact, cheap-to-manufacture, 3D-printable turbine suitable to simultaneously power the methane and Oxygen pumps that feed the thruster. The total power consumed by the pumps for which this turbine was designed is 152 kW. The solution proposed in this paper includes measures such as elimination of the bladed diffuser, which was carried out to reduce the weight and the overall dimensions of the turbine. Comparing it with an axial turbine with the same power output, it has lower overall dimensions because it does not require a direction change at the inlet to the turbine bladed components, it does not require a stator to work, and its casing has a conical shape and is not cylindrical like the axial construction one. The proposed design has been analysed by CFD, which revealed that it can power the pumps. Analysis performed in off-design conditions indicated that the turbine has the best efficiency if the rotation speed and mass flow are varied at the same time. A breadboard model of the turbopump for which the turbine in this paper has been designed has been built using plastic and tested at pressures up to 6 bars using compressed air. The results indicate that above 1.5 bars of inlet pressure the turbine can overcome the internal resistances of the components and the rotor starts to spin. No indication of imbalance of the rotor was observed at maximum test pressure. Two configurations of the seals between the turbine and the adjacent pump have been tested, indicating that labyrinth seals must be doubled by floating ring seals. Full article

The staggered labyrinth seal is widely used in aerospace, transportation, mining, and other fields due to its advantages of adapting to high speed, reliable sealing performance, and low or even frictionless friction between dynamic and static rotors. The traditional calculation method of labyrinth seal leakage mostly focuses on the fact that the internal medium is an ideal gas and only considers a single effect, which cannot accurately describe the leakage of liquid medium lubricating oil in the labyrinth seal. Therefore, this study focuses on the leakage characteristics of labyrinth seals, and it proposes a leakage calculation method based on liquid medium in view of the shortcomings of existing calculation methods under liquid medium conditions. By considering the thermodynamic and frictional effects of the staggered labyrinth sealing, the resistance loss and thermodynamic effect of the lubricating oil in the sealing cavity were analyzed. The flow field analysis was used to reveal the leakage law of lubricating oil under different conditions, and the factors such as total inlet pressure, spindle speed, and sealing clearance were considered. Finally, the leakage characteristics of the staggered labyrinth seal and the accuracy of the calculation method of the leakage of the staggered labyrinth seal under multiple effects were revealed through experimental verification. This study provides useful guidance for the performance optimization of labyrinth seals in practical applications. Full article

In order to promote the development of new power systems and the consumption of clean energy, pumped storage hydropower stations tend to become increasingly larger in capacity and higher in head height. In this paper, a three-dimensional model of the full channel of a high-head pump turbine is established, and the influence of the gap thickness between the runner crown and the headcover on the internal flow field characteristics, pressure fluctuation characteristics and axial water thrust are studied by means of computational fluid dynamics (CFD). The results indicate that the area where the pressure and velocity vary greatly in the flow field of the crown clearance is at the seal of the labyrinth ring. In addition, the pressure balance pipe has a greater impact on the pressure and flow rate of the water passing through the clearance, and the crown clearance near the pressure balance pipe generates a vortex, resulting in energy loss. Decreasing the thickness of the clearance has no obvious effect on the pressure on the flow-passing components, and increasing the thickness of the clearance has a great change in the pressure values at the upper crown inlet, in front of the labyrinth ring of the crown and in front of the labyrinth ring of the band. The upper part of the vaneless area, the crown inlet and the lower ring inlet are close to the runner; hence, the interference from the rotating parts is the strongest. The effect of increasing the thickness of the crown clearance on the axial water thrust is greater than that of decreasing the thickness of the crown clearance. The pulsation frequency of the axial thrust on the crown, band and blade and the resultant force of the axial thrust increase with the increase in the crown clearance thickness. Full article

In the typical structure of a turboshaft aero-engine, the mass flow of the cooling air in the rotor-stator cavity is controlled by the inlet seal labyrinth. This study focused on the swirl flow and heat transfer characteristics in a rotor-stator cavity with considerations of the inlet seal thermal deformation effect. A numerical framework was established by integrating conjugate heat transfer (CHT) analysis and structural finite element method (FEM) analysis to clarify the two-way aero-thermo-elasto coupling interaction among elastic deformation, leakage flow, and heat transfer. Simulation results showed that the actual hot-running clearance was non-uniform along the axial direction due to the temperature gradient and inconsistent structural stiffness. Compared with the cold-built clearance (CC), the minimum tip clearance of the actual non-uniform hot-running clearance (ANHC) was reduced by 37–40%, which caused an increase of swirl ratio at the labyrinth outlet by 5.3–6.9%, a reduction of the Nusselt number by up to 69%. The nominal uniform hot-running clearance (NUHC) was defined as the average labyrinth tip clearance. The Nusselt number of the rotating disk under the ANHC was up to 81% smaller than that under the NUHC. Finally, a clearance compensation method was proposed to increase the coolant flow and decrease the metal temperature. Full article

Labyrinth seals are widely used in centrifugal compressors, turbines, and many other pneumatic systems due to their simplicity of design, reliability, and low cost. The calculation scheme for the movement of the working medium in a labyrinth seal is constructed by analogy with the movement of the working medium through holes with a sharp edge. Annular and flat slots, holes, and such a factor as the shaft rotation with a calculated sector of 3 degrees were studied. The purpose of the study is to determine the flow coefficient when the working medium flows through slots of various shapes. To achieve this purpose, modeling of the working medium flow in the FlowVision software was performed. The mass flow and flow coefficients are determined for the studied slot shapes. The convergence of the calculation results was determined by comparing the values of the mass flow rate at the inlet and outlet of the slot. Differences in visualizations of the flow for the studied variants of slots were established. The resulting difference should be taken into account in practical calculations of the working medium mass flow through the slot using a conditional flow rate factor which is determined by the slot design. Full article

Many randomly uncertain factors inevitably arise when gas flows through a labyrinth seal, and the orbit of the rotor center will not rotate along a steady trajectory, as previously studied. Here, random uncertainty is considered in an interlocking labyrinth seal-rotor system to investigate the fluctuations of dynamic coefficients. The bounded noise excitation is introduced into the momentum equation of the gas flow, and as a result, the orbit of the rotor center is expressed as the combination of an elliptic trajectory with the bounded noise perturbation. Simulation results of the coefficients under randomly uncertain perturbations with various strengths are comparatively investigated with the traditional predictions under ideal conditions, from which the influences of random uncertain factors on dynamic coefficients are analyzed in terms of the rotor speed, pressure difference, and inlet whirl velocity. It is shown that the deviation levels of the dynamic coefficients are directly related to the random perturbations and routinely increase with such perturbation strengths, and the coefficients themselves may exhibit distinct variation patterns against the rotor speed, pressure difference, and inlet whirl velocity. Full article

In this paper, the numerical model of a centrifugal compressor low-flow stage is verified. The gaps and labyrinth seals were simulated in the numerical model. The task was to determine the optimal settings for high-quality modeling of the low-flow stages. The intergrid interface application issues, turbulence and roughness models are considered. The obtained numerical model settings are used to validate seven model stages for the range of the optimal conditional flow coefficient with Φ_opt = 0.008–0.018 and the conditional Mach number M_u = 0.785–0.804. The simulation results are compared with the experimental data. The high pressure stage-7 (HPS-7) stage with Φ_opt = 0.010 and M_u = 0.60 at different inlet pressure of 4, 10 and 40 atm is considered separately. Acceptable validation results are obtained with the recommended numerical model settings; the modeling uncertainty for the polytropic pressure coefficient δη*pol < 4% for the efficiency coefficient δη*pol exceeds the limit of 4% only in the two most low-flow stages, U and V. Full article

The seal cavity leakage flow has a considerable impact on the performance of the aeroengine, especially on the multistage compressor. Thus, a quasi-three-dimensional simulation program named CAM is developed basing on circumferentially averaged throughflow method. The program enables a rapid diagnosis for the performance degradation of multistage compressor caused by labyrinth wear. The coupling flow field between the seal cavity leakage flow and the main flow field at the root of the shrouded stator of a high-loading three-stage compressor with inlet guide vanes (IGV) was simulated by CAM and the results indicate that seal cavity leakage flow has a significant impact on the overall performance of the compressor. That is, for a 1% increase in the seal-tooth clearance-to-span ratio, the decrease in total pressure ratio was 2.6%, and the reduction in efficiency was 0.6%. Stage performance shows that the seal cavity leakage flow reduces the pressurization capacity of the current stator and the work capacity of the downstream rotor, but has little effect on the upstream blade row. Spanwise distribution of blade element performance shows that the leakage flow leads to an increased flow blockage near the hub, resulting in spanwise migration. The incidence of the stator and rear rotor then change through the entire span. The leakage flow leads to the flow blockage and migration and hence changes the incidence angle, which results in the deterioration of compressor performance. Full article