Search Results (66)

The gap seal ring is a critical component in high-speed centrifugal pumps. The leakage rate and performance of the pump are sensitive to variation in seal ring parameters. This study investigates the influence of seal ring tooth profile on the leakage flow of pump chambers. Numerical simulation and experimental tests are used to analyze the impact of four different tooth-height labyrinth seal ring structures on the pressure pulsation characteristics of pump leakage chambers. It can be concluded that the use of labyrinth seal rings can significantly reduce the pressure pulsation and leakage rate of pump chambers. For the Case 2 structure with a tooth height of 0.18 mm, the pressure pulsation in the pump chamber can be reduced by a maximum of 22.5%, and the leakage rate can be reduced by 41.1%. For the Case 3 structure with a tooth height of 0.23 mm, the pressure pulsation in the pump chamber can be reduced by a maximum of 30.3%, and the leakage rate can be reduced by 40.6%. The use of labyrinth seal rings significantly reduces the pressure pulsation intensity of the impeller surfaces, which improves the force stability of the high-speed centrifugal pump impeller. This study is helpful in providing theoretical support for the design of labyrinth seal rings in high-speed centrifugal pumps. Full article

This study examines the labyrinth seal disc of an aero-engine, specifically analysing the radial deformation caused by centrifugal force and heat stress during operation. This distortion may lead to discrepancies in the performance attributes of the labyrinth seal and could potentially result in contact between the labyrinth seal tip and neighbouring components. A numerical analytical model incorporating the rotor and stator cavities, along with the labyrinth seal disc structure, has been established. The sealing integrity of a standard labyrinth seal disc’s flow channel is evaluated and studied at different clearances utilising the fluid–solid-thermal coupling method. The findings demonstrate that, after considering radial deformation, a cold gap of 0.5 mm in the conventional labyrinth structure leads to stabilisation of the final hot gap and flow rate, with no occurrence of tooth tip rubbing; however, both the gap value and flow rate show considerable variation relative to the cold state. When the cold gap is 0.3 mm, the labyrinth plate makes contact with the stator wall. To resolve the problem of tooth tip abrasion in the conventional design with a 0.3 mm cold gap, two improved configurations are proposed, and a stability study for each configuration is performed independently. The leakage and temperature rise attributes of the two upgraded configurations are markedly inferior to those of the classic configuration at a cold gap of 0.5 mm. At a cold gap of 0.3 mm, the two improved designs demonstrate no instances of tooth tip rubbing. Full article

Labyrinth seals, extensively used in aerospace and turbomachinery as non-contact sealing devices, undergo accelerated wear and enhanced leakage due to repeated rub-impact between rotating shafts and sealing rings. To address the problem of increased leakage under rub-impact conditions, this research integrates experimental and numerical methods to investigate the deformation mechanisms and leakage characteristics of thermoplastic labyrinth seals. A custom designed rub-impact test rig was constructed to measure dynamic forces and validate finite element analysis (FEA) models with an error of 5.1% in predicting tooth height under mild interference (0.25 mm). Computational fluid dynamics (CFD) simulations further demonstrated that thermoplastic materials, such as PAI and PEEK, displayed superior resilience (with rebound ratios of 57% and 70.3%, respectively). Their post-impact clearances were 4.8–18.3% smaller than those of PTFE and F500. Leakage rates were predominantly correlated with interference, causing a substantial increase compared to the original state; at 0.25 mm interference (reverse flow), increases ranged from 151% (PAI) to 217% (PTFE), highlighting material-dependent performance degradation. Meanwhile, tooth orientation modulated leakage by 0.5–3% through the vena contracta effect. Based on these insights, two optimized inclined-tooth geometries were designed, reducing leakage by 28.2% (Opt1) and 28.1% (Opt2) under rub-impact. These findings contribute to the development of high-performance labyrinth seals suitable for extreme operational environments. Full article

In this study, the frictional behaviours of three different guide elements—guide rings, labyrinth seals, and hydrostatic bearings—in hydraulic cylinders is investigated experimentally. A modular, double-acting hydraulic cylinder was designed to compare these three different design elements under different pressures (0 bar, 120 bar, and 240 bar), velocities, and radial loads. The results show that the guide rings exhibit the highest friction, especially at high pressures. Labyrinth seals exhibit significantly lower friction and extend the service life of the components. Hydrostatic bearings allow low friction but require precise control of the fluid, which limits their use. The results provide practical guidelines for selecting guide elements and optimising the friction performance, durability, and efficiency of hydraulic systems. We found that the best solution from the points of view of design, friction, and economics is to use labyrinth seals as guiding elements for the fast reciprocal moving rods of hydraulic cylinders. Full article

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

This study investigates the influence of idler roller diameter on indentation rolling resistance and idler rotating resistance in belt conveying systems, crucial for long-distance bulk material transport. It encompasses the impact on grease-lubricated rolling bearings, grease-filled labyrinth seals, and lip seals, with the aim of optimizing energy consumption. Experimental devices were used to refine predictive models, demonstrating that larger idler rollers reduce both resistances, leading to a 40% to 55% efficiency improvement. The study offers a detailed breakdown of friction losses under various operating conditions and provides valuable insights for lubricant selection and system enhancement, highlighting the significance of idler roller diameter in reducing energy costs and enhancing system performance. Full article

Innovating seal structures and optimizing size parameters are effective ways to enhance the leakage characteristics of labyrinth seals (LSs). Inspired by the ecological fishways with high flow resistance on dam sides, a novel bio-inspired staggered labyrinth seal is proposed. The leakage characteristics of both the curved-edged bio-inspired labyrinth seal (CELS) and the straight-edged bio-inspired labyrinth seal (SELS) at different tooth-incline angles are studied numerically and experimentally. The influence of key geometrical parameters on the leakage characteristics and flow field parameters of the CELSs are investigated, and the leakage control mechanism of bio-inspired LSs is revealed via analyzing flow field parameter distribution. The results indicate that, compared to conventional double-sided staggered straight-tooth labyrinth seals, the leakage rate reduction in CELSs is up to 30% when the incline angle is equal to 25°, outperforming that of the SELS in leakage control. This improvement is mainly attributed to the flow path bending and jet contraction effects at the tooth-tip entrance, along with the thermodynamic effects of the high-turbulence dissipation zone adjacent to the tooth top. The optimum leakage characteristics can be achieved when seal clearance h < 0.5 mm, aspect ratio δ < 0.6, and tooth thickness t < 1.5 mm. This work provides new insights into the structural design of high-resistance and low-leakage labyrinth seals. 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

Nuclear energy, as an important component of the power system, has become a key focus of future energy development research. Various equipment and pipelines in nuclear power plants require regular inspection, maintenance, and repair. The pipelines in nuclear power plants are typically large, necessitating a device that can locally isolate sections of the pipeline during maintenance operations. Ice plug freezing technology, an economical and efficient method for maintaining and replacing equipment without shutdown, has been widely applied in nuclear power plants. The structure of the ice plug jacket, a type of low-temperature jacket heat exchanger, affects the flow path of the working fluid within the jacket and consequently impacts heat transfer. This study utilizes Computational Fluid Dynamics (CFD) to establish five types of jacket structures: standard, center-offset (center-in, side-out), helical, helical fin, and labyrinth. The effects of different structures on the freezing characteristics of ice plugs are analyzed and compared. The research indicates that the labyrinth jacket enhances the heat transfer performance between liquid nitrogen and the liquid inside the pipe, forming a larger ice layer at the same liquid nitrogen flow rate. Additionally, the standard jacket has the shortest sealing time at high liquid nitrogen flow rates. Full article

In order to optimize sealing performance, a novel labyrinth seal with semi-elliptical teeth (SET) structure is proposed in this paper, which includes semi-elliptical teeth and a series of cavities. The simulation results calculated by the numerical methods are compared with the experimental and theoretical results, and static and dynamic characteristics of the novel SET structure are further investigated. The numerical simulations of labyrinth seals with the SET structure demonstrate high accuracy and reliability, with a maximum relative error of less than 6% as compared to experimental results, underscoring the validity of the model. Notably, leakage rates are directly influenced by pressure drop and axial offset, with optimal sealing achieved at zero axial displacement. The direct damping coefficient increases as the pressure drop increases while the other dynamic coefficients decrease. Additionally, the stability results show that the novel SET structure exhibits higher stability for positive axial offsets. The novel model and corresponding results can provide a meaningful reference for the study of sealing structure and coupled vibration in the field of fluid machinery. Full article

This study presents a numerical approach to the design and optimization of centrifugal impellers used in the pumps of active thermal control systems of spacecraft. Although launch costs have shrunk in the last decade, the performance requirements, such as efficiency and reliability, have increased, as such systems are required to work up to 15 years, depending on the mission. To that effect, our paper deals with the first step in this pump design, namely the hydraulic optimization of the impeller. Constructively, this type of impeller allows for certain balancing systems and labyrinth seals to be applied in a more effective way, as well as allowing for additive manufacturing methods to be used—however, details regarding these aspects are beyond the scope of the current paper. By combining empirical formulas, computational fluid dynamics (CFD) analysis, and artificial neural networks (ANNs), the research focuses on achieving high efficiency and fast manufacturing. A series of geometries have been sized and validated using steady-state RANS (Reynolds Averaged Navier-Stokes) simulations, leading to the identification of the most efficient configuration. Subsequent optimization using an ANN resulted in a refined impeller design with notable improvements in hydraulic performance: a 3.55% increase in efficiency and a 7.9% increase in head. Key parameters influencing impeller performance, including blade number, incidence, and backsweep angles, are identified. This approach offers a comprehensive method to address the evolving requirements of space missions and contributes to the advancement of centrifugal pump technology in the space domain. Full article

Labyrinth seals are commonly used in turbomachinery in order to control leakage flows. Flutter is one of the most dangerous potential issues for them, leading to High Cycle Fatigue (HCF) life considerations or even mechanical failure. This phenomenon depends on the interaction between aerodynamics and structural dynamics; mainly due to the very high uncertainties regarding the details of the fluid flow through the component, it is very hard to predict accurately. In 2014, as part of the E-Break research project funded by the European Union (EU), an experimental campaign regarding the flutter behaviour of labyrinth seals was conducted at “Centro de Tecnologias Aeronauticas” (CTA). During this campaign, three realistic seals were tested at different rotational speeds, and the pressure ratio where the flutter onset appeared was determined. The test was reproduced using a linearised uncoupled structural-fluid methodology of analysis based on Computational Fluid Dynamics (CFD) simulations, with results only in moderate agreement with experimental data. A procedure to adjust the CFD simulations to the steady flow measurements was developed. Once this method was applied, the matching between flutter predictions and the measured data improved, but some discrepancies could still be found. Finally, a set of simulations to retain the influence of the external cavities was run, which further improved the agreement with the testing data. Full article

This paper describes the process of the design and verification of a milling tool and tooling that may contribute to the renouncement of the flood cooling method when mineral oils and oil-in-water emulsions are used as coolants. The proposed solutions are based on the idea of coolant supply in internal channels created inside of a cutting tool. As an alternative to the aforementioned mineral oil-based coolants, liquids with higher cooling efficiency and environmental friendliness (green coolants) were considered. Given coolants’ possible lack of lubricating properties and negative (corrosive, etc.) influence on a machine tool’s units, tooling delivers these coolants to the cutting tool and bypasses the standard machine tool’s supply system. The geometry of the milling tool (a cutting insert with an internal channel) was tested in the framework of a stress simulation. To perform it, cutting force components $F_z$, $F_y$, and $F_x$ were determined empirically and then applied to the simulated area of contact between the tool and the workpiece. Based on the obtained principal stress values $P_1$, $P_2$, and $P_3$, the factor of safety was calculated with the Mohr–Coulomb, $P_{1 max}$, and $P_{3 min}$ failure criteria. The proposed milling tool, equipped with a novel type of labyrinth seal with no friction between its components, was experimentally tested to confirm its ability to maintain leak-tightness at different values of spindle speed (200~2000 rpm) and coolant supply volume (1.0~10.0 L/min). Based on the results of the stress simulation and the leak-tightness experiment, conclusions were drawn about further modernization and utilization prospects of the proposed milling tool and tooling design. Full article

High-performance aeroengine design is an important component of modern industry, and advanced sealing technology is a key technology to meet the engine fuel consumption rate, thrust-to-weight ratio, pollutant emission, durability, and lifetime. Reducing the internal airflow leakage of the engine through a sealing technology can improve the performance and efficiency of the engine. In this paper, the typical sealing technology for an aeroengine is introduced in more detail, including the structural characteristics and use limitations of the labyrinth seal, brush seal, honeycomb seal, gas film face seal, and cylindrical gas film seal. It focuses on the development history, typical structure type, working principle, basic technology research method, steady-state performance, dynamic characteristics, multi-physical field coupling, structural deformation, experimental testing, processing technology. Finally, it summarizes the problems and future development trends of the current application of the cylindrical gas film seal in aeroengines, and points out that the seal performance test and evaluation based on advanced composite sensor technology and the innovative design of the seal based on new material, a new principle, and a new structure will be the new research direction. Full article