航空发动机典型篦齿封严泄漏特性的数值和实验研究
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摘要
篦齿封严是一种结构简单、性能可靠的封严结构,在航空发动机等旋转机械中得到了广泛的应用。它主要利用流道的突扩和突缩,消耗流体的动能增加流阻以限制或阻止流体泄漏。篦齿封严性能的提高对发动机性能的改善具有显著的作用。但目前国内对一些典型篦齿封严结构如金属蜂窝衬套、过渡状态下篦齿切入衬套等结构的泄漏特性尚缺乏详细的研究,尚不具备完善的篦齿封严数据库。本文针对这些问题开展了一定的深入研究。
首先对国内外有关篦齿封严的文献进行了综合分析,归纳了各主要影响因素对篦齿封严特性的影响规律。其次设计并建立了篦齿封严旋转实验台,该台最大转速为3000r/min,进口最大压力为0.8Mpa,可对齿尖直径介于70～590mm之间的篦齿封严结构的泄漏特性进行实验。然后对直通篦齿-光滑衬套、直通篦齿-蜂窝衬套和台阶篦齿-光滑衬套等3种篦齿封严结构的泄漏特性进行了实验研究和数值计算。分析了齿腔的射流特性、篦齿临界特性以及压力损失特性,研究了篦齿结构尺寸、转速和压比等参数的影响规律。在此基础上发展了封严性能更好的直通篦齿-齿间浅槽衬套封严结构。
研究表明在发动机起动阶段,篦齿前腔压力逐渐升高的过程中,齿腔内的流体在射流的卷吸作用和流体的粘性作用下运动并产生旋涡,齿腔内旋涡的大小和位置不断发生变化并逐步趋于稳定。在稳定状态下,齿间压力沿流动方向线性下降。齿腔内的射流符合二维壁面射流特性,据此发展的泄漏量计算公式比基于自由射流理论的公式得到的泄漏量更接近于实验值。
篦齿封严的泄漏系数随着篦齿组件进出口压比的增加迅速增加;当最后一节篦齿齿尖处流动处于堵塞状态时,随着进出口压比的进一步增加,篦齿泄漏系数不再发生变化,但临界截面向来流方向移动。在节流间隙小于0.25mm时,篦齿-蜂窝衬套结构的封严性能比等间隙下篦齿-光滑衬套要差。上台阶篦齿和下台阶篦齿的封严特性相当,其泄漏系数比齿型相同的直通齿降低了30%。在不考虑实际结构由于转速和温度变化引起的间隙变化时,除了在高转速时台阶篦齿的泄漏量随转速的增加线性下降外,旋转对所研究的其余各种篦齿封严的泄漏量影响不大。
静止衬套上由于篦齿切入而造成的磨损槽的存在改变了节流后的壁面射流运动和扩散方向。篦齿切入磨损槽时,节流作用增强,封严性能显著提高。在与齿腔正对的静止衬套上预先人工车制环形浅槽可以破坏壁面射流附面层的轴向连续性,使射流在流经环形浅槽时流动方向发生偏转,进而大大降低透气效应提高封严性能。
Labyrinth seal is a kind of simple and reliable sealing structure. Typically it consists of a rotor, with multiple teeth on its circular surface, and a co-axial static bush. When flow pass through the passage between the rotor and the static bush, kinetic energy is quickly dissipated into heat, leakage flow was restricted. Engine efficiency is strongly dependent on the sealing effect of labyrinth seal. However, at present the detailed research on the leakage characteristics of some kinds of labyrinth seal, such as the structure with honeycomb bush and the transient condition with tooth cut into the static bush, is still in lack, the industry urgently needs the more completed database for labyrinth seal design. This thesis presents some deep study on these problems.
Firstly, the author comprehensively reviewed the literature on the research of labyrinth seal, analyzed the effect of some major factors on the leakage characteristics. Then a rotating experiment rig for labyrinth seal leakage measurement was designed and established, which has a maximum rotating speed of 3000 rpm, maximum inlet pressure of 0.8 MPa, and allowed teeth tip diameter between 70~590 mm. By using this rig and numerical method, the leakage characteristics of three kinds of labyrinth seal were studied, which include straight-though labyrinth seal with smooth bush, straight-though labyrinth seal with honeycomb bush, and step labyrinth seal with smooth bush. The jet flow in the teeth cavity, the critical condition, and pressure loss in the flow passage of the seal have been studied. The effect of structure of the labyrinth seal, rotating speed and the pressure ratio of upstream and downstream of the seal on the leakage was investigated. Based on these studies, a new straight-through labyrinth seal was developed, which has a bush with a shallow groove machined opposite the teeth cavity. The experimental and numerical studies show that it has a better sealing effect.
At start stage of the engine, the pressure in front of the seal gradually increase, the originally static fluid in the teeth cavity was driven into flow by the jet from the clearance between the tip of the teeth and the bush. Due to the viscous effect of the fluid, vortex was formed in the cavity, and the size and location of the vortex gradually change and finally reach a steady state. On the steady condition, the jet flow has the similar basic characteristics of two-dimensional wall jet flow. An empirical formula developed based on the 2D wall jet theory is better than that based on the free jet theory.
The leakage coefficient of labyrinth seal rapidly increase with the increase of the upstream and downstream pressure ratio; but when the flow at the last tooth tip research chock condition, the leakage coefficient will no longer change with the further increase of the pressure ratio, while the critic section moves upward. For the studied clearance (< 0.25mm), the leakage coefficient of labyrinth-honeycomb bush structure is larger than labyrinth-smooth bush structure; upward step and downward step labyrinth seal have similar sealing performance, and both have a leakage coefficient 30% less than straight-through labyrinth seal. If not considering the variation of clearance caused by rotation and temperature change, rotating speed has negligible effect on leakage for all studied seals, except for, the leakage of step labyrinth seal linearly decrease with the increase of rotating speed at high rotating speed.
The groove on the static bush, which is caused by the rub of tooth and bush, varies the wall jet flow condition. When the tooth cut in the groove, the leakage is reduced. The shallow groove manufactured on the smooth bush opposite to the tooth cavity destroys the continuity of the wall jet boundary layer, which lead to the jet flow change it direction and greatly improve sealing effect.
首先对国内外有关篦齿封严的文献进行了综合分析,归纳了各主要影响因素对篦齿封严特性的影响规律。其次设计并建立了篦齿封严旋转实验台,该台最大转速为3000r/min,进口最大压力为0.8Mpa,可对齿尖直径介于70～590mm之间的篦齿封严结构的泄漏特性进行实验。然后对直通篦齿-光滑衬套、直通篦齿-蜂窝衬套和台阶篦齿-光滑衬套等3种篦齿封严结构的泄漏特性进行了实验研究和数值计算。分析了齿腔的射流特性、篦齿临界特性以及压力损失特性,研究了篦齿结构尺寸、转速和压比等参数的影响规律。在此基础上发展了封严性能更好的直通篦齿-齿间浅槽衬套封严结构。
研究表明在发动机起动阶段,篦齿前腔压力逐渐升高的过程中,齿腔内的流体在射流的卷吸作用和流体的粘性作用下运动并产生旋涡,齿腔内旋涡的大小和位置不断发生变化并逐步趋于稳定。在稳定状态下,齿间压力沿流动方向线性下降。齿腔内的射流符合二维壁面射流特性,据此发展的泄漏量计算公式比基于自由射流理论的公式得到的泄漏量更接近于实验值。
篦齿封严的泄漏系数随着篦齿组件进出口压比的增加迅速增加;当最后一节篦齿齿尖处流动处于堵塞状态时,随着进出口压比的进一步增加,篦齿泄漏系数不再发生变化,但临界截面向来流方向移动。在节流间隙小于0.25mm时,篦齿-蜂窝衬套结构的封严性能比等间隙下篦齿-光滑衬套要差。上台阶篦齿和下台阶篦齿的封严特性相当,其泄漏系数比齿型相同的直通齿降低了30%。在不考虑实际结构由于转速和温度变化引起的间隙变化时,除了在高转速时台阶篦齿的泄漏量随转速的增加线性下降外,旋转对所研究的其余各种篦齿封严的泄漏量影响不大。
静止衬套上由于篦齿切入而造成的磨损槽的存在改变了节流后的壁面射流运动和扩散方向。篦齿切入磨损槽时,节流作用增强,封严性能显著提高。在与齿腔正对的静止衬套上预先人工车制环形浅槽可以破坏壁面射流附面层的轴向连续性,使射流在流经环形浅槽时流动方向发生偏转,进而大大降低透气效应提高封严性能。
Labyrinth seal is a kind of simple and reliable sealing structure. Typically it consists of a rotor, with multiple teeth on its circular surface, and a co-axial static bush. When flow pass through the passage between the rotor and the static bush, kinetic energy is quickly dissipated into heat, leakage flow was restricted. Engine efficiency is strongly dependent on the sealing effect of labyrinth seal. However, at present the detailed research on the leakage characteristics of some kinds of labyrinth seal, such as the structure with honeycomb bush and the transient condition with tooth cut into the static bush, is still in lack, the industry urgently needs the more completed database for labyrinth seal design. This thesis presents some deep study on these problems.
Firstly, the author comprehensively reviewed the literature on the research of labyrinth seal, analyzed the effect of some major factors on the leakage characteristics. Then a rotating experiment rig for labyrinth seal leakage measurement was designed and established, which has a maximum rotating speed of 3000 rpm, maximum inlet pressure of 0.8 MPa, and allowed teeth tip diameter between 70~590 mm. By using this rig and numerical method, the leakage characteristics of three kinds of labyrinth seal were studied, which include straight-though labyrinth seal with smooth bush, straight-though labyrinth seal with honeycomb bush, and step labyrinth seal with smooth bush. The jet flow in the teeth cavity, the critical condition, and pressure loss in the flow passage of the seal have been studied. The effect of structure of the labyrinth seal, rotating speed and the pressure ratio of upstream and downstream of the seal on the leakage was investigated. Based on these studies, a new straight-through labyrinth seal was developed, which has a bush with a shallow groove machined opposite the teeth cavity. The experimental and numerical studies show that it has a better sealing effect.
At start stage of the engine, the pressure in front of the seal gradually increase, the originally static fluid in the teeth cavity was driven into flow by the jet from the clearance between the tip of the teeth and the bush. Due to the viscous effect of the fluid, vortex was formed in the cavity, and the size and location of the vortex gradually change and finally reach a steady state. On the steady condition, the jet flow has the similar basic characteristics of two-dimensional wall jet flow. An empirical formula developed based on the 2D wall jet theory is better than that based on the free jet theory.
The leakage coefficient of labyrinth seal rapidly increase with the increase of the upstream and downstream pressure ratio; but when the flow at the last tooth tip research chock condition, the leakage coefficient will no longer change with the further increase of the pressure ratio, while the critic section moves upward. For the studied clearance (< 0.25mm), the leakage coefficient of labyrinth-honeycomb bush structure is larger than labyrinth-smooth bush structure; upward step and downward step labyrinth seal have similar sealing performance, and both have a leakage coefficient 30% less than straight-through labyrinth seal. If not considering the variation of clearance caused by rotation and temperature change, rotating speed has negligible effect on leakage for all studied seals, except for, the leakage of step labyrinth seal linearly decrease with the increase of rotating speed at high rotating speed.
The groove on the static bush, which is caused by the rub of tooth and bush, varies the wall jet flow condition. When the tooth cut in the groove, the leakage is reduced. The shallow groove manufactured on the smooth bush opposite to the tooth cavity destroys the continuity of the wall jet boundary layer, which lead to the jet flow change it direction and greatly improve sealing effect.
引文
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