A Three-Dimensional Tube Bundle Model Analysis for Leakage Flow Characteristics of Variable Bristle Diameter Brush Seals With Bristle Pack Stratification

The leakage flow characteristics of the variable bristle diameter (VBD) brush seals are numerically investigated using the three-dimensional (3D) tube bundle model with consideration of bristle pack stratification. The discretization of the computational domain applies the multiblock structured mesh, which ensures that there is no need to set interfaces between the fluid domains of the bristle pack and the cavities to eliminate interpolation errors. The bristle pack stratification is achieved by using mesh motion technique from the point of cause-effect. The effects of pressure ratio (⁠$Rp=1.5, 2.5, 3.5$⁠), axial rows of bristles (⁠$Nx=9–21$⁠), sealing clearance (⁠$c=0, 0.1 mm$⁠), bristle pack arrangements, and bristles gapping (⁠$gi=0, 0.005, 0.010, 0.015 mm$⁠) on the leakage flow characteristics and aerodynamic forces are conducted. The recorded leakage flow of the 3D tube bundle model is multiplied by circumferential loop number (⁠$Ncl$⁠) to determine total leakage flow rate of the brush seal. The numerical results agreed well with the experimental data, which verifies the reliability of the numerical method. The numerical results indicate that the leakage flow rate increases linearly with the pressure ratio. The increase of $Nx$ has a distinctly different effect on the relative rate of leakage flow for the contacting and clearance brush seals. The use of large diameter bristles weakens the sealing performance of the brush seals, particularly in the rear region. Bristle pack stratification can improve the sealing performance of the brush seals. The large diameter bristles increase the porosity and reduce the flow resistance coefficients. On the contrary, the bristle pack stratification decreases the porosity and rises the flow resistance coefficients in the rear region. The results of this article indicate when designing VBD brush seals, the effects of bristle diameter and bristle density on the sealing performance and pressure loading capacity of the brush seals should be fully considered.