Wear and Leakage Behaviors of Brush Seal Considering Eccentricity and Radial Deformation

Brush seals can improve engine performance by reducing leakage. Wear models of brush seals provide methods to predict wear and leakage. However, rotor eccentricity, radial deformation, and hysteresis effect of bristles are not considered systematically in the existing models, which may lead to large errors in some cases. To investigate the influence of rotor-stator eccentricity and radial deformation on the wear process and leakage performance of brush seal, a brush seal test was planned and executed, in which the air leakage rates were measured at different testing times and operating conditions, the eccentricity and radial deformation was measured using eddy current sensors. The test results showed that the eccentricity and radial deformation significantly affected the wear behavior and leakage performance. In the theoretical research, the abrasive wear equation is adopted to describe the material loss of bristles, and a simplified description is used to express the rotor-stator eccentric motions. To describe the effect of hysteresis on wear behavior, the deformation of the bristle pack is divided into rebounding deformation and locked deformation, and the two deformation modes are modeled separately. Then a brush seal wear model considering rotor-stator eccentricity and radial deformation is obtained, in which the hysteresis effect is especially represented. The wear model was verified quantitatively based on the brush seal test data, and the results show that there is an error of 20% with the calculated wear loss when rotor eccentricity, radial deformation, and hysteresis effect are comprehensively considered. In contrast, ignoring the hysteresis effect may increase the error by several times. This study provides a quantitative and practical method for predicting the wear and leakage of brush seals.