Numerical analysis of brush seal hysteresis based on orthogonal test method

Abstract By the finite element analysis software ABAQUS, utilizing General Contact and Contact damping algorithm, the brush seal hysteresis numerical model with pressure differential considered was established. The hysteresis was quantified by the hysteresis energy, and the hysteresis energy and maximum stress are obtained by numerical calculations. An orthogonal test was conducted to study the effects of bristle diameter, bristle cant angle, fence height, bristle length, upstream and downstream differential pressure, and rotor radial displacement on the hysteresis and maximum stress of the brush seal. Results show that the primary and secondary orders of parameters affecting hysteresis are: rotor radial displacement, bristle diameter, upstream and down-stream differential pressure, bristle cant angle, bristle length, and fence height. The primary and secondary orders of parameters affecting maximum stress are: upstream and downstream differential pressure, fence height, bristle cant angle, bristle diameter, bristle length, and rotor radial displacement. Finally, based on the numerical results, a fitted correlation was developed. Comprehensive effects of the six parameters on both performances were analyzed, and structural design optimization methods focusing on single performance and comprehensive performance were proposed, providing references for the design of brush seals in practical engineering applications.