Predictions of windage heating and flow characteristics in a high-speed rotating seal of aero-engine

The labyrinth seal plays a crucial role within the secondary air system of an aeroengine, significantly impacting its safety and reliability. This paper presents a comprehensive evaluation of the complex windage heating phenomenon within a high-speed rotating labyrinth seal system. Employing similarity criteria and dimensional analysis, the multifactorial influences on the seal system are thoroughly characterized. A dedicated high-speed rotating labyrinth seal test rig was constructed to conduct an experimental investigation into the windage heating characteristics of a four-tooth, stepped-slanted labyrinth seal. The results demonstrate a peak windage heating of 11.8 K and windage heating coefficient of 1.14 when the inlet temperature rose from ambient to 100 °C, under the rotating Mach number of 0.418 and pressure ratio of 1.1. Conversely, as the seal clearance increased from 0.2 mm to 0.6 mm, with a rotating Mach number of 0.487 and a pressure ratio of 2.0, the windage heating coefficient decreased to 0.57. Furthermore, five dimensionless operating cases were analyzed using similarity principles to elucidate the correlation between system performance and the combined effects of strong rotating flow and windage heating characteristics. The analysis revealed that the windage heating coefficient exhibited a decreasing trend with increasing flow Reynolds number, effective pressure ratio, inlet swirl ratio, and dimensionless clearance, as the effective pressure ratio increase from 1.1 to 5.0, with the rotating Mach number of 0.624 and flowing Reynolds number of 9600, the windage heating coefficient decrease from 1.831 to 0.797, representing a 56 % reduction. Conversely, the windage heating coefficient increased with a rising rotating Mach number, while the flowing Reynolds number demonstrated a minor influence.