Design improvements on labyrinth seal teeth and a honeycomb land are examined by three-dimensional CFD numerical modeling of the flow field. The only objective is reduction of the total leakage through the new seal. CFD assumptions and analysis was validated by comparison with leakage data from labyrinth seal experiments conducted by Stocker [1]. The baseline chosen for comparison of sealing effectiveness is a conventional low clearance straight-through labyrinth seal with four teeth and a honeycomb land of symmetrical hexagonal cells. The proposed new seal has a staggered honeycomb land and straight teeth with an inclined notch. CFD predicts ∼17% reduction in seal leakage at a radial clearance of 0.005 inch (0.122mm) due to higher wall friction and flow turbulence.

Labyrinth seal designs for reduced leakage have been analyzed by three-dimensional CFD simulations. The objective is to learn the effect of seal geometry modifications on total leakage through the seal and arrive at an advanced seal setting for improved seal effectiveness through reduction in leakage. Numerical modeling of the flow field were conducted at various operating conditions. The baseline seal model for this study is a conventional straight-through rotating four-tooth labyrinth seal and static honeycomb land having symmetrical hexagonal cells. The tooth design configurations include stepped single & double notched straight and inclined teeth. Another objective is to learn the effect of staggered honeycomb land with respect to rotor/teeth rotation. The effect of teeth inclination & teeth rotation compared to stationary is also discussed. CFD results indicate improved seal effectiveness with staggered honeycomb cell land. The maximum improvement of ∼9% was observed with stepped and notched inclined teeth configuration when combined with staggered honeycomb land. The leakage reduction leading to improvement in seal effectiveness as compared to baseline configuration is largely due to higher flow resistance, higher turbulence and higher blockages by introducing vortex in leakage flow through step and cavities.

A modification of a conventional straight four-tooth labyrinth seal with inclined teeth including single and double stepped notches is proposed. The variants are to be numerically modeled and evaluated for potential leakage reduction through the seal as a result of the developing flow field. The CFD methodology for numerical investigation is first validated by comparison with literature data from static labyrinth seal experiments. The objective is to numerically analyze the proposed “Notched Inclined Teeth” with solid and honeycomb lands and verify the leakages. Another objective is to compare these leakages with the “Stepped Double Notched Straight Tooth” variant discussed by the present authors in a previous paper. Results indicate that the proposed modifications — single and double stepped notched inclined teeth, systematically reduce the seal leakage compared to the baseline straight and forward inclined teeth due to higher turbulence, higher blockages by introducing vortex in leakage flow through step and cavities, and higher flow resistance as compared to baseline model.

A variant “Stepped Double Notched Tooth” for conventional sharp teeth of a labyrinth seal has been proposed and investigated by three-dimensional CFD numerical modeling of the flow field. The purpose is to reduce total leakage through the seal. The tooth is numerically tested with both solid and honeycomb lands. CFD assumptions and analysis were validated by comparison with leakage data from stationary labyrinth seal experiments conducted by Stocker [1]. The baseline model considered for comparison study consists of the conventional straight-through four sharp knife shaped teeth in combination with solid and honeycomb land. The variant tooth is also straight having a sharp tip but has a stepped inclined notch opposing the flow at both sides of the tip. CFD analyses revealed that this double notched tooth reduces seal leakage by ∼10.7% when used with solid land and ∼12.5% when used with honeycomb land compared to a conventional baseline tooth.

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