This paper investigates the impact of the face waviness and pressure inversions on the leakage and on the outer fluid entry of mechanical face seals using a numerical model and an experimental setup. The numerical model couples a transient Reynolds equation, an analytical contact model, a force balance solver, and a solver for the thermo-mechanical deformations. The experimental tests on a face seal with low waviness and on a face seal with high waviness provide leakage and outer fluid entry data, which are reproduced by the model. Contrary to the face seal with low waviness, the face seal with high waviness has poor performance and the pressure inversions increase significantly the ingression of outer fluid. The parametric study shows a decrease of leakage with increasing spring force, and an increase of leakage and outer fluid entry with increasing values of waviness amplitude. The higher leakage observed for wavy seals is shown to be due to the higher average film thickness, and to some extent due to the mechanisms associated with waviness: hydrodynamic pressure generation, film squeeze and stretching.

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