The flow behavior through a brush seal has been investigated by developing a flow analysis procedure with a porous medium approach. In order to increase the brush seal performance and use at more severe operating conditions, the complex flow in the bristle pack has become the major concern affecting seal features such as blow-down, hang-up, hysteresis, and bristle flutter. In this study, an axisymmetric CFD model is employed to calibrate anisotropic permeability coefficients for the bristle pack based on available experimental data: leakage, axial pressure on the rotor surface, and radial pressure on the backing plate. A simplified form of the force balance equation is introduced for the flow in the porous bristle pack. Different sets of permeability coefficients are defined for the fence height region below the seal backing plate and the upper region of the seal to correlate the different physical structures and behavior of these regions during operation. The upper region is subject to more stiffening due to backing plate support while the fence height region is free to spread and bend in the axial direction. It is found that flow resistance for the upper region should be 20% higher than the fence height region in order to match the experimental pressure within the bristle pack. Analysis results prove that the brush seal is well represented as a porous medium with this approach. Based on the model developed, characteristic flow and pressure fields in the entire bristle pack have been explored.

Pressure and flow fields lay at the basis of such common phenomena affecting brush seal performance as bristle flutter, blow-down, hang-up, hysteresis, pressure stiffening, wear, and leakage. Over the past two decades of brush seal evolution, manufacturers and researchers have applied many geometric configurations to the front and backing plates of a standard brush seal in order to control the flow field and consequent seal performance. The number of studies evaluating the effect of geometric configurations on the brush seal flow field remains limited in spite of the high number of filed patent disclosures. This study presents a numerical analysis of brush seal pressure and flow fields with regard to common conceptual front plate configurations. A CFD model has been employed to calculate pressure and flow fields in the seal domain. The model incorporates a bulk porous medium approach for the bristle pack. The effectiveness of various conceptual geometries has been outlined in terms of flow field formation. Results disclose unique effects of geometry on pressure and flow fields such that a longer front plate drives outward radial flow while playing a protective role against upstream cavity disturbances. Findings also indicate that variations in front plate geometry do not directly affect leakage performance. A long front plate or damper shim considerably changes the flow field while at the same time having limited effect on the pressure field. Moreover, a strong suction towards the clearance enhances inward radial flow in clearance operation.

Brush seals are designed to survive transient rotor rubs. Inherent brush seal flexibility reduces frictional heat generation. However, high surface speeds combined with thin rotor sections may result in local hot spots. Considering large surface area and accelerated oxidation rates, frictional heat at bristle tips is another major concern especially in challenging high-temperature applications. This study investigates temperature distribution in a brush seal as a function of frictional heat generation at bristle tips. The two-dimensional axisymmetric computational fluid dynamics (CFD) analysis includes the permeable bristle pack as a porous medium allowing fluid flow throughout the bristle matrix. In addition to effective flow resistance coefficients, isotropic effective thermal conductivity as a function of temperature is defined for the bristle pack. Employing a fin approach for a single bristle, a theoretical analysis has been developed after outlining the brush seal heat transfer mechanism. Theoretical and CFD analysis results are compared. To ensure coverage for various seal designs and operating conditions, several frictional heat input cases corresponding to different seal stiffness values have been studied. Frictional heat generation is outlined to introduce a practical heat flux input into the analysis model. Effect of seal stiffness on nominal bristle tip temperature has been evaluated. Analyses show a steep temperature rise close to bristle tips that diminishes further away. Heat flux conducted through the bristles dissipates into the flow by a strong convection at the fence-height region.

Compared to widening usage of CNG in commercial gasoline engines, insufficient but increasing number of studies have appeared in open literature during last decades while engine characteristics need to be quantified in exact numbers for each specific fuel converted engine. In this study, a dual sequential spark ignition engine (Honda L13A4 i-DSI) is tested separately either with gasoline or CNG at wide open throttle. This specific engine has unique features of dual sequential ignition with variable timing, asymmetrical combustion chamber, and diagonally positioned dual spark-plug. Thus, the engine led some important engine technologies of VTEC and VVT. Tests are performed by varying the engine speed from 1500 rpm to 4000 rpm with an increment of 500 rpm. The engine’s maximum torque speed of 2800 rpm is also tested. For gasoline and CNG fuels, engine performance (brake torque, brake power, brake specific fuel consumption, brake mean effective pressure), emissions (O₂, CO₂, CO, HC, NO_x, and lambda), and the exhaust gas temperature are evaluated. In addition, numerical engine analyses are performed by constructing a 1-D model for the entire test rig and the engine by using Ricardo-Wave software. In the 1-D engine model, same test parameters are analyzed, and same test outputs are calculated. Thus, the test and the 1-D engine model are employed to quantify the effects of gasoline and CNG fuels on the engine performance and emissions for a unique engine. In general, all test and model results show similar and close trends. Results for the tested commercial engine show that CNG operation decreases the brake torque (12.7%), the brake power (12.4%), the brake mean effective pressure (12.8%), the brake specific fuel consumption (16.5%), the CO₂ emission (12.1%), the CO emission (89.7%). The HC emission for CNG is much lower than gasoline. The O₂ emission for CNG is approximately 55.4% higher than gasoline. The NO_x emission for CNG at high speeds is higher than gasoline. The variation percentages are the averages of the considered speed range from 1500 rpm to 4000 rpm.