To obtain an optimal range of structural parameters for dry-gas seals with good performance, this study employed advanced sensing technology to monitor and analyze the internal flow characteristics of dry-gas seals in real time. Additionally, the validity of the calculation program was verified through experimentation. Using steady-state performance parameters as evaluation indices, a calculation model with lubrication characteristics was developed. The results indicate that when there are 12 grooves, the gas film pressure distribution is uniform and has a high value. At pressures greater than 2 MPa, the opening force, leakage, and gas film stiffness change significantly due to enhanced dynamic pressure effects with high-pressure differences, which reduces the local contact forces and frictional forces. At a constant speed, decreasing the gas film thickness increases the pressure difference while increasing both the opening force and film stiffness; however, at higher rotational speeds where the gas flow becomes non-uniform, the stability of the gas film is affected, leading to increased frictional forces. When there are between 10 and 16 grooves with depths ranging from 5.0 to 6.0 μm, dynamic pressure effects caused by pressure gradients become apparent, resulting in good dry-gas sealing performance being achieved. This research provides a theoretical reference for optimizing the design of dry-gas seals, as well as their steady-state seal performance.

In recent years, the use of dry gas seal technology in high-end industrial applications has become increasingly widespread. Existing research has primarily focused on unidirectional grooves. This study introduces an innovative approach by incorporating bidirectional grooves inspired by the biomimetic design of a carp tail, aiming to enhance sealing performance. The analysis of flow-field characteristics was conducted using Fluent software to evaluate the effect of different groove designs on sealing efficacy. The results indicate that curved grooves are more effective in directing gas flow and reducing fluid dynamic losses, thus improving the overall sealing efficiency. In particular, the outer-curved carp-tail groove exhibited superior dynamic pressure effects and reduced pressure drops across various operating conditions. The optimal radial dam-to-groove width ratio ranged from 3.8 to 4.1, and the optimal groove depth ranged from 6.5 to 9.6 μm. This investigation focused on the design and performance evaluation of biomimetic carp-tail grooves for dry gas seals, presenting a novel groove configuration for end-face sealing and further advancing the theoretical understanding of dry gas seals.