Multi-objective optimization of face grooves for dry gas seals under force equilibrium conditions

Abstract

Under extreme operating conditions, the stability of dry gas seals (DGS) can be disrupted, leading to face contact and excessive leakage. Therefore, optimizing sealing performance becomes critical. Conventional optimization metrics are typically computed based on a fixed film thickness, which lacks physical consistency. This study proposes a novel metric—Stability Maintenance Energy—to quantify the seal's capacity to withstand external disturbances under force-equilibrium conditions. This metric is coupled with the minimum leakage rate to form a set of conflicting optimization objectives. A T-groove DGS is selected as the case study, with optimization performed using the NSGA-II algorithm. To improve computational efficiency, a Kriging surrogate model is employed in place of the high-fidelity thermo–fluid–solid coupling model, with dynamic updates incorporated during the optimization process. Considering manufacturability, the optimal groove configuration is selected from the Pareto front.