This paper aims to guide the parameter design of the hole cavity of the hole-pattern clearance seal (HPCS) to enhance sealing performance. Based on the self-developed test rig for a flat-plate configuration, the leakage rate of the seal with different geometrical parameters of stator surface under multiple working conditions was obtained. A novel leakage behavior characterization model of the HPCS defined as follows was proposed quantitatively. The leakage characteristics of the HPCS with different rotate speeds and its internal mechanism were analyzed by ANSYS FLUENT. The results demonstrate that the leakage characteristics of the HPCS and the smooth clearance seal (SCS) have their own properties under different working conditions because of the flow effects affect. When the clearance was small at laminar flow, the wall friction effect was the main factor, and the leakage resistance effect of SCS was better than that of HPCS. When the flow state is turbulent at appropriate clearance, the leakage resistance effect of HPCS is more prominent than that of SCS. The leakage relative reduction rate phi of the HPCS with a specific structure compared to the SCS under multiple working conditions float within a particular zone, which is called the novel leakage behavior characterization model. The model has characterization parameters such as optimal leakage reduction clearance, minimum leakage relative reduction rate, and effective leakage reduction clearance range.
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