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Tribology GroupRotordynamics Laboratory

Luis San AndresMast-Childs Professor

Turbomachinery LaboratoryMechanical Engineering Department

Texas A&M University

32nd Turbomachinery Research Consortium Meeting

http://rotorlab.tamu.edu

May 2012

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Tribology GroupMission: To advance state of the art in fluid film bearings for high performance turbomachinery

Types of funded research projects:• Engineering science fundamentals & development of computational engineering tools,

• Experimental – Bearing & Seal parameter identification

• Test-product verification & design validation• Education

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Students Tribology Group

Top: Feng Yu

Owen Zhang

Jose Hernandez

Sung-Hwa Jeung

Gary Bradley

Bottom Yujiao Tao

Alain Anderson

Joshua Norsworthy

Stephanie Simerskey

Qing Liu

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Thermal energy transport for bearing systems in turbochargers

Honeywell Turbocharging Technologies

(09/10-09/12) $ 208k

Efficient energy transport by oil flow determines TC performance

TB

TJ

Shaft (journal)

RING

CASING

Oil inlet

TB

TJ

Shaft (journal)

RING

CASING

Oil inlet

TB

TJ

Shaft (journal)

RING

CASING

Oil inlet

Heat from shaft

Drag Power (inner & outer~0)

100%

Heat to casing

Heat to fluid (i+o)Heat to fluid (i)

Heat to fluid (o)

Heat to ring65%

35%

24 % 17 %

83 %

8 %

76 %

high speed (240 krpm)

Analysis/test product & design validation

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Modeling thrust foil bearings for PV & CV TurbosBorg-Warner (2011-2012) $ 90.4 k

Deliverable: Predictive tool for ready integration into B&W engineering design flow. Test validation at B&W (Germany)

Needs: more reliable & + power efficient TCs, lighter oils (0-5W) and higher inlet temperatures (~150C).

Oil free TCs dispense with contaminated engine oil to increase reliability.

Analysis: product verification & design validation

W (Load)

Rotor collarr

Top foil

Gas film

Underspring

P

X

Y

Supportdisk

Bearing pad with top foil and underspring

Line weld

Direction of rotor

Spinning,

r

P

T

W (Load)

Rotor collarr

Top foil

Gas film

Underspring

P

X

Y

Supportdisk

Bearing pad with top foil and underspring

Line weld

Direction of rotor

Spinning,

r

P

T

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InsulationShaft

Bearing Assembly

Exhaust duct

Air inlet

Rotor

Test sealPressurization Vessel Centering spring

Cold air inlet

MotorSeal

High temperature seal test rig (300 C=572 F)

Measurement of leakage in a novel all metal non-contacting annular seal at high temperature

TRC (10-12) $ 74.8k (2 years)

2010-12 TRC funding

Labyrinth seal

HALOTM seal

Project progress status follows

HALO™ Seal

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Computational model for tilting pad journal bearings

TRC (10-12) $ 70.4k (2 years)

For high load bearings (> 150 psi), improve

correlation to experimental force

coefficients by adding pad-pivot flexibility and fluid energy transport &

thermal effectsASME GT2008-50069

Carter & Childs,

2010-12 TRC funding

New ModelNew Model

Test Test

YY

XX XX

YY

rotor speed 13.1 krpm

Test TAMU TPB (Wilkes)

Technical presentation follows

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Automated Analysis of XLTRC2 Time Transient Responses in Nonlinear Rotor Bearing Systems

TRC (11-12) $ 34.8k (1 year)

Manage output of XLTRC2 time response of NL

rotor-bearing motions &

characterize frequency and modal content

0 5 10 15 20 25 30 35 40

100

0

100

Xspeed (kRPM)

Res

ponse

(um

)

Vertical response (x)

0 10 20 30 40 Rotor speed [krpm]

Am

pli

tud

e [µ

m]

100

-100

0

1 × fn 2 × fn 3 × fn

WFM_YWFM_X

Frequency [Hz]

0 200 400 600 800

Ro

tor

spe

ed [

krp

m]

2

1

3

24

35 1X

1 × fn

2 × fn

3 × fn

Vertical response (x)

½WFR½ WFR3½ WFR3

2011-12 TRC funding

Technical presentation follows

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Metal Mesh Foil Bearings: Operation at High Temperature

Oil free TM research past fundingTRC (2003-2009) $ 312 kNSF (2003-2006) $ 255.5kNASA GRC (2007-2009) $ 284.6kCapstone (2007) $ 64.7 k

State of the art predictive tools benchmarked to test data

TRC (11-12) $ 36.6k (1 year)

2011-12 TRC funding: Gas bearings for MTM

Technical presentation follows.Report TRC-BC001-12

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SFD TESTING & ANALYTICAL METHODS DEVELOPMENT Large load (500 lbf) SFD test rig

Pratt & Whitney (08/08-12/12) $ 436kStatic loader

Shaker assembly (Y direction)

Shaker assembly (X direction)

SFD test bearing

TRC (12) $ 39.k (1 year)

Technical presentation followsReport TRC-SFD-01-12

2011-12 TRC funding: Linear/Nonlinear SFDs

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Other industrial projectComputational analysis of textured gas face seals for

steam turbinesCIATEQ A.C. (Mexico) (2010-12) Sponsors1 grad student

Typical steam turbine for lubrication system mechanical drive

Replace carbon rings to

increase turbine

reliability. Model novel

textured face seal geometries and

GUI for whole seal cartridgeNon-contacting gas face

seal with textured pattern

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Invited submissions (May 31)

NSF China-TAMU program Xi’an Jiaotong University

• DESIGN AND OPERATION OF LUBRICATED HIGH SPEED SPINDLES: COUPLED SYSTEM THERMO MECHANICAL AND DYNAMICS EFFECTS

• NOVEL THRUST FOIL BEARINGS FOR OIL-FREE MICROTURBOMACHINERY

More collaborative research programs expected with Asian OEMs, and KOSEF (Korea Science Foundation), NSF-China, CONACYT-Mexico, Brazil Education Ministry.

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U.S. News and World Report Ranking of Mechanical Engineering Graduate Programs among Public Institutions, 2005 - 2012

2005 2006 2007 2008 2009 2010/11 2012

Ran

k

School

Ran

k

School

Ran

k

School

Ran

k

School

Ran

k

School

Ran

k

School

Ran

k

School

1 UC Berkeley 1 UC Berkeley 1 UC Berkeley 1 UC Berkeley 1 UC Berkeley 1 UC Berkeley 1 UC Berkeley

2 Michigan 2 Illinois 2 Michigan 2 Michigan 2 Michigan 2 Michigan 2 Michigan

3 Illinois Michigan 3 Illinois 3 Illinois 3 Georgia Tech 3 Georgia Tech 3 Georgia Tech

4 Georgia Tech 4 Georgia Tech 4 Georgia Tech 4 Georgia Tech Illinois Illinois 4 Illinois

5 Purdue 5 Purdue Purdue Purdue 5 Purdue 5 Purdue 5 Purdue

6 UT Austin 6 UT Austin 6 Minnesota 6 UT Austin 6 UCLA 6 UT Austin 6 UT Austin

7 UCLA 7 Penn State UT Austin 7 Penn State UT Austin 7 Minnesota 7 Texas A&M

8 Penn State Wisconsin 8 Penn State UCLA 8 Minnesota Virginia Tech Penn State

Minnesota 9 UCLA UCLA Minnesota Wisconsin 9 Texas A&M Minnesota

10 UC San Diego UC San Diego Wisconsin Wisconsin 10 Texas A&M Penn State 10 Ohio State

Wisconsin Minnesota Virginia Tech 11 Virginia Tech Penn State UCLA UCLA

12 Maryland Virginia Tech 12 Texas A&M 12 Texas A&M Virginia Tech Wisconsin Maryland

Virginia Tech 13 Texas A&M Ohio State Ohio State 13 Maryland 13 Ohio State Wisconsin

14 Texas A&M Ohio State UC San Diego UC San Diego 14 Ohio State Maryland Virginia Tech

Ohio State Maryland UC San Diego 15 UC San Diego

UC Santa BarbaraMarch 16, 2012

The rankings 2012: 15th among all institutions

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Tribology Group Students

• Prepared for global competency

• Learn communication skills (written & oral)

• Training in teams that work and deliver

• Ready for open-ended multidisciplinary problems with no unique answer

• Experience in research tied to industrial needs

• Learn of compelling need for professional integrity

• Do more with less

Graduating 08/2012PhD Thomas

Chirathadam (SwRI)

MS Yujiao TaoMS Jose Hernandez

(CIATEQ, Mx)

MS Feng Yu Do more with nothing!

Diversity students 2012

2 PhD (1F)6 MS (1F, 1H)2 UGS (1F, 2AM)

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Funding 2010-2012$ 208.3k (Honeywell) + 97.2k (Pratt & Whitney) + 90.4k (Borg Warner) + 146.2k (TRC-2011) 542.1k + $ 68.0k software licenses

Research expenditures $ 246.4k (FY 11)$ 182.2k (FY 12)

Performance

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Scholarship08 09 10 11 12 Total

2011-2012

Journal (peer reviewed) 5 6 11 6 2 8

Conference (peer reviewed) 6 7 7 5 5 10

Conference (NOT peer reviewed) 2 2 2

Book Chapters 1 1 3 3

Accepted/awaiting publication 4 4

• 2011 BEST Rotordynamics Paper Award – IGTI Structures and Dynamics CommitteeSan Andrés, L., and Delgado, A., “A Novel Bulk-Flow Model for Improved Predictions of Force Coefficients in Grooved Oil Seals Operating Eccentrically,” ASME Paper GT2011-45274.

• 2010 Best Paper Award for ASME Journal of Tribology (2011 IJTC Conference, LA) Kim, T. H., and San Andrés, L., 2010, “Thermohydrodynamic Model Predictions and Performance Measurements of Bump-Type Foil Bearing for Oil-Free Turboshaft Engines in Rotorcraft Propulsion Systems,” ASME Journal of Tribology, 132, p. 011701

Total: FIVE Best paper awards 2002-2012

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2012 TRC reportsTRC-SFD-01-12 Force Coefficients for a Large Clearance Open Ends SFD with a Central Feed Groove: Test Results and Predictions TRC-BC001-12 Measurements of Rotordynamic Response in a High temperature Rotor Supported on two Metal Mesh Foil BearingsIn the works after n+1 revisionsSummer 2012:

Reports on computational model for tilting pad bearings (Y. Tao, M.S. Thesis) and NL rotordynamics XLTRC2 modeling (Q.Liu)

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2012 TRC proposals# years Cost

Automated analysis of time transient responses in nonlinear rotor bearing systems (Year II)

2 $ 41,484

Computational model for tilting pad journal bearings (Year III)

4 $ 40,984

Linear-nonlinear force coefficients for SFDs (Year II)

2 $28,470

Making a wet (foamy) seal and estimating its dynamic forced coefficients

2 $ 44,984

Engineered analysis for pocket damper seals and combined labyrinth-brush seals

2 $40,984

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Questions:Luis San Andres: Lsanandres@tamu.edu

More information at http://rotorlab.tamu.edu

All presentations and annual report available

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Graduate Program in Mechanical EngineeringGraduate Program in Mechanical Engineering

•Enrollment --- with 387 graduate students (fall 2011; almost all full-time students); the 7th largest and one of the most diverse mechanical engineering graduate programs in the U.S.

•Faculty --- 54 T/TT faculty (http://meen.tamu.edu/, spring 2012), including 4 endowed chair professors, 20 professors, 11 associate professors*, and 19 assistant professors*

•Ranking --- 7th among U.S. public institutions and 15th overall (U.S. News & World Report, 2012)

•Diversity --- 78 (20%) women; 214 (55%) Ph.D. students (with M.S. degrees), or 250 (65%) including direct Ph.D. students; students from 23 states in the United States and 18 other countries (fall 2011)

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Project in negotiation

Samsung Techwin (S Korea) (2 years) $160 kPredictive model for thrust collars in helically

geared compressors. (+ experimental benchmarking at TurboLab: Childs)

Bull gear

Pinion gear

Thrust washers

Pinion gear

Expected + use in drive trains for wind turbines

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Honeywell Turbocharging Technologies (2001-2009) $600k

VIRTUAL TOOL for TC rotordynamics

Integration of nonlinear rotordynamics & bearing performance – reduces time for prototype development (35%) and saves costs in product development (30%)

Predicted Steady-State Waterfall / Y DisplacementRBS with ODminIDmax / Oil Texaco-Havoline Energy 5W30, 150°C, 4bar

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000

Frequency (Hz)

Mo

tio

n A

mp

litu

de

Subsynchronous ComponentsSynchronous Component

Predicted Steady-State Waterfall / Y DisplacementRBS with ODminIDmax / Oil Texaco-Havoline Energy 5W30, 150°C, 4bar

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000

Frequency (Hz)

Mo

tio

n A

mp

litu

de

Subsynchronous ComponentsSynchronous Component

Measured Steady-State Waterfall / Y DisplacementRBS with ODminIDmax / Oil Texaco-Havoile Energy 5W30, 150°C, 4bar

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000

Frequency (Hz)

No

rma

lize

d N

on

lin

ea

r R

es

po

ns

e

Subsynchronous ComponentsSynchronous Component

Measured Steady-State Waterfall / Y DisplacementRBS with ODminIDmax / Oil Texaco-Havoile Energy 5W30, 150°C, 4bar

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000

Frequency (Hz)

No

rma

lize

d N

on

lin

ea

r R

es

po

ns

e

Subsynchronous ComponentsSynchronous Component

Predicted shaft motion Measured shaft motion

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Compare leakage: four seal types

HALO™ Seal

Hybrid Brush Seal

0

5

10

15

20

25

30

35

40

1.0 2.0 3.0 4.0 5.0 6.0

Pressure Ratio [Ps/Pe]

Flow

Fac

tor

[kg-

K0.

5/(M

Pa-

m-s

)]

Labyrinth SealBrush SealHybrid Brush SealHALO™ Seal

Flow factor Φ for four seal types versus inlet/exhaust pressure ratio [Ps/Pe] for increasing gas inlet temperatures (300 °C).

Flow factor

DP

Tm

s

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Oil-free Microturbomachinerywhen green becomes white white

Oil-lessturbocharger

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Oil-Free Bearings for MTMPV/CV turbochargers and midsize gas turbines need gas bearings to secure compact units with improved efficiency in an oil-free environment.

Applications as portable fuel cells (< 60 kW) to midsize GTs (< 400 kW) for distributed power, hybrid vehicles, CO2 waste heat and compression systems.

Gas Bearings allow• weight reduction, lower number of parts• higher temperatures & no cooling • improved overall engine efficiency & system availability

2025 mandate on + efficiency for IC vehicle engines: Materials and oil-free bearing systems could enable 55 miles/gallon.

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Gas Bearings for MTM

What are the needs?Make READY technology for industrial

application by PUSHING development to• make out of the shelf item with proven

results for a wide range of applications;• engineered product with well known

manufacturing process;• known (verifiable) performance with

proven laboratory and field experiences

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Project in limbo

GE O&G (Italy) (1 year) $100 kEnhanced model for prediction of leakage and force

coefficients in pocket damper seals

GT2011-4556

GE O&G interest in improving reliability of

annular seals in subsea compressors,

including operation under wet conditions.

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Oil-free MTM at TAMU• Best known program in the USA. • Licensed engineering predictive tools for gas bearings and seals and ready integration in MTM packages – high efficiency

• Validation of performance – static and dynamic – on dedicated high speed test rigs.

BEST PAPER AWARDS2011 IJTC J. Tribology (with KIST)2008 IGTI S&D - Rotordynamics2005 IGTI S&D - Rotordynamics2003 IGTI S&D - Rotordynamics

Cooperation with NASA GRC, KIST, Capstone

Honeywell, Borg-Warner, Becker-Turbo,

Capstone MT, Barber-Nichols, NASA, SNECMA, Dresser-Rand,

SWRI, R&D Dynamics, KIST, Bosch

Software Licenses

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The future in the works