tc shaft motions virtual tool january, 2011 luis san andrés mast-childs tribology professor texas...

TC shaft motions virtual tool

January, 2011

Luis San AndrésLuis San AndrésMast-Childs Tribology Professor

Texas A&M University, Turbomachinery Laboratory

Supported by Honeywell Turbocharger Technologies (HTT)(2002-2011)

Vehicle Turbocharger Nonlinear Rotordynamics

Modeling and ExperimentalValidation

Research Progress


Overview

• Introduction to turbocharger rotordynamics

• Experimental facilities • Development of predictive

models (Virtual Tool)• Comparisons predictions vs

test data • Closure


Oil Inlet

Compressor Wheel

Shaft

TC Center Housing

Semi-Floating Bearing Anti-Rotating Pin

Turbine Wheel

• Increase internal combustion (IC) engine power output by forcing more air into cylinder

• Aid in producing smaller, more fuel-efficient engines with larger power outputs

Turbochargers


RBSFully Floating Bearing

RBSSemi Floating Bearing

RBSBall Bearing

RBS: TC Rotor Bearing System(s)

Increased IC engine performance & efficiency demands of robust & turbocharging solutions

The driver:


Bearing types

Shaft

Ball Bearing

Squeeze Film

Inner Race

Locking Pin

Outer Race

Ball-Bearing

Shaft

Inner Film

Outer Film

Oil Feed Hole

Floating Ring

Locking Pin

Semi-Floating Ring Bearing

(SFRB)

Floating Ring Bearing(FRB)

• Low shaft motion• Relatively expensive• Limited lifespan

• Economic• Longer life span• Prone to

subsynchronous whirl


Major challenges: extreme operating conditions

• - Low Oil Viscosity, e.g. 0W30 or 0W20

• - High Oil Temperature (up to 150°C)• - Low HTHS (2.9); Low Oil Pressure (1 bar)• - Increased Maximum Turbocharger Speed• - Variable Geometry Turbo Technology & Assisted e-power start up• - High Engine Vibration Level• - More Stringent Noise Requirements

Viscosity Plot

1

10

100

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

Oil Temperature (deg C)

Vis

co

sit

y (

cS

)

0W-30 Castrol SLX

0W-30 Castrol SLX Longlife

Water

Need predictive too to reduce costly engine test stand qualification


• TC linear and nonlinear rotordynamic codes – GUI based – including engine induced excitations

• Realistic bearing models: thermohydrodynamic

• Novel methods to estimate imbalance distribution and shaft temperatures

• NL analysis for frequency jumps and noise reduction

• Measured ring speeds with fiber optic sensors

Literature Review: San Andres and students

Predictive tool for shaft motion benchmarked by test data

2004 IMEchE J. Eng. Tribology

2005 ASME J. Vibrations and Acoustics ASME DETC 2003/VIB-48418 ASME DETC 2003/VIB-48419

2007 ASME J. Eng. Gas Turbines Power ASME GT 2006-90873

2007 ASME J. Eng. Gas Turbines Power ASME GT 2005-68177

2007 ASME J. Tribology IJTC 2006-12001

2007 ASME DETC2007-34136

2010 ASME J. Eng. Gas Turbines Power ASME GT2009-59108

2010 IFToMM Korea TC testing: expensive and time consuming Predictive tool saves time and money

Benchmarked against test data

TC shaft motions virtual toolMain Tasks – KEY OBJECTIVES

1. Measure shaft motion response in dedicated PV and CV turbocharger test rigs (cold & hot gas)

2. Development of software for prediction of (S) floating ring bearing static and dynamic forced response

3. Integration of FRB and SFRB tools into nonlinear rotordynamics code – VIRTUAL LABORATOY

4. Comparisons of test data to predictions:

Validate predictive tool


KEY OBJECTIVE # 1

Test rigs for TC rotordynamic performance evaluation

Turbine wheel Compressor wheel

Oil supplyTurbine Bearing Oil Supply Hole

Compressor Bearing Oil Supply Hole

SFRB Anti-Rotation Pin Hole


Experiments to measure the rotordynamic response of a turbocharger supported on semi-floating ring bearings and fully floating ring bearings

KEY OBJECTIVE # 1

Test RigsConstruct various test rigs, develop measurement methods, strategy to sensor selection and measurement locations, acquire data, processing tools, etc


TAMU TC test rig

• Infrared tachometer

• RAM BN sensors for shaft

motion•Fiber optics for

ring motion detection

2002


TAMU TC test rig

• Infrared tachometer• KAMAN sensors for shaft displacement at compressor side• Accelerometers for casing motion

•240 krpm max (4 KHz)

2004


TC gas stand test rig – HTT (France) 2008

• KAMAN sensors for shaft displacement at compressor side• connection to shakers

•300 krpm max (5 KHz)


3-axes accelerometers:

engine isolated atop a large shaker table

Accelerometers accelerometers

accelerations are collected with three-axis accelerometers.

Fig. 4 Turbocharger Engine Test Facility Stand

Compressor Housing

Air Inlet

Engine

Proximity Probes (X, Y)

TC engine stand test rig–HTT (Shanghai) 2008


Measure rotordynamic response of PV turbocharger

Shaft speed 25 - 240 krpm, Oil 5W-30, 150 C inlet temperature, feed pressure 1- 4 bar

compressorturbine

Semi-floating ring bearing

inches

Ant-rotation pin

Nose –displacementmeasurementplane

TC shaft motions virtual tool TEST DATA - Compressor End

243 krpm

29 krpm

1X

waterfall compressor end shaft motions whirl frequency ratio and amplitudes (mm) of vibration. Oil supply pressure = 1 bar, T=150 C

TLV TEST DATA - compressor end

0 50 100 150 200 2500

0.2

0.4

0.6Selected bandwith

kRPM

Fre

quen

cy r

atio

0 50 100 150 200 2500

0.03

0.06

SUB SYNCSYNCHRONOUS

Selected bandwith

kRPM

Am

plit

ude

Amplitude (mm)

Dominance of sub synchronous motions at all speeds

TLV TEST DATA


TC failure (cold air operation) 10 - 110 krpm : Oil ISO VG 10

TAMU TEST DATA


TC failure (cold air operation) 10 - 110 krpm : Oil ISO VG 10

Purpose of

analysis is to reduce

risk for this type of failure

TAMU TEST DATA


Compressor Specified WFR Analysis - X Direction at Proximitor

ratio 1

0 20 40 60 80 100 1200

200

400

600

Comp OverallComp PeakComp at WFR

C - X motions

rotor speed (kRPM)

RM

S a

mp

litu

des

synchronous

Overall RMS amplitude of motion (microns) at compressor end versus rotorspeed. Synchronous component also shown. Failure of GT 1544Z

Compressor Waterfalls - X Direction at Proximitor

1000 0 1000 2000 3000 40000

500

1000

1500

2000Waterfall - X - COMPRESSOR

Frequency [Hz]

Am

plitu

de

CX max 589.28

microns

maxkRPM 109

minkRPM 15.4

1X

(cold air operation) 10 - 110 krpm : Oil ISO VG 10

TC failure

TAMU TEST DATA


KEY OBJECTIVE # 2

TC fluid film bearings

Compressor side bearing oil supply holes

Turbine side bearing oil supply holes

Turbine side bearing ½ moon groove

Oil supply

Anti-rotation pinSFRB

Turbine Comp

Turbine bearing outer film Comp bearing

outer film

Center housing

Oil supply

Turbine bearing inner film

Comp bearing inner film

ShaftTurbine Comp

Turbine bearing inner film

Comp bearing inner film

Shaft


Development of software for prediction of (semi) floating ring bearing (S-FRB) static and dynamic forced response

KEY OBJECTIVE # 2

XLBRG Tool

EXCEL & Fortran FEM code for prediction of FRBs and SFRBs forced response (static and dynamic)

Finite length bearing model with global thermal balance and shear thinning effects

Interface to XLTRC2 software for rotordynamics analysis

TC shaft motions virtual toolModels for fluid films

- Balance of drag torques from outer and inner oil films- Thermal energy transport (heat conduction & convection)

Ring

Housing

Shaft

Inner oil film

Outer oil film

Y

Outer film pressure, Po

cos sin12 2 2R R R R

o R Ro X Y Y X

o

hP e e e e

cos sin12 2 2

ii X Y Y X

i

hP e e e e

; ;2J R J R

J RX X X Y Y Ye e e e e e

cos( ) sin( )i i X Yh c e e

cos( ) sin( )R Ro o X Yh c e e

Inner film pressure, Pi

Film thickness:

Film thickness:

X

Reynolds Equations


TC shaft motions virtual toolLumped Parameter Thermal Model

shaft

bearing

Inner film

Outer film

Mechanical powerby fluid shearingP ~ Torque x Rot Speed

Inner film Temp Rise

Outer film Temp Rise

Oil energy increase ~ Heat flowSp Heat x Mass flow x Temperature Difference

Floatingring

Energy convected to solids and conducted through shaft, ring and bearing



Example: Turbine side bearing

XLBRG® INPUT

Geometry (cold) – L,D,CFluid Type (commercial oil)

Material propertiesOperation (speed and load)

TC shaft motions virtual toolXLBRG®: types of bearings

shaft

ring

Oil inlet,Ps, TS

Half-moon

groove

Straight feed hole

ring

Oil inlet,Ps, TS

shaft

Oil supply – outboard side

Oil supply in bearing Types of oil supply

Figures NOT to scale


(Semi & Fully) Floating Bearing Ring• Actual geometry (length, diameter, clearance) of inner and outer films, holes size and distribution• Supply conditions: temperature & pressure• Lubricant viscosity varies with temperature and shear rate (commercial oil)• Side hydrostatic load due to feed pressure • Temperature of casing • Temperature of rotor at turbine & compressor sides derived from semi-empirical model: temperature defect model

XLBRG® ETHD fluid film bearing model predicts operating clearance and oil viscosity (inner and outer films) and eccentricities (static and dynamic) as a function of shaft & ring speeds and applied (static & dynamic) loads.

XLBRG® INPUT


Fluid Exit Temperature – Prediction vs. Test Data

37

38

39

40

41

42

43

44

0 10000 20000 30000 40000 50000 60000 70000 80000

Turbocharger Speed (rpm)

Lub

rica

nt E

xit

Tem

p (C

)

Measured Exit Temp

Predicted Exit Temp

Predicted

Test data

Oil Inlet Pressure = 2.06 barOil Inlet Temperature = 38°C

Test data

Predictions

5 oC5 oC

ASME GT2006-90873

XLBRG® Output


(S)FRB Predictions :

90

100

110

120

130

140

150

160

170

0 20000 40000 60000 80000 100000 120000 140000 160000 180000Shaft speed (rpm)

Max

imu

m t

emp

era

ture

(C

)

100% Engine Load - Inner Film 100% Engine Load - Outer Film50% Engine Load - Inner Film 50% Engine Load - Outer Film25% Engine Load - Inner Film 25% Engine Load - Outer FilmLubricant Supply Temperature

Peak film temperatures

Supplytemperature

Inner film

Outer film

Increase in power losses (with speed) leads to raise in inner film & ring temperatures.

No effect of engine loadASME GT 2009-59108

XLBRG® Output


0

1

2

3

4

5

6

7

0 20000 40000 60000 80000 100000 120000 140000 160000 180000Shaft speed (rpm)

Eff

ecti

ve v

isco

sit

y (

cP)

100% Engine Load - Inner Film 100% Engine Load - Outer Film50% Engine Load - Inner Film 50% Engine Load - Outer Film25% Engine Load - Inner Film 25% Engine Load - Outer Film

(S)FRB Predictions : Oil effective viscosity

Supply viscosity: 8.4 cP

Inner film

outer film

LUB: SAE 15W-40

Higher film temperatures determine lower lubricant viscosities. Operation parameters

independent of engine load

Lubricant type:

SAE 15W - 40

ASME GT 2009-59108

XLBRG® Output


0.80

0.85

0.90

0.95

1.00

1.05

1.10

1.15

1.20

0 20000 40000 60000 80000 100000 120000 140000 160000 180000Shaft speed (rpm)

Film

cle

aran

ceC

old

cle

aran

ce

100% Engine Load - Inner Film 100% Engine Load - Outer Film50% Engine Load - Inner Film 50% Engine Load - Outer Film25% Engine Load - Inner Film 25% Engine Load - Outer Film

Thermal growth relative to nominal inner or outer cold radial clearance

(S)FRB Predictions : Film clearances

nominalclearance

Inner film

outer film

Inner film clearance grows and outer film clearance decreases – RING grows more

than SHAFT and less than CASING. Material parameters are importantASME GT 2009-59108

XLBRG® Output


KEY OBJECTIVE # 3

TC rotordynamicslinear and nonlinear


XLTRC² Rotordynamics Virtual Tool

• Beam Finite-Element Formulation

• Real Component-Mode Synthesis (CMS) model

• Multi-line Rotor/Housing Modeling Capability

• Linear and transient response nonlinear analyses• Fully integrated with an extensive suite of support codes

• User-Friendly GUIs for rapid model development and report generation

Integration of FRB and SFRB codes into nonlinear rotordynamics program

KEY OBJECTIVE # 3

General EOMs

(t)QqKqGqCqM


Component-Mode Synthesis (CMS)

• Timoshenko-beam, FE-formulation

• Calculates real modes• Reduces model

dimensionality by using a limited number of modes

1

m1 m2 m3 m4

f1(t) f4(t)

XLTRC² rotordynamics code

TC shaft motions virtual toolRotor structural FE models

Shaft378

Shaft376

Shaft275

Shaft273

Shaft17270

6560

55

5045403530

25

20

15

105Shaft1

1

-0.04

-0.03

-0.02

-0.01

0

0.01

0.02

0.03

0.04

0 0.02 0.04 0.06 0.08 0.1 0.12

Axial Location, meters

Sh

aft

Rad

ius,

met

ers

compressor (left side) - turbine (right side)

FRB FRB

2nd shaft3rd shaft

Typical FE rotor structure model

Compressor thrust disk shaft turbine

Typical TC rotor hardware


-0.03

-0.02

-0.01

0

0.01

0.02

0.03

0 0.02 0.04 0.06 0.08 0.1 0.12

Axial Location [m]

Sh

aft

Ra

diu

s

[m]

Compressor Wheel

Feed Pressure Unbalance Planes

Thrust Collar

BearingCompressor

BearingTurbine

Semi-FloatingRing Bearing

CG Rotor

Turbine Wheel

Shaft Motion Target

Rotor finite element model: 2 shaft model

Rotor: 6Y gramSFRB: Y gram

Static weight load distribution

Compressor Side: Z Turbine Side: 5Z

Compressor Turbine

SFRB

Thrust Collar

Validate rotor model with

measurements of free-fee

modes(room Temp)

Validate rotor model


-0.04

-0.03

-0.02

-0.01

0

0.01

0.02

0.03

0.04

0 0.02 0.04 0.06 0.08 0.1 0.12


Sh

aft

Ra

diu

s,

me

ters

Measured (Freq = 1.799 kHz)

Predicted (Freq = 1.823 kHz)

Compressor End Turbine End

First mode

Second mode

measuredprediction

-0.04

-0.03

-0.02

-0.01

0

0.01

0.02

0.03

0.04

0 0.02 0.04 0.06 0.08 0.1 0.12


Sh

aft

Ra

diu

s,

me

ters




First mode

Second mode

measuredprediction

-0.04

-0.03

-0.02

-0.01

0

0.01

0.02

0.03

0.04

0 0.02 0.04 0.06 0.08 0.1 0.12


Sh

aft

Rad

ius,

mete

rs




First mode

Second mode

measuredprediction

-0.04

-0.03

-0.02

-0.01

0

0.01

0.02

0.03

0.04

0 0.02 0.04 0.06 0.08 0.1 0.12


Sh

aft

Rad

ius,

mete

rs




First mode

Second mode

measuredprediction

Free-free natural frequency & shapes

Measured and predicted free-free natural frequencies and mode shapes

agree: rotor model validation

measured Predicted % diff

KHz KHz -

First 1.799 1.823 1.3

Second 4.938 4.559 7.7

Validate rotor model


XLHYPAD

XLBRG

XLTRC2

FRB Geometry and Operating Conditions

Linear Model

Non- Linear Model

Synchronous responseEigenvalue analysis

Synchronous responseSubsynchronous motionsLimit Cycle Orbits

L1 L2

L3

Outer film

Inner film

LG1

LG2

HG

A

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

0 10000 20000 30000 40000 50000 60000 70000 80000

Shaft speed (rpm)T

emp

erat

ure

rai

se (

C)

Comp FRB inner film °C

Comp FRB outer film °C

Turb FRB inner film °C

Turb FRB outer film °C

206 kPa - 38 C Nominal inlet temperature

Inner lubricant film

Outer lubricant film

6.00

6.20

6.40

6.60

6.80

7.00

7.20

7.40

7.60

7.80

8.00

0 10000 20000 30000 40000 50000 60000 70000 80000

Shaft speed (RPM)

Eff

ectiv

e vi

scos

ity (C

pois

e)

Comp FRB inner film

Comp FRB Outer film

Turb FRB inner film

Turb FRB Outer film

206 kPa - 38 C Nominal inlet temperature

7.84 Cpoise

Nominal Viscosity@38 oC

Inner lubricant film

Outer lubricant film

0.985

0.990

0.995

1.000

1.005

1.010

1.015

0 10000 20000 30000 40000 50000 60000 70000 80000

Shaft speed (RPM)

Inne

r an

d ou

ter

film

cle

aran

ce c

hang

e

Comp FRB inner film

Comp FRB outer film

Turb FRB inner film

Turb FRB outer film

206 kPa - 38 C Nominal inlet temperatureInner clearances

Outer clearance

Ci/Co: 35.5/97 microns

Thermal growth relative to Ci+Co

Turbocharger + FRB model

Shaft349

Shaft345

Shaft244

Shaft240

Shaft139

35

30252015

10

5

Shaft11

-0.06

-0.04

-0.02

0

0.02

0.04

0.06

0.00 0.05 0.10 0.15 0.20 0.25 0.30

Axial Location

Sh

aft

Rad

ius

L: Compressor , R: Turbine

Compressor Turbine

CG rotor

imbalance planes

FRB FRB

Rotordynamic Response PlotTURBINE NOSE

STATION 46

0

0.001

0.002

0.003

0.004

0.005

0.006

0.007

0.008

0.009

0.01

0 50000 100000 150000 200000Rotor Speed, rpm

Resp

on

se 0

-pk

Major Amp

Horz Amp

Vert Amp

Excitation = 1x

Rotordynamic Deflected Shape Plot

-0.01

-0.005

0

0.005

0.01

0.015

0.02

0.025

0.03

0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16

Axial Location

Res

pons

e A

mpl

itu

de Major Amp

Horz Amp

Vert Amp

L: Compressor , R: TurbineDeflected Shape at 35000 rpm

Excitation = 1x

Rotordynamic Damped Natural Frequency Map

0200

400600

80010001200

14001600

18002000

0. 50000. 100000. 150000. 200000.

Rotor Speed, rpm

Na

tura

l Fre

qu

en

cy, H

z

1X

Rotordynamic Stability Map

-0.2

0

0.2

0.4

0.6

0.8

1

1.2

0. 50000. 100000. 150000. 200000.

Rotor Speed, rpm

Da

mp

ing

Ra

tio

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0 1000 2000 3000 4000 5000 6000

Frequency (Hz)

Am

plit

ud

e (-

)

Compressor end

1X

1X - synchronous

Compressor Nose (stn 4)

0.00

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0 40000 80000 120000 160000 200000

Shaft Speed (rpm)

Am

pli

tud

e (

0-p

k)

Nonlinear Sync (1X)

Linear Sync (1x)

Test data

Compressor EndY - Direction

NONLINEAR RESULTS

LINEAR RESULTSTEST DATA

SYNCHRONOUS RESPONSE

0.00

0.20

0.40

0.60

0.80

1.00

0 40000 80000 120000 160000 200000

shaft speed (rpm)

Am

plitu

de

(-)

Predicted orbit size

Test data

Compressor EndY - Direction

TOTAL MOTION

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

0 200 400 600 800 1000 1200 1400 1600 1800 2000

Shaft speed (rpm)

Am

pli

tud

e (

-)

Nonlinear pred

Test data

29 krpmSynchronous (1X)

Virtual Laboratory

Successful integration of FRB tools into rotordynamics program

XLTRC²

XLTRC² & XLBRG interfacing

TC shaft motions virtual toolNL predictions: typical responses

Predictions of TC shaft motion response – displacement versus time: rotor acceleration & deceleration

18 krpm 240 krpm

0 1 2 3 4 5 6 7-0.15

-0.1

-0.05

0

0.05

0.1

0 1 2 3 4 5 6 7-0.12

-0.1

-0.08

-0.06

-0.04

-0.02

0

0.02

0.04

0.06

0.08

240 krpm 18 krpm


Important:Massive amounts of time domain data rarely show any value (do not add knowledge nor establish firm design rules not even rules of thumb)

NL predictions: analyses in frequency domain

Analysis stresses on frequency domain analysis to build waterfalls, find total motion and synchronous motions, filtering of major whirl frequencies to determine effect on rotor elastic motions, calculation of forces transmitted to casing and rotor.


Test data vs. predictions

KEY OBJECTIVE # 4

ValidationsIf successful, a) Ready tool for PRODUCTIONb)Demonstrate savingsc) Install tool at all TC core engineering

centers


Costly procedure to qualify TCs

Four corners clearance limits

IDmin IDmax

ODmin

ODmaxComin

RING

ID casing

Inner film

IDOD

OD shaft

Outer film

Comax

CimaxCimin

Inner film

Ou

ter

film

Variations in manufactured RING dimensions


Past: NHS tests at 4 corners

IDmin IDmax

ODmin

ODmax

RING

ID casing

Inner film

IDOD

OD shaft

Outer film

Inner film

Ou

ter

film

Costly TC qualification certification


Current: One (or no) NHS test

IDmin IDmax

ODmin

ODmax

RING

ID casing

Inner film

IDOD

OD shaft

Outer film

Inner film

Ou

ter

film

Savings in TC qualification certification

Determined from Virtual Tool


Validation: shaft motion for PV TC


TC rotor & bearing system 2 shaft model

Compressor Turbine

126.44 mm

Spacer

Example: RBS with Semi

Floating Bearing

shaft speed 18 - 240 krpmOil 5W-30, 100 C inlet temperature, feed pressure 2,4 bar

C T

u

ASME DETC2007-34136

TC shaft motions virtual toolODmax-IDmax - compare

ASME DETC2007-34136

Measured at compressor end

ODmaxIDmax, Oil 5W30, Inlet Temp. = 150°C, Inlet Pressure = 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)

Synchronous

No

rmal

ized

No

nlin

ear

Res

po

nse

4062 Hz

Predicted at compressor end

WATERFALLs of SHAFT MOTION

TC shaft motions virtual toolODmax-IDmax - compare

ASME DETC2007-34136

Total motion &1X motion

ODmaxIDmax Oil 5W30, Inlet Temp. = 150°C, Inlet Pressure = 4bar

0

10

20

30

40

50

60

70

0 500 1000 1500 2000 2500 3000 3500 4000 4500

Turbocharger Speed (Hz)

Mo

tio

n A

mp

litu

de

[-]

Test: Total MotionPredicted: TotalTest: SynchronousPredicted: Synchronous

ODmaxIDmax Oil 5W30, Inlet Temp. = 150°C, Inlet P bar

0

150

300

450

600

750

900

1050

1200

1350

1500

0 500 1000 1500 2000 2500 3000 3500 4000 4500


Su

bs

yn

ch

ron

ou

s F

req

. (H

z) Test

Prediction1X

Whirl frequency


Nonlinear predictions reproduce test data – Linear eigenvalue analysis is limited in accuracy

Cylindrical - Deformed Mode Shape

Conical Mode Shape

0

100

200

300

400

500

600

700

800

900

0 500 1000 1500 2000 2500 3000 3500 4000 4500


Nat

ura

l Fre

qu

ency

(H

z)

Mode 1

Mode 2

Mode 3

Nonlinear Prediction

Test data

1X

Mode 1

Mode 3

Mode 2 Compressor - End Ring Mode

ODmin-IDmax - compare

ASME DETC2007-34136


Validation: shaft motion for CV TC


shaft speeds 30 - 180 krpmOil 0W-30, 92 C inlet temperature, feed pressure 4 bar

TC rotor & bearing system 3 shaft model


TC – Waterfalls: Test data and Nonlinear predictions

29.7 krpm

184.3 krpm

0 1000 2000 3000 4000 5000 60000

0.027

0.053

0.08TEST DATA - DISPLACEMENT

Frequency [Hz]

Am

plitu

de [

mm

]

4 bar

Ymax 0.038

RPMNcase

1.843 105

RPM0

2.976 104

TESTS Test data shows broad bands in sub synchronous frequency regions.

Whirl motions persist at all speeds.

Predictions show sub synchronous frequencies to 184 krpm. More severe than test data at low shaft speeds.

0 1000 2000 3000 4000 5000 60000

0.02

0.04

0.06

0.08Y-Compressor end

Frequency [Hz]

Am

plitu

de [

mm

]

184.3 krpm

*

29.76 krpm

Prediction

Validation CV TC


Imbalance response (linear and nonlinear) vs test data

Nonlinear response

predictions (1X

filtered) compares best

with test data at low shaft

speeds

0

0.005

0.01

0.015

0.02

0.025

0.03

0 25000 50000 75000 100000 125000 150000 175000 200000

Shaft Speed (rpm)

Am

pli

tud

e (m

m 0

-pk)

Nonlinear Sync (1X)

Linear Sync (1x)

Test data

Y - Direction 4 bar; variable temp Compressor Nose (stn 4)

TESTS

Nonlinear response (1X filtered)

8% of physical limit


Good correlation with

test data, in particular at

mid shaft speed range (70-130

kprm).

Test data & predictions

show persistent sub sync motions

GT 2560

0.000

0.100

0.200

0.300

0.400

0.500

0 25000 50000 75000 100000 125000 150000 175000 200000

shaft speed (rpm)

Am

pli

tud

e (

mm

)

Predicted Orbit Size

Test data

0.517 mm (pk-pk) physical limit

4 bar; variable temp

Compressor Nose (stn 4)

Nonlinear response (orbit analysis)

60 % of physical limit

Total Motion: test data and predictions

TESTS


Validation: engine induced excitations

ASME GT 2009-59108


– TC speed ranges from 48 krpm – 158 krpm

– Engine speed ranges from 1,000 rpm – 3,600 rpm

– 25%, 50%, 100% of full engine load

– Nominal oil feed pressure & temperature: 2 bar, 100°C

Operating conditions from test data:

Compressor Housing

Air Inlet

Engine


accelerations are collected with three-axis accelerometers.

Fig. 4 Turbocharger Engine Test Facility Stand

Compressor Housing

Air Inlet

Engine


TC Engine Test Facility Stand

ASME GT 2009-59108

IC engine induced excitations


0 2 4 6 8 10 12 14 16 18 200

100

200

300

Order of engine frequency

Am

plitu

de

0 2 4 6 8 10 12 14 16 18 200

100

200

300

Order of engine frequency

Am

plitu

de

TC housing acceleration analysis

Combined manifold & TC system natural

frequencies

Center Housing

Comp. Housing

m/s2

m/s2

100% engine load

~300 Hz

~570 Hz

1000 rpm

3600 rpm

2, 4, and 6 times engine

(e) main frequency contribute

significantly

1e order frequency

does not appear

ASME GT 2009-59108



Housing accelerations into model

Center Housing

Compressor

Turbine

Semi Floating Ring Bearing Assembly

Shaft

Axial Bearing Assembly

Connection to engine mount

Compressor housing

Eddy current sensor

Accelerometer

Specified housing motiondue to engine

ASME GT 2009-59108



0

0.05

0.1

0.15

0.2

0.25

0 500 1000 1500 2000 2500 3000 3500 4000

Frequency (Hz)

Am

pli

tud

e 0

-pk

(-)

Predictions without Housing Acceleration

TC synchronous response

1.0 krpm

3.6 krpm

1.0 krpm

3.6 krpm

0

0.05

0.1

0.15

0.2

0.25

0 500 1000 1500 2000 2500 3000 3500 4000

Frequency (Hz)

Am

pli

tud

e 0

-pk

(-)

Test Data


1.0 krpm

3.6 krpm

0

0.05

0.1

0.15

0.2

0.25

0 500 1000 1500 2000 2500 3000 3500 4000

Frequency (Hz)

Am

pli

tud

e 0

-pk

(-)

Test Data


1.0 krpm

3.6 krpm

1.0 krpm

3.6 krpm

0

0.05

0.1

0.15

0.2

0.25

0 500 1000 1500 2000 2500 3000 3500 4000

Frequency (Hz)

Am

pli

tud

e 0

-pk (

-)

Predictions with Housing Acceleration


1.0 krpm

3.6 krpm

0

0.05

0.1

0.15

0.2

0.25

0 500 1000 1500 2000 2500 3000 3500 4000

Frequency (Hz)

Am

pli

tud

e 0

-pk (

-)

Predictions with Housing Acceleration


1.0 krpm

3.6 krpm

1.0 krpm

3.6 krpm

Housing accelerations induce broad range, low frequency

whirl motions

Test data shows broad frequency response at low

frequencies (engine speeds)

Waterfalls of shaft motion at compressor end 100% engine load

1000 rpm

3600 rpm

ASME GT 2009-59108



0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

0 500 1000 1500 2000 2500 3000 3500 4000

Shaft speed (rpm)

Am

pli

tud

e p

k-p

k (-

)

Test Data

Nonlinear Predictions

Good correlation

with test data for all shaft

speeds

Total shaft motion at compressor end (amplitude)100% engine load

Test data

NL pred.

Am

plit

ud

e p

k-p

k (-

)

Rotor speed (RPM)

ASME GT 2009-59108



order engine frequencies, most likely due to the engine firing

0

50

100

150

200

250

300

350

400

450

500

550

600

0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000

Engine speed (rpm)

Fre

qu

ency

[H

z]

Test Data


12e

2e

1e

3e

4e

5e

6e

7e

8e

9e10e11e

TC shaft self-excited freqs.

0

50

100

150

200

250

300

350

400

450

500

550

600

0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000

Engine speed (rpm)

Fre

qu

ency

[H

z]

Test Data


12e

2e

1e

3e

4e

5e

6e

7e

8e

9e10e11e

TC shaft self-excited freqs.

predictionmeasured

Fig. 15. Predicted and measured subsynchronous whirl frequencies

Subsynchronous freq. vs. IC engine speed

Subsynch. freqs. are

multiples of IC engine frequency

Higher engine

order frequencies

not predicted

100% engine load

Test

NL

Su

bsy

nch

ron

ou

s fr

eq

uen

cy

(H

z)

Engine speed (RPM)

TC manifold nat freq.ASME GT 2009-59108



Validation: noise generation & frequency jump

IFToMM 2010

TC shaft motions virtual toolFrequency jumps: test data

Shaft accelerates Top speed ~180 krpm (3 kHz) Oil inlet temp= 30C Oil inlet pressure = 4 bar

Jump from 1st to 2nd whirl frequency increases noise

center housing acceleration (test data)

Objective: study bearing parameters and rotor characteristics affecting frequency jump

Ro

tor

Sp

eed

Frequency (Hz)

Bifurcation speed ~105 krpm (1.75 kHz)

Mode 2: Cylindrical2

31

22 Synchronous: 1X

1

Mode 1: Conical

21

bifurcation =2 1+2

Jump


68WFM_Y Frequency (Hz)

1000 2000 3000 4000

30 krpm

30 krpm

WFM_Y

WFM_X

0.177

Am

pli

tud

e (-

)

0 1000 2000 3000 4000

Frequency (Hz)

0 1000 2000 3000 4000

Frequency (Hz) Rotor Speed (krpm)

30 105

240 105

30

Rotor Speed (krpm)

30 105

240 105

30

0.1

0.2

0.3

ω1

ω2 ω1

Jump at 182krpm (ramp down)

Jump at 165 krpm (ramp up)

1X

Horizontal direction

NL predictions: frequency jumps

Waterfalls of shaft motion (compressor end)

Contour map

Jump at 182 krpm (ramp down)

Max speed, 240 krpm

Jump at 165 krpm (ramp up)

1X

1X

ω1 ω2IFToMM 2010


Rotor subsynchronous frequency (and amplitude) versus shaft speed (compressor end)

Rotor accelerates

Rotor decelerates

@ Ωb= 165krpm (2.75kHz) 5ω1 ~ 4ω2 3ω1 + ω2~ Ωb

ω2 = 815 Hz Ωb= 165krpm

Cylindrical bending rotor filtered whirling mode

CT

ω1 = 654 Hz Ωb= 165krpm

Conical rotor filtered whirling mode

CT

JUMP165 krpm

JUMP182 krpm

UP

@ Ωb=182krpm (~3kHz) 5ω1 ~ 4ω2 2ω1 + 2ω2~ Ωb

DOWN

ω2 = 845 Hz Ωb= 182krpm

CT

Cylindrical bending rotor filtered whirling mode

ω1 = 674 Hz Ωb= 182krpm

CT

Conical rotor filtered whirling mode

0.1

(-)

NL predictions: frequency jumps

IFToMM 2010


0 1 2 3 4 5 6 7-0.1

-0.08

-0.06

-0.04

-0.02

0

0.02

0.04

0.06

0.08

0 1 2 3 4 5 6 7-0.2

-0.15

-0.1

-0.05

0

0.05

0.1

0.15

NL predictions: noise

Predictions of TC shaft motion response – displacement versus time: rotor acceleration

18 krpm 240 krpm 18 krpm 240 krpm

IFToMM 2010


Closure

1. Tests SHOW dominance of SUB SYNCHRONOUS MOTIONS on rotordynamic response of PV TCs

2. TOOL for prediction of fully floating and semi-floating ring bearing (SFRB) static and dynamic forced response is ACCURATE

3. VIRTUAL TOOL: Seamless Integration of FRB and SFRB codes into nonlinear rotordynamics program

TAMU & HTT

XLBRG

XLTRC2

Test vs. predictions


TAMU-HTT VIRTUAL TOOL for Turbocharger NL Shaft Motion Predictions XLTRC2® & XLBRG® have a demonstrated 70% cycle time reduction in the development of new CV TCs. Since 2006, code aids to developing PV TCs with savings up to $150k/year in qualification test time

ASME DETC2007-34136

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


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


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


Predicted shaft motion Measured shaft motion


HTT 2011-12 Project

Complete thermal analysis of FRBs and S-FRBs for TCs• Prediction of thermal fields in entire TC system • Quantification of power losses and prediction of bearing

seizure & oil coking• Analysis of frequency jump phenomena and multiple internal and combined resonances

•$ 350 k (2 years)

TC shaft motions virtual toolOil-less turbochargers

Driver: HT ceramic ICEs with improved reliability

Advantages: + TH efficiency, HT limited by materials only, less contamination

Disadvantages:+ cost, more parts & balancingUnknown performance for large dynamic loads & road conditionsUnknown thermal soaking

Cheap solution sought: metal wire mesh bearings!

TC shaft motions virtual toolOther forces and issues

Thrust bearings: Tools availableIssues: thermal & coupling to lateral RD in PV TCs CV TC

PV TC

Aerodynamic forces: Tools availableIssue: At + high speeds, turbine develops a destabilizing force

Piston ring seal:Unknown forces. Issue: oil coking locks ring

TC shaft motions virtual toolAerodynamic force in turbines

Tip Clearance Excitation Force Review

As rotor whirls, regions of low clearance improve efficiency of blades and generate a force (from torque)

Low clearance,High blade efficiencyIncreased turbine force

Large clearance,low blade efficiencyReduced turbine force

rotation

Whirl direction

X

X

Y

DH

TKK yxxy

XKFYKF YXYXYX ,

Thomas-Alford Force Model

T: torque

D: tip diameterH: blade height efficiency parameter (empirical) =1-1.5


Acknowledgments

Honeywell Turbocharging Technologies (2002-2011)

TAMU Turbomachinery Laboratory Turbomachinery Research Consortium

(XLTRC2®)

Learn more athttp://rotorlab.tamu.edu

Luis San Andres © 2011


References

San Andrés, L., and Vistamehr, A., 2010, “Nonlinear Rotordynamics of Vehicle Turbochargers: Parameters Affecting Sub Harmonic Whirl frequencies and Their Jump,” Proc. of the 8th IFToMM International Conference on Rotordynamics, September, Seoul, Korea, Paper P-1115

Gjika, K., C. Groves, L. San Andrés, and LaRue, G., 2010, “Nonlinear Dynamic Behavior of Turbocharger Rotor-Bearing Systems with Hydrodynamic Oil Film and Squeeze Film Damper in Series: Prediction and Experiment,” ASME Journal of Computational and Nonlinear Dynamics, Vol. 5 (October), p. 041006-(1-8).

San Andrés, L., Maruyama, A., Gjika, K., and Xia, S., 2010, “Turbocharger Nonlinear Response with Engine-Induced Excitations: Predictions and Test Data,” ASME J. Eng. Gas Turbines Power, Vol. 132(March), p. 032502 (ASME Paper No. GT2009-59108)

San Andrés, L., J.C. Rivadeneira, K. Gjika, C. Groves, and G. LaRue, 2007, “A Virtual Tool for Prediction of Turbocharger Nonlinear Dynamic Response: Validation Against Test Data,” ASME Journal of Engineering for Gas Turbines and Power, 129(4), pp. 1035-1046 (ASME Paper GT 2006-90873)

San Andrés, L., J.C. Rivadeneira, K. Gjika, C. Groves, and G. LaRue, 2007, “Rotordynamics of Small Turbochargers Supported on Floating Ring Bearings – Highlights in Bearing Analysis and Experimental Validation,” ASME Journal of Tribology, Vol. 129, pp. 391-397.

San Andrés, L., J.C. Rivadeneira, M. Chinta, K. Gjika, G. LaRue, 2007,”Nonlinear Rotordynamics of Automotive Turbochargers – Predictions and Comparisons to Test Data,” ASME Journal of Engineering for Gas Turbines and Power, 129, pp. 488-493 (ASME Paper GT 2005-68177)

San Andrés, L., J.C. Rivadeneira, K. Gjika, M. Chinta, and G. LaRue, 2005, “Advances in Nonlinear Rotordynamics of Passenger Vehicle Turbochargers: a Virtual Laboratory Anchored to Test data,” Paper WTC 2005-64155, III World Tribology Conference, Washington D.C., September.


References

San Andrés, L., J.C. Rivadeneira, K. Gjika, C. Groves, and G. LaRue, 2006, “Rotordynamics of Small Turbochargers Supported on Floating Ring Bearings: Highlights in Bearing Analysis and Experimental Validation,” Paper CELT06-76, Memorias del IX Congreso y Exposición Latinoamericana de Turbomaquinaria, Boca del Río Veracruz, Mexico, June 22-23, 2006, ISBN 968-6114-20-3

Holt, C., L. San Andrés, S. Sahay, P. Tang, G. LaRue, and K. Gjika, 2005, “Test Response and Nonlinear Analysis of a Turbocharger Supported on Floating Ring Bearings,” ASME Journal of Vibrations and Acoustics, 127, pp. 107-212.

San Andrés, L. and J. Kerth, 2004, “Thermal Effects on the Performance of Floating Ring Bearings for Turbochargers”, Journal of Engineering Tribology, Special Issue on Thermal Effects on Fluid Film Lubrication, IMechE Proceedings, Part J, Vol. 218, 5, pp. 437-450

Holt, C., L. San Andrés, S. Sahay, P. Tang, G. LaRue, and K. Gjika, 2003, “Test Response of a Turbocharger Supported on Floating Ring Bearings – Part I: Assessment of Subsynchronous Motions,” ASME Paper DETC 2003/VIB-48418, Proceedings of the 19th Biennial Conference on Mechanical Vibration and Noise,” Chicago (IL), September

Holt, C., L. San Andrés, S. Sahay, P. Tang, G. LaRue, and K. Gjika, 2003, “Test Response of a Turbocharger Supported on Floating Ring Bearings – Part II: Comparisons to Nonlinear Rotordynamic Predictions,” ASME Paper DETC 2003/VIB-48419, Proceedings of the 19th Biennial Conference on Mechanical Vibration and Noise,” Chicago (IL), September

Naranjo, J., C. Holt, and L. San Andrés, 2001, “Dynamic Response of a Rotor Supported in a Floating Ring Bearing,. 1st International Conference in Rotordynamics of Machinery, ISCORMA1, Paper 2005, August 2001 (CD only).

Over 80 proprietary monthly progress reports to sponsor (Honeywell Turbocharging Systems), 2002-2011.

tc shaft motions virtual tool january, 2011 luis san andrés mast-childs tribology professor texas...

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