Tribology Group Year XX

Luis San AndresMast-Childs Professor

Turbomachinery LaboratoryMechanical Engineering Department

Texas A&M University

May 2011

31th TRC meeting

http://rotorlab.tamu.edu

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

Tribology Group Students

Thomas Chirathadam

Feng Yu

Alain Anderson

Qing Liu

Jose Hernandez

Paola Mahecha

Yujiao Tao Sanjeev Seshaghiri

2010-2011

MissingKeun Ryu (Borg-Warner)

UGsJames LawSarabeth

Froneberger

SFD EXPERIMENTAL TESTING & ANALYTICAL METHODS DEVELOPMENT Large load (500 lbf) SFD test rigPratt & Whitney (08/08-12/10) $ 330k

Industry Grants

Static loader

Shaker assembly (Y direction)

Shaker assembly (X direction)

Static loader

Shaker in X direction

Shaker in Y direction

SFD test bearing

TEST RIG available for further identification of commercial SFDS

Analysis/test product verification & design validation

Honeywell Turbocharging Technologies (2001-2012)

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

Thermal Energy Transport Analysis for Floating Ring Bearings in Turbochargers

Honeywell Turbocharging Technologies (09/10-09/12) $ 208k

Analysis of hydrodynamic bearing with enhancements in heat transfer model + prediction

capability of external excitation and frequency response function modeling

capability

TB

TJ

Shaft (journal)

RING

CASING

Oil inlet

TB

TJ

Shaft (journal)

RING

CASING

Oil inlet

TB

TJ

Shaft (journal)

RING

CASING

Oil inlet

Analysis/test product verification & design validation

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)

HALO™ Seal

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

TRC (10-11) $ 39.8k (1st year)

2010-11 TRC funding

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

Computational model for tilting pad journal bearings

TRC (10-11) $ 34.8k (1st year)

For high load bearings (> 150 psi), improve

correlation to experimentally derived

force coefficients by adding pad-pivot

flexibility and fluid energy transport &

thermal effects

Journal Pad

Pivot

e

Rotor speed

Fluid film

W, static load

ASME GT2008-50069

Carter & Childs,

2010-11 TRC funding

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

TRC (10-11) $ 34.8k (1 year)

Automate 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

2010-11 TRC funding

Other projects

Computational analysis of textured gas face seals for steam turbines

CIATEQ A.C. (Mexico) (2010-11) Support 1 grad student

Typical steam turbine for lubrication system mechanical drive

Ro

RgoRgi

Ri

r

Inner seal dam

Outer seal dam

Shape grooveRotating textured surface

Non-contacting gas face seal with textured

grooves

Model novel textured face seal

geometries and develop GUI for

whole seal cartridge.

Replacements to carbon rings

increase turbine efficiency and

reduce leakage

Unfunded projects

Gas bearings for high turbomachinery:(a) Thermal management of foil bearings(b) Dynamic forced performance of metal

mesh foil bearingsSupport for two students from licensing Gas Seal and Gas Foil Bearing

codes

Past funding includesTRC (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

Funding$ 208,340 (HTT) + 153.5k (P&W) + $109k (TRC)

$ 343.8 k research expenditures (FY 10-11)

Tribology Group Performance

Publications 2010 2011 Total

Journal (peer reviewed) 11 5 16Conference (peer reviewed) 7 5 12Conference (NOT peer

reviewed)2 2

Accepted / awaiting publication

3 3

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 2010/11PhD Keun Ryu (Borg-

Warner)

MS Sanjeev SeshagiriMS Paola Mahecha

Do more with nothing!

2011 TRC Research Progress Reports

• Comparison of leakage between a labyrinth seal and an all-metal compliant gas seal at high temperature (completed TRC-S-02-11) – Alain Anderson presents progress

• Computational model for tilting pad journal bearings (in progress) – Yujiao Tao presents progress

2011 TRC Project Proposals

Summaries in Tribology Group Annual Report (2011)

Continuation # year

s

Cost

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

1 $ 35,000

Computational model for tilting pad journal bearings

1 $ 35,558

New

Linear-Nonlinear Force Coefficients for Squeeze Film Dampers

1 $37,108

Metal Mesh Foil Bearings: Operation at High Temperature

1 $38,608

2011 TRC Meeting

Questions:

Luis San Andres: Lsanandres@tamu.edu

See also http://rotorlab.tamu.edu/me489 forPractices of Modern Engineering Course