tribology group year xx luis san andres mast-childs professor turbomachinery laboratory mechanical...
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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: [email protected]
See also http://rotorlab.tamu.edu/me489 forPractices of Modern Engineering Course