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Tribology GroupRotordynamics Laboratory

Luis San AndresMast-Childs Professor

Turbomachinery Laboratory

33rd Turbomachinery Research Consortium Meeting

http://rotorlab.tamu.edu

May 22, 2013

Access to presentations and proposals at

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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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2013 Students/Scholars

Joshua Brooks

JieyunZHang

SangshinPark

Gary Bradley

Joshua Norsworthy

TayuyaKinoshita

AndriyZahorulk

o

Bottom

Sung-HwaJeung

WeilianShan

XiaowanShan

YingkunLi

Qing LiuTop:

Missing Travis Cable, Jerry Haripin, Mathew Hilton

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• Turbocharger Bearing Systems Honeywell Turbo Technologies

• Gas Foil Bearings for Oil-Free TurbosBorg-Warner Turbochargers

• Novel Squeeze Film DampersPratt & Whitney Engines

• Thrust collars for integrally geared compressorsSamsung Techwin

Turbomachinery Research Consortium:• Nonlinear Rotordynamics – Data Analysis • Gas Pocket Damper Seals & Brush Seals• Wet Seals for Subsea Compression• Tilting Pad Bearings – Effects of pad flexibility

CollaborationsCIATEQ (Mx) & KIST (Korea)Gas face seals, Metal mesh foil bearings

Research projects (2012-2014)http://rotorlab.tamu.edu

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SFD TESTING & ANALYTICAL METHODS DEVELOPMENTLarge load (500 lbf) Pratt & Whitney (2008-13)

Static loader

Shaker assembly (Y direction)

Shaker assembly (X direction)

SFD test bearing

TRC (11-13)

Linear/Nonlinear SFDs

BEST PAPER AWARD 2011 IGTI Rotordynamics

TRC-SFD-01-13

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Model for lubricated thrust collars in integrally geared compressors. Samsung Techwin (2 years)

Bull gear

Pinion gear

Thrust washers

Pinion gear

Expected use in drive trains for wind turbines

Analysis/test product & design validation

(+ experimental benchmarking at Turbo Lab: Childs)

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Honeywell Turbocharging Technologies (2001-10)

Virtual tool for TC rotordynamics

gy , ,

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Subsynchronous ComponentsSynchronous Component

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Predicted shaft motion Measured shaft motion

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

Analysis/test product & design validation

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Thermal energy transport for bearing systems in turbochargers

Honeywell Turbocharging Technologies (10-13)

Efficient energy transport by oil flow determines TC performance

TB

TJ

Shaft (journal)

RING

CASING

Oil inletTB

TJ

Shaft (journal)

RING

CASING

Oil inletTB

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 ring

65%

35%

24 % 17 %

83 %

8 %

76 %

high speed (240 krpm)

Analysis/test product & design validation

BEST PAPER AWARD2012 IGTI Microturbomachinery & TCs

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Modeling thrust foil bearings for PV & CV Turbos Borg-Warner Turbo (2012)

Delivered 01/13: Predictive tool for ready integration into B&W engineering design flow.

Need: 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.

W (Load)

Rotor collarr

Top foil

Gas film

Underspring

P

X

Y

Supportdisk

Bearing pad with top foil and underspring

Line weld

Direction of rotorSpinning,

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 rotorSpinning,

r

P

T

Analysis/test product & design validation

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TRC funded projects

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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.

2010-12 TRC

Labyrinth seal

HALOTM seal

HALO™ Seal

TRC-SEAL-01-13

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Computational model for tilting pad journal bearings

For high load bearings (> 150 psi), XLTPJB© improves correlation to experimental force coefficients by adding pad & pivot flexibility and fluid energy transport & thermal effects

2010-13 TRC

TRC-B&C-01-13 Effect of pivot flexibility on TPJB force performance (static & dynamic)

TRC-B&C-03-13 Effect of pad surface elasticity on TPJB static load performance

Hydrodynamic pressure P

Hot oil flow

Pivot

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Automated Analysis of Time Transient Responses in Nonlinear Rotor Bearing Systems

Manage large output of time response of NL rotor-bearing motions & characterize frequency and modal content

0 5 10 15 20 25 30 35 40

Vertical response (x)

0 10 20 30 40 Rotor speed [krpm]

Am

plitu

de [µ

m]

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-100

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1 × fn 2 × fn 3 × fn

Frequency [Hz]0 200 400 600 800

Rot

or s

peed

[krp

m]

2

13

24

35

1X

1 × fn

2 × fn

3 × fn

Vertical response (x)

½WFR½ WFR3½ WFR3

2011-13 TRC TRC-RD-01-13

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• Added click & run worksheets: multiple cases, multiple loading conditions, multiple bearing configurations, efficient storage of data

• Post-processing tools: analyze tons of data (thousands of data points), make FFTS and waterfalls, filter responses to obtain 1X and any other sub or super-synchronous motions, filtered mode shapes at selected frequencies, etc.

• Set up test rig (flex rotor on JBs) to measure responses and to benchmark predictions of rotor NL dynamics.

Saves time in diagnosing & troubleshooting

TRC-RD-01-13Automated Analysis of Time Transient Responses in Nonlinear RBS

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Oil-free microtubomachinery•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 AWARDS2012 IGTI S&D – Bearings & Seals2011 IJTC J. Tribology (with KIST)2008 IGTI S&D - Rotordynamics2005 IGTI S&D - Rotordynamics2003 IGTI S&D - Rotordynamics

Honeywell, Borg-Warner, Beck-Turbo,

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

SWRI, R&D Dynamics, KIST, AENTL.

Software Licensees

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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

2011-12 TRC Gas bearings for MTM

TRC-B&C-02-13Shimmed Foil Bearings: Structural

stiffness and material loss factorTRC-B&C-04 -13

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Design/construct compression systems to handle wet gas conditions- eliminate L/G separators,- reduce weight and parts- increase reliability & efficiency- extend operation hours

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

2012-13 TRCSubsea application with wet gas compression

Progress detailed later (Gary Bradley)

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Stator (segmented)

flow

Combined brush seal -labyrinth seal

2012-13 TRCApplications in power steam turbinesEngineered analysis for pocket damper seals and combined labyrinth-brush seals

FPDS with 4 pockets and 3cavities

PDS with 4 pockets and 3cavities

TRC-SEAL-02-13

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Travis A. Cable Graduate Research Assistant

GUI for simple thrust bearings

A revamping of TRC-B&C-4-96

Ω

h(θ,t)CMAX

α

Thrust Collar

δ

Drive Shaft

Fixed Pad Taper Angle

CMIN

Ro

Ri

L

Tapered SectionUniform

Section

β

θiθo

SupplyExit

Side View

Top View

Ω

h(θ,t)CMAX

α

Thrust Collar

δ

Drive Shaft

Fixed Pad Taper Angle

CMIN

Ω

h(θ,t)CMAX

α

Thrust Collar

δ

Drive Shaft

Fixed Pad Taper Angle

CMIN

Ro

Ri

L

Tapered SectionUniform

Section

β

θiθo

SupplyExit

Ro

Ri

L

Tapered SectionUniform

Section

β

θiθo

SupplyExit

Side View

Top View

Original TRC code by (UG) N. Zirkelback(1996) – Fortran CONSOLE.Solves Reynolds equation using finite elements.Lumped thermal parameter model.

2013: built Excel GUI to interface with 1996-code to calculate thrust bearing performance for multiple shaft speeds.

A freebie for TRC members. Could be updated to model tilting pad thrust bearings.

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2012 TRC reports (overdue)

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

TRC-RD-01-13 Qing Liu

A Novel Computational Model for Tilting Pad Journal Bearings with Soft Pivot Stiffnesses TRC-B&C-01-13

Yujiao Tao Gas Seal Leakage at High Temperature: a Labyrinth Seal and an All-Metal

Compliant Seal of Similar Clearances TRC-SEAL-01-13

Alain Anderson Metal Mesh Foil Bearings: Prediction and Measurement of Static and

Dynamic Performance Characteristics TRC-B&C-02-13

Thomas Chirathadam

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A FE Model for Static Load in Tilting Pad Journal Bearings with Pad Flexibility

TRC-B&C-03-13 Yingkun Li

Identification of Structural Stiffness and Material Loss Factor in a Shimmed (Generation One) Bump-Type Foil Bearing

TRC-B&C-04-13 Joshua Norsworthy

On the Forced Performance of an Squeeze Film Damper Operating with Large Amplitude Orbital Motions: Measurements and Assessment of the

Accuracy of the Linearized Force Coefficients Model. TRC-SFD-01-13

Seung-Hwa Jeung Predictions vs. Test Results for Leakage and Rotordynamic Force

Coefficients of a Fully Partitioned Pocket Damper Seals and a Labyrinth Seal – Limitations of the Current Computational Model

TRC-SEAL-02-13 Welian Shan

2013 TRC reports (current)

June 1, 2013 (I hope)

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2013 TRC proposals

$ 44,0001A test rig for evaluation of thrust foil bearings or face seals

$ 37,9661Effect of shimming on the force coefficients of shimmed foil bearings

$ 35,8662Engineered analysis for pocket damper seals & combined labyrinth-brush seals

$ 40,6663Linear-nonlinear force coefficients for SFDs (Year III)

$ 37,0734Computational model for tilting pad journal bearings (Year III)

Cost# years

$ 195.6 k

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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 2013MS Feng Yu MS Gary BradleyMS Alain Anderson MS Sung-Hwa JeungMS Jose Hernandez

Do more with nothing!

Diversity students 20132 PhD (2F)6 MS (3F, 1A)3 UGS

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Old Friends at the Turbomachinery Laboratory

June 10 The influence of thermally induced inputs on the dynamics and design of rotating machines

Patrick Keogh, University of Bath, UK.

Vector and operator norms in rotor response computation

Eric Maslen, James Madison University, USA

Some aspects of rotordynamic forces and aerodynamic instabilities in turbomachinery

Seung Jing Song, Seoul National University, Seoul, Korea

June 11 Foundation identification using modal parameters

Eric Hahn U. South Wales, Australia

Theoretical and experimental analysis of hybrid aerostatic bearings

Mihai Arghir Institut Prime, Université de Poitiers, France

Recent improvements in rotordynamic performance of gas foil bearings for micro turbomachinery

Tae-Ho Kim Kookmin University Seoul, Korea

A special event after Turbo Expo 2013 (San Antonio)A tour de force into the latest developments in

rotordynamics of turbomachinery

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Questions (?)

Luis San Andres: Lsanandres@tamu.edu

http://rotorlab.tamu.eduAll slide shows for presentations and annual report available

Learn more at

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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

Rank School Rank School Rank School Rank School Rank School Rank School Rank 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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Scholarship

33Accepted/awaiting publication

11Book Chapters

2222Conference (NOT peer reviewed)

1156577Conference (peer reviewed)

666116Journal (peer reviewed)

Total 2012-2013

1312111009

Total: SEVEN Best paper awards 2002-2013.

ASME IGTI (June 2013) 2012 Best Paper Award, Structures & Dynamics Committee, Ryu, K., and San Andrés, L., 2012, ”Effect of Cooling Flow on The Operation of a Hot

Rotor-Gas Foil Bearing System,” ASME J. Eng. Gas Turbines Power, 134.2012 Best Paper Award, Microturbines, Turbochargers, & Small

Turbomachines CommitteeSan Andrés, L.., Barbarie, V., Bhattacharya, A., and Gjika, K., 2012, “On the Effect of

Thermal Energy Transport to the Performance of (Semi) Floating Ring Bearing Systems for Automotive Turbochargers,” ASME J. Eng. Gas Turbines Power, 134.

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Funding 2012-2013$ 158.6k (Samsung)+ 97.2k (Pratt & Whitney) + 196.2k (TRC-2012)452.0k +

$ 60.0k software licenses

Research expenditures$ 279.7k (FY 12)$ 241.1k (FY 13)

Performance

Not bad considering how much I complain …

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Other industrial projectComputational analysis of textured gas face seals

for steam turbinesCIATEQ A.C. (Mexico) (2010-13) funds 1 MS student

steam turbine & 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