Performance Characteristics of Metal Mesh Foil Bearings: Predictions Versus Measurements

2013 ◽  
Vol 135 (12) ◽  
Author(s):  
Luis San Andrés ◽  
Thomas Abraham Chirathadam
Keyword(s):  
Low Cost ◽  
Excitation Frequency ◽  
Element Model ◽  
Rotating Machinery ◽  
Performance Characteristics ◽  
Dynamic Force ◽  
Metal Mesh ◽  
Force Coefficients ◽  
Foil Bearings ◽  
Damping Coefficients

Proven low-cost gas bearing technologies are sought to enable more compact rotating machinery products with extended maintenance intervals. The paper presents an analysis for predicting the static and dynamic forced performance characteristics of metal mesh foil bearings (MMFBs) which comprise a top foil supported on a layer of metal mesh of a certain compactness. The analysis couples a finite element model of the top foil and underspring support with the gas film Reynolds equation. A comparison of the predictions against laboratory measurements with two bearings aims to validate the analysis. The predicted drag friction factor in one bearing (L = D = 28.00 mm) during full film operation is just f ∼ 0.03 at ∼50,000 rpm, in good agreement with measurements at increasing applied loads. The predictions further elucidate the effect of the applied load and rotor speed on the bearing minimum film thickness, journal eccentricity, and attitude angle. For a second bearing (L = 38.0 mm, D = 36.5 mm), predicted bearing force coefficients show magnitudes comparable with the measurements, with less than a 20% difference, in the 250–350 Hz excitation frequency range. While the predicted direct stiffness coefficients are rather constant, the experimental force coefficients increase with frequency (maximum 400 Hz), due mainly to the increasing amplitudes of dynamic force applied to excite the bearing with a set amplitude of motion. The analysis underpredicts the direct damping coefficients at high frequencies (>300 Hz). The cross-coupled stiffness and damping coefficients are typically lower (<40%) than the direct ones. The bearings operated stably at all speeds without any subsynchronous whirl. The reasonable agreement of the predictions with the available test data promote the better design and further development of MMFB supported rotating machinery.

Performance Characteristics of Metal Mesh Foil Bearings: Predictions vs. Measurements

2013 ◽  
Author(s):  
Luis San Andrés ◽  
Thomas Abraham Chirathadam
Keyword(s):  
Low Cost ◽  
Excitation Frequency ◽  
Element Model ◽  
Rotating Machinery ◽  
Performance Characteristics ◽  
Dynamic Force ◽  
Metal Mesh ◽  
Force Coefficients ◽  
Foil Bearings ◽  
Damping Coefficients

Proven low-cost gas bearing technologies are sought to enable more compact rotating machinery products with extended maintenance intervals. The paper presents an analysis for predicting the static and dynamic forced performance characteristics of metal mesh foil bearings (MMFBs) which comprise of a top foil supported on a layer of metal mesh of certain compactness. The analysis couples a finite element model of the top foil and underspring support with the gas film Reynolds equation. Comparison of predictions against laboratory measurements with two bearings aims to validate the analysis. The predicted drag friction factor in one bearing (L = D = 28.00 mm) during full film operation is just f ∼ 0.03 at ∼ 50 krpm, agreeing well with measurements at increasing applied loads. The predictions further elucidate the effect of the applied load and rotor speed on the bearing minimum film thickness, journal eccentricity and attitude angle. For a second bearing (L = 38.0 mm, D = 36.5 mm), predicted bearing force coefficients show magnitudes comparable with the measurements, with less than 20% difference, in the 250–350 Hz excitation frequency range. While the predicted direct stiffness coefficients are rather constant, the experimental force coefficients increase with frequency (max. 400 Hz), due mainly to the increasing amplitudes of dynamic force applied to excite the bearing with a set amplitude of motion. The analysis under predicts the direct damping coefficients at high frequencies (>300 Hz). The cross-coupled stiffness and damping coefficients are typically lower (< 40%) than the direct ones. The bearings operated stable at all speeds without any sub synchronous whirl. The reasonable agreement of the predictions with the available test data promote the better design and further development of MMFB supported rotating machinery.

Experimental Identification of Dynamic Force Coefficients for a 110 mm Compliantly Damped Hybrid Gas Bearing

2014 ◽  
Author(s):  
Adolfo Delgado
Keyword(s):  
Load Capacity ◽  
Excitation Frequency ◽  
Dynamic Test ◽  
Inlet Pressure ◽  
Dynamic Force ◽  
Metal Mesh ◽  
Gas Bearings ◽  
Force Coefficients ◽  
Test Parameters ◽  
Gas Bearing

Compliant hybrid gas bearings combine key enabling features from both fixed geometry externally pressurized gas bearings and compliant foil bearings. The compliant hybrid bearing relies on both hydrostatic and hydrodynamic film pressures to generate load capacity and stiffness to the rotor system, while providing damping through integrally mounted metal mesh bearing support dampers. This paper presents experimentally identified force coefficients for a 110 mm compliantly damped gas bearing using a controlled-motion test rig. Test parameters include hydrostatic inlet pressure, excitation frequency, and rotor speed. The experiments were structured to evaluate the feasibility of implementing these bearings in large size turbomachinery. Dynamic test results indicate weak dependency of equivalent direct stiffness coefficients to most test parameters except for frequency and speed, where higher speeds and excitation frequency decreased equivalent bearing stiffness values. The bearing system equivalent direct damping was negatively impacted by increased inlet pressure and excitation frequency, while the cross-coupled force coefficients showed values an order of magnitude lower than the direct coefficients. The experiments also include orbital excitations to simulate unbalance response representative of a target machine while synchronously traversing a critical speed. The results indicate that the gas bearing can accommodate vibration levels larger than the set bore clearance while maintaining satisfactory damping levels.

Structural and Rotordynamic Force Coefficients of a Shimmed Bump Foil Bearing: An Assessment of a Simple Engineering Practice

2015 ◽  
Vol 138 (1) ◽  
Author(s):  
Luis San Andrés ◽  
Joshua Norsworthy
Keyword(s):  
Loss Factor ◽  
High Speed ◽  
Static Load ◽  
Low Cost ◽  
Mechanical Energy ◽  
Excitation Frequency ◽  
Engineering Practice ◽  
Force Coefficients ◽  
Damping Coefficients ◽  
Stiffness And Damping

High speed rotors supported on bump-type foil bearings (BFBs) often suffer from large subsynchronous whirl motions. Mechanically preloading BFBs through shimming is a common, low cost practice that shows improvements in rotordynamic stability. However, there is an absence of empirical information related to the force coefficients (structural and rotordynamic) of shimmed BFBs. This paper details a concerted study toward assessing the effect of shimming on a first generation BFB (L = 38.1 mm and D = 36.5 mm). Three metal shims, 120 deg apart, are glued to the inner surface of the bearing cartridge and facing the underside of the bump foil strip. The shim sets are of identical thickness, either 30 μm or 50 μm. In static load tests, a bearing with shims shows a (nonlinear) structural stiffness larger than for the bearing without shims. Torque measurements during shaft acceleration also demonstrate a shimmed BFB has a larger friction coefficient. For a static load of 14.3 kPa, dynamic loads with a frequency sweep from 250 Hz to 450 Hz are exerted on the BFB, without and with shims, to estimate its rotordynamic force coefficients while operating at ∼50 krpm (833 Hz). Similar measurements are conducted without shaft rotation. Results are presented for the original BFB (without shims) and the two shimmed BFB configurations. The direct stiffnesses of the BFB, shimmed or not, increase with excitation frequency, thus evidencing a mild hardening effect. The BFB stiffness and damping coefficients decrease slightly for operation with rotor speed as opposed to the coefficients when the shaft is stationary. For frequencies above 300 Hz, the direct damping coefficients of the BFB with 50 μm thick shims are ∼30% larger than the coefficients of the original bearing. The bearing structural loss factor, a measure of its ability to dissipate mechanical energy, is derived from the direct stiffness and damping coefficients. The BFB with 50 μm thick shims has a 25% larger loss factor—average from test data collected at 300 Hz to 400 Hz—than the original BFB. Further measurements of rotor motions while the shaft accelerates to ∼50 krpm demonstrate the shimmed BFB (thickest shim set) effectively removes subsynchronous whirl motions amplitudes that were conspicuous when operating with the original bearing.

A Metal Mesh Foil Bearing and a Bump-Type Foil Bearing: Comparison of Performance for Two Similar Size Gas Bearings

2012 ◽  
Vol 134 (10) ◽  
Author(s):  
Luis San Andrés ◽  
Thomas Abraham Chirathadam
Keyword(s):  
Manufacturing Cost ◽  
Dynamic Force ◽  
Metal Mesh ◽  
Gas Bearings ◽  
Force Coefficients ◽  
Foil Bearings ◽  
Advantages And Disadvantages ◽  
Foil Bearing ◽  
Start Up ◽  
Lift Off

Gas bearings in oil-free microturbomachinery for gas process applications and power generation (<400 kW) must be reliable and inexpensive, ensuring low drag power and thermal stability. Bump-type foil bearings (BFBs) and overleaf-type foil bearings are in use in specialized applications, though their development time (design and prototyping), exotic materials, and excessive manufacturing cost still prevent their widespread usage. Metal mesh foil bearings (MMFBs), on the other hand, are an inexpensive alternative that use common materials and no restrictions on intellectual property. Laboratory testing shows that prototype MMFBs perform similarly as typical BFBs, but offer significantly larger damping to dissipate mechanical energy due to rotor vibrations. This paper details a one-to-one comparison of the static and dynamic forced performance characteristics of a MMFB against a BFB of similar size and showcases the advantages and disadvantages of MMFBs. The bearings for comparison are a generation I BFB and a MMFB, both with a slenderness ratio L/D = 1.04. Measurements of rotor lift-off speed and drag friction at start-up and airborne conditions were conducted for rotor speeds to 70 krpm and under identical specific loads (W/LD = 0.06 to 0.26 bar). Static load versus bearing elastic deflection tests evidence a typical hardening nonlinearity with mechanical hysteresis, the MMFB showing two to three times more material damping than the BFB. The MMFB exhibits larger drag torques during rotor start-up, and shut-down tests though bearing lift-off happens at lower rotor speeds (∼15 krpm). As the rotor becomes airborne, both bearings offer very low drag friction coefficients, ∼0.03 for the MMFB and ∼0.04 for the BFB in the speed range 20–40 krpm. With the bearings floating on a journal spinning at 50 krpm, the MMFB dynamic direct force coefficients show little frequency dependency, while the BFB stiffness and damping increases with frequency (200–400 Hz). The BFB has a much larger stiffness and viscous damping coefficients than the MMFB. However, the MMFB material loss factor is at least twice as large as that in the BFB. The experiments show that the MMFB, when compared to the BFB, has a lower drag power and earlier lift-off speed and with dynamic force coefficients having a lesser dependency on whirl frequency excitation.

Experimental Identification of Dynamic Force Coefficients for a 110 MM Compliantly Damped Hybrid Gas Bearing

2015 ◽  
Vol 137 (7) ◽  
Author(s):  
Adolfo Delgado
Keyword(s):  
Load Capacity ◽  
Excitation Frequency ◽  
Dynamic Test ◽  
Inlet Pressure ◽  
Dynamic Force ◽  
Metal Mesh ◽  
Gas Bearings ◽  
Force Coefficients ◽  
Test Parameters ◽  
Gas Bearing

Compliant hybrid gas bearings (HGBs) combine key enabling features from both fixed geometry externally pressurized gas bearings and compliant foil bearings. The compliant hybrid bearing relies on both hydrostatic and hydrodynamic film pressures to generate load capacity and stiffness to the rotor system, while providing damping through integrally mounted metal mesh bearing support dampers. This paper presents experimentally identified force coefficients for a 110 mm compliantly damped gas bearing using a controlled-motion test rig. Test parameters include hydrostatic inlet pressure, excitation frequency, and rotor speed. The experiments were structured to evaluate the feasibility of implementing these bearings in large size turbomachinery. Dynamic test results indicate weak dependency of equivalent direct stiffness coefficients to most test parameters except for frequency and speed, where higher speeds and excitation frequency decreased equivalent bearing stiffness values. The bearing system equivalent direct damping was negatively impacted by increased inlet pressure and excitation frequency, while the cross-coupled force coefficients showed values an order of magnitude lower than the direct coefficients. The experiments also include orbital excitations to simulate unbalance response representative of a target machine while synchronously traversing a critical speed. The results indicate the gas bearing can accommodate vibration levels larger than the set bore clearance while maintaining satisfactory damping levels.

Identification of Dynamic Characteristics of Hybrid Bump-Metal Mesh Foil Bearings

2018 ◽  
Vol 140 (5) ◽  
Author(s):  
Zilong Zhao ◽  
Kai Feng ◽  
Xueyuan Zhao ◽  
Wanhui Liu
Keyword(s):  
Dynamic Characteristics ◽  
High Speed ◽  
Dynamic Stiffness ◽  
Load Test ◽  
Dynamic Force ◽  
Static Load Test ◽  
Metal Mesh ◽  
Force Coefficients ◽  
Foil Bearings ◽  
Foil Bearing

The stability of oil-free high-speed turbo-machinery can be effectively improved by increasing the damping characteristic of the gas foil bearing (GFB). Novel hybrid bump-metal mesh foil bearings (HB-MFBs) have been previously developed. Prior experimental results show that the parallel combination of bump structure and metal mesh not only can improve the structure stiffness but also provide better damping property compared with the bump-type foil structure. To investigate the dynamic behavior of floating HB-MFBs and promote its application, this study measured the dynamic force coefficients of HB-MFBs on a rotating test rig. The vibrations of HB-MFBs with different mesh densities (40%, 32.5%, and 25%) and a generation І bump-type foil bearing (BFB) with similar size are measured under static and impact loads to estimate the bearing characteristics. Static load test results show that the linear stiffness decreases when the air film is generated (from 0 rpm to 20 krpm) but increases gradually with speed (from 20 krpm to 30 krpm, and 40 krpm). Moreover, the dynamic force coefficients of HB-MFBs indicate the significant influence of metal mesh density on bearing dynamic characteristics. The growth in block density increases the dynamic stiffness and damping coefficients of bearing. The comparison of HB-MFB (32.5% and 40%) and BFB emphasizes the good damping characteristics of HB-MFB.

Metal Mesh Foil Bearing: Effect of Motion Amplitude, Rotor Speed, Static Load, and Excitation Frequency on Force Coefficients

2011 ◽  
Vol 133 (12) ◽  
Author(s):  
Luis San Andrés ◽  
Thomas Abraham Chirathadam
Keyword(s):  
Energy Dissipation ◽  
High Speed ◽  
Mechanical Energy ◽  
Excitation Frequency ◽  
Wire Mesh ◽  
Test Element ◽  
Metal Mesh ◽  
Force Coefficients ◽  
Damping Coefficients ◽  
Mechanical Energy Dissipation

Metal mesh foil bearings (MMFBs), simple to construct and inexpensive, are a promising bearing technology for oil-free microturbomachinery operating at high speed and high temperature. Prior research demonstrated the near friction-free operation of a MMFB operating to 60 krpm and showing substantial mechanical energy dissipation characteristics. This paper details further experimental work and reports MMFB rotordynamic force coefficients. The test rig comprises a turbocharger driven shaft and overhung journal onto which a MMFB is installed. A soft elastic support structure akin to a squirrel cage holds the bearing, aiding to its accurate positioning relative to the journal. Two orthogonally positioned shakers excite the test element via stingers. The test bearing comprises a cartridge holding a Copper wire mesh ring, 2.7 mm thick, and a top arcuate foil. The bearing length and inner diameter are 38 mm and 36.5 mm, respectively. Experiments were conducted with no rotation and with journal spinning at 40–50 krpm, with static loads of 22 N and 36 N acting on the bearing. Dynamic load tests spanning frequencies from 150 to 450 Hz were conducted while keeping the amplitude of bearing displacements at 20 µm, 25 µm, and 30 µm. With no journal spinning, the force coefficients represent the bearing elastic structure alone because the journal and bearing are in contact. The direct stiffnesses gradually increase with frequency while the direct damping coefficients drop quickly at low frequencies (< 200 Hz) and level off above this frequency. The damping combines both viscous and material types from the gas film and mesh structure. Journal rotation induces airborne operation with a hydrodynamic gas film separating the rotor from its bearing. Hence, cross-coupled stiffness coefficients appear although with magnitudes lower than those of the direct stiffnesses. The direct stiffnesses, 0.4 to 0.6 MN/m within 200–400 Hz, are slightly lower in magnitude as those obtained without journal rotation, suggesting the air film stiffness is quite high. Bearing direct stiffnesses are inversely proportional to the bearing motion amplitudes, whereas the direct equivalent viscous damping coefficients do not show any noticeable variation. All measurements evidence a test bearing system with material loss factor (γ) ∼ 1.0, indicating significant mechanical energy dissipation ability.

Identification of Rotordynamic Force Coefficients of a Metal Mesh Foil Bearing Using Impact Load Excitations

2010 ◽  
Author(s):  
Luis San Andre´s ◽  
Thomas Abraham Chirathadam
Keyword(s):  
High Speed ◽  
Impact Load ◽  
Mechanical Energy ◽  
Excitation Frequency ◽  
Forced Response ◽  
Dynamic Force ◽  
Rotating Shaft ◽  
Metal Mesh ◽  
Force Coefficients ◽  
Shaft Rotation

Metal mesh foil bearings (MMFB) are an inexpensive compliant gas bearing type that aims to enable high speed, high temperature operation of small turbomachinery. A MMFB with an inner diameter of 28.00 mm and length of 28.05 mm is constructed with low cost and common materials. The bearing incorporates a copper mesh ring, 20% in compactness and offering large material damping, beneath a 0.127mm thick preformed top foil. Prior experimentation (published papers) provide the bearing structure force coefficients and the break away torque for bearing lift off. Presently, the MMFB replaces a compressor in a small turbocharger driven test rig. Impact load tests aid to identify the direct and cross-coupled rotor dynamic force coefficients of the floating MMFB while operating at a speed of 50 krpm. Tests conducted with and without shaft rotation show the MMFB direct stiffness is less than its structural (static) stiffness, ∼25% lower at an excitation frequency of 200 Hz. The thin air film acting in series with the metal mesh support, and separating the rotating shaft and the bearing inner surface while airborne, reduces the bearing stiffness. The equivalent viscous damping is nearly identical with and without shaft rotation. The identified loss factor, best representing the hysteretic type damping from the metal mesh, is high at ∼0.50 in the frequency range 0–200 Hz. This magnitude reveals large mechanical energy dissipation ability from the MMFB. The measurements also show appreciable cross directional motions from the unidirectional impact loads, thus generating appreciable cross coupled force coefficients. Rotor speed coast down measurements reveal pronounced subsynchronous whirl motion amplitudes locked at distinct frequencies. The MMFB stiffness hardening nonlinearity produces the rich frequency forced response. The synchronous as well as subsynchronous motions peak while the shaft traverses its critical speeds. The measurements establish reliable operation of the test MMFB while airborne.

Metal Mesh Foil Bearing: Effect of Motion Amplitude, Rotor Speed, Static Load, and Excitation Frequency on Force Coefficients

2011 ◽  
Author(s):  
Luis San Andre´s ◽  
Thomas Abraham Chirathadam
Keyword(s):  
Energy Dissipation ◽  
High Speed ◽  
Mechanical Energy ◽  
Excitation Frequency ◽  
Wire Mesh ◽  
Test Element ◽  
Metal Mesh ◽  
Force Coefficients ◽  
Damping Coefficients ◽  
Mechanical Energy Dissipation

Metal mesh foil bearings (MMFBs), simple to construct and inexpensive, are a promising bearing technology for oil-free microturbomachinery operating at high speed and high temperature. Prior research demonstrated the near friction-free operation of a MMFB operating to 60 krpm and showing substantial mechanical energy dissipation characteristics. This paper details further experimental work and reports MMFB rotordynamic force coefficients. The test rig comprises of a turbocharger driven shaft and overhung journal onto which a MMFB is installed. A soft elastic support structure akin to a squirrel cage holds the bearing, aiding to its accurate positioning relative to the journal. Two orthogonally positioned shakers excite the test element via stingers. The test bearing comprises of a cartridge holding a Copper wire mesh ring, 2.7 mm thick, and a top arcuate foil. The bearing length and inner diameter are 38 mm and 36.5 mm, respectively. Experiments were conducted with no rotation and with journal spinning at 40–50 krpm, with static loads of 22 N and 36 N acting on the bearing. Dynamic load tests spanning frequencies from 150 to 450 Hz were conducted while keeping the amplitude of bearing displacements at 20 μm, 25 μm, and 30 μm. With no journal spinning, the force coefficients represent the bearing elastic structure alone since the journal and bearing are in contact. The direct stiffnesses gradually increase with frequency while the direct damping coefficients drop quickly at low frequencies (< 200 Hz) and level off above this frequency. The damping combines both viscous and material types from the gas film and mesh structure. Journal rotation induces airborne operation with a hydrodynamic gas film separating the rotor from its bearing. Hence, cross-coupled stiffness coefficients appear though with magnitudes lower than those of the direct stiffnesses. The direct stiffnesses, 0.4 to 0.6 MN/m within 200–400 Hz, are slightly lower in magnitude as those obtained without journal rotation suggesting the air film stiffness is quite high. Bearing direct stiffnesses are inversely proportional to the bearing motion amplitudes, whereas the direct equivalent viscous damping coefficients do not show any noticeable variation. All measurements evidence a test bearing system with material loss factor (γ) ∼ 1.0, indicating significant mechanical energy dissipation ability.

Structural and Rotordynamic Force Coefficients of a Shimmed Bump Foil Bearing: An Assessment of a Simple Engineering Practice

2015 ◽  
Author(s):  
Luis San Andrés ◽  
Joshua Norsworthy
Keyword(s):  
Loss Factor ◽  
High Speed ◽  
Static Load ◽  
Low Cost ◽  
Mechanical Energy ◽  
Excitation Frequency ◽  
Engineering Practice ◽  
Force Coefficients ◽  
Damping Coefficients ◽  
Stiffness And Damping

High speed rotors supported on bump-type foil bearings (BFBs) often suffer from large sub synchronous whirl motions. Mechanically preloading BFBs through shimming is a common, low cost practice that shows improvements in rotordynamic stability. However, there is absence of empirical information related to the force coefficients (structural and rotordynamic) of shimmed BFBs. This paper details a concerted study towards assessing the effect of shimming on a first generation BFB (L=38.1 mm, D =36.5 mm). Three metal shims, 120° apart, are glued to the inner surface of the bearing cartridge and facing the underside of the bump foil strip. The shim sets are of identical thickness, either 30 μm or 50 μm. Static load tests show that shimming produces nonlinear static load vs. deflection curves leading to a larger structural stiffness than for the bearing without shims. Torque measurements during shaft acceleration also demonstrate a shimmed BFB has a larger friction coefficient. For a static load of 14.3 kPa, dynamic loads with a frequency sweep from 250 Hz to 450 Hz are exerted on the BFB, without and with shims, to estimate its rotordynamic force coefficients while operating at ∼50 krpm (833 Hz). Similar measurements are conducted without shaft rotation. Results are presented for the original BFB (without shims) and the two shimmed BFB configurations. The direct stiffnesses of the BFB, shimmed or not, increase with excitation frequency thus evidencing a mild hardening effect. The BFB stiffness and damping coefficients decrease slightly for operation with rotor speed as opposed to the coefficients when the shaft is stationary. For frequencies above 300 Hz, the direct damping coefficients of the BFB with 50 μm thick shims are ∼ 30% larger than the coefficients of the original bearing. The bearing structural loss factor, a measure of its ability to dissipate mechanical energy, is derived from the direct stiffness and damping coefficients. The BFB with 50 μm thick shims has a 25% larger loss factor — average from test data collected at 300 Hz to 400 Hz — than the original BFB. Further measurements of rotor motions while the shaft accelerates to ∼50 krpm demonstrate the shimmed BFB (thickest shim set) effectively removes sub synchronous whirl motions amplitudes that were conspicuous when operating with the original bearing.

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