Effect of Side Feed Pressurization on the Dynamic Performance of Gas Foil Bearings: A Model Anchored to Test Data

2008 ◽  
Author(s):  
Tae Ho Kim ◽  
Luis San Andre´s
Keyword(s):  
Test Data ◽  
High Speed ◽  
Gas Flow ◽  
Dynamic Performance ◽  
Rotor Speed ◽  
Mass Distributions ◽  
Foil Bearings ◽  
Feed Pressure ◽  
Run Up ◽  
Forced Cooling

Comprehensive modeling of gas foil bearings (GFBs) anchored to reliable test data will enable the widespread usage of these bearings into novel high speed turbomachinery applications. GFBs often need a forced cooling gas flow, axially fed through one end of the bearing, for adequate thermal management. The paper presents rotordynamic response measurements on a rigid rotor supported on GFBs during rotor speed run-up and coastdown tests with the GFBs supplied with increasing feed gas pressures to 2.8 bar. Rotor speed run-up tests to 35 krpm show that bearing end side feed gas pressurization delays the onset speed of rotor subsynchronous whirl motions. The test data validate closely predictions of the threshold speed of instability and whirl frequency ratio derived from a GFB model that implements the axial evolution of gas circumferential flow velocity as a function of the imposed side feed pressure. Rotor speed coastdown tests from 25 krpm with a low feed pressure of 0.35 bar evidences a nearly linear synchronous rotor response for small and moderately large imbalance mass distributions. A structural FE rotordynamics model integrates linearized synchronous speed GFB force coefficients and predicts synchronous responses, amplitude and phase angle, agreeing with the test data. The analysis and measurements demonstrate the profound effect of end side, feed gas pressurization on the rotordynamic performance of GFBs.

Effect of Side Feed Pressurization on the Dynamic Performance of Gas Foil Bearings: A Model Anchored to Test Data

2008 ◽  
Vol 131 (1) ◽  
Author(s):  
Tae Ho Kim ◽  
Luis San Andrés
Keyword(s):  
Test Data ◽  
High Speed ◽  
Gas Flow ◽  
Dynamic Performance ◽  
Rotor Speed ◽  
Mass Distributions ◽  
Foil Bearings ◽  
Feed Pressure ◽  
Run Up ◽  
Phase Angles

Comprehensive modeling of gas foil bearings (GFBs) anchored to reliable test data will enable the widespread usage of these bearings into novel high speed turbomachinery applications. GFBs often need a forced cooling gas flow, axially fed through one end of the bearing, for adequate thermal management. This paper presents rotordynamic response measurements on a rigid rotor supported on GFBs during rotor speed run-up and coastdown tests with the GFBs supplied with increasing feed gas pressures to 2.8bars. Rotor speed run-up tests to 35krpm show that the bearing end side feed gas pressurization delays the onset speed of rotor subsynchronous whirl motions. The test data validate closely the predictions of the threshold speed of instability and the whirl frequency ratio derived from a GFB model that implements the axial evolution of gas circumferential flow velocity as a function of the imposed side feed pressure. Rotor speed coastdown tests from 25krpm with a low feed pressure of 0.35bar evidence a nearly linear synchronous rotor response for small and moderately large imbalance mass distributions. A structural finite element rotordynamics model integrates linearized synchronous speed GFB force coefficients and predicts synchronous responses, amplitude, and phase angles, agreeing with the test data. The analysis and measurements demonstrate the profound effect of the end side feed gas pressurization on the rotordynamic performance of GFBs.

Thermohydrodynamic Analysis of Bump Type Gas Foil Bearings: A Model Anchored to Test Data

2010 ◽  
Vol 132 (4) ◽  
Author(s):  
Luis San Andrés ◽  
Tae Ho Kim
Keyword(s):  
Test Data ◽  
Thermal Energy ◽  
Gas Flow ◽  
Energy Transport ◽  
Static Load ◽  
Isothermal Condition ◽  
Gas Temperature ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Forced Cooling

The paper introduces a thermohydrodynamic (THD) model for prediction of gas foil bearing (GFB) performance. The model includes thermal energy transport in the gas film region and with cooling gas streams, inner or outer, as in typical rotor-GFBs systems. The analysis also accounts for material property changes and the bearing components’ expansion due to temperature increases and shaft centrifugal growth due to rotational speed. Gas inlet feed characteristics are thoroughly discussed in bearings whose top foil must detach, i.e., not allowing for subambient pressure. Thermal growths determine the actual bearing clearance needed for accurate prediction of GFB forced performance, static and dynamic. Model predictions are benchmarked against published measurements of (metal) temperatures in a GFB operating without a forced cooling gas flow. The tested foil bearing is proprietary; hence, its geometry and material properties are largely unknown. Predictions are obtained for an assumed bearing configuration, with bump-foil geometry and materials taken from prior art and best known practices. The predicted film peak temperature occurs just downstream of the maximum gas pressure. The film temperature is higher at the bearing middle plane than at the foil edges, as the test results also show. The journal speed, rather than the applied static load, influences more the increase in film temperature and with a larger thermal gradient toward the bearing sides. In addition, as in the tests conducted at a constant rotor speed and even for the lowest static load, the gas film temperature increases rapidly due to the absence of a forced cooling air that could carry away the recirculation gas flow and thermal energy drawn by the spinning rotor; predictions are in good agreement with the test data. A comparison of predicted static load parameters to those obtained from an isothermal condition shows the THD model producing a smaller journal eccentricity (larger minimum film thickness) and larger drag torque. An increase in gas temperature is tantamount to an increase in gas viscosity, hence, the noted effect in the foil bearing forced performance.

Effect of Side Feed Pressurization on the Dynamic Performance of Gas Foil Bearings

2007 ◽  
Author(s):  
Luis San Andre´s ◽  
Tae Ho Kim
Keyword(s):  
Gas Turbines ◽  
Gas Flow ◽  
Dynamic Performance ◽  
Mechanical Efficiency ◽  
System Stability ◽  
Remarkable Effect ◽  
Foil Bearings ◽  
Feed Pressure ◽  
Side Pressure ◽  
The Difference

Oil-free micro turbomachinery implementing gas foil bearings (GFBs) has improved mechanical efficiency and reliability. Adequate thermal management for operation in high temperature environments is an issue of importance in applications such as in gas turbines and turbochargers. GFBs often need a cooling gas flow, axially fed through one end of the bearing, to transport the heat conducted from a hot turbine, for example. Side gas pressurization, however, has a paramount effect on reducing amplitudes of motion, synchronous and subsynchronous. Presently, shaft motion measurements in a test rotor supported on GFBs show this remarkable effect. A computational gas film model implementing the evolution of gas circumferential flow velocity as a function of the imposed side pressure is advanced. Predicted direct stiffnesses and damping coefficients for the test GFB increase as the magnitude of feed pressure raises, while the difference in cross-coupled stiffnesses, directly related to rotor-bearing system stability, decreases. Predictions of threshold speed of instability and whirl frequency ratio are in close agreement with the measurements.

Thermohydrodynamic Analysis of Bump Type Gas Foil Bearings: A Model Anchored to Test Data

2009 ◽  
Author(s):  
Luis San Andre´s ◽  
Tae Ho Kim
Keyword(s):  
Test Data ◽  
Thermal Energy ◽  
Gas Flow ◽  
Energy Transport ◽  
Static Load ◽  
Isothermal Condition ◽  
Gas Temperature ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Forced Cooling

The paper introduces a thermohydrodynamic (THD) model for prediction of gas foil bearing (GFB) performance. The model includes thermal energy transport in the gas film region, and with cooling gas streams, inner or outer, as in typical rotor-GFBs systems. The analysis also accounts for material property changes and the bearing components’ expansion due to temperature rises and shaft centrifugal growth due to rotational speed. Gas inlet feed characteristics are thoroughly discussed in bearings whose top foil must detach, i.e., not allowing for subambient pressure. Thermal growths determine the actual bearing clearance needed for accurate prediction of GFB forced performance, static and dynamic. Model predictions are benchmarked against published measurements of (metal) temperatures in a GFB operating without a forced cooling gas flow. The tested foil bearing is proprietary; hence its geometry and material properties are largely unknown. Predictions are obtained for an assumed bearing configuration, with bump-foil geometry and materials taken from prior art and best known practices. The predicted film peak temperature occurs just downstream of the maximum gas pressure. The film temperature is higher at the bearing middle plane than at the foil edges, as the test results also show. The journal speed, rather than the applied static load, influences more the rise in film temperature and with a larger thermal gradient towards the bearing sides. In addition, as in the tests conducted at a constant rotor speed and even for the lowest static load, the gas film temperature increases rapidly due to the absence of a forced cooling air that could carry away the recirculation gas flow and thermal energy drawn by the spinning rotor, Predictions are in good agreement with the test data. A comparison of predicted static load parameters to those obtained from an isothermal condition shows the THD model producing a smaller journal eccentricity (larger minimum film thickness) and larger drag torque. A rise in gas temperature is tantamount to an increase in gas viscosity, hence the noted effect in the foil bearing forced performance.

Effect of Mechanical Preloads on the Dynamic Performance of Gas Foil Bearings

2008 ◽  
Author(s):  
Tae Ho Kim ◽  
Luis San Andre´s
Keyword(s):  
Large Amplitude ◽  
High Speed ◽  
Low Cost ◽  
Dynamic Performance ◽  
Cycle Performance ◽  
High Power Density ◽  
Shaft Speed ◽  
Foil Bearings ◽  
Bearing Force ◽  
Good Agreement

Gas foil bearings (GFBs) enable efficient, reliable and maintenance free operation of high-power-density microturbomachinery (< 200 kW). High speed rotors supported on bump-type GFBs, however, are prone to show large-amplitude subsynchronous motions albeit reaching limit cycle performance. Presently, commercial GFBs are simply modified to introduce a mechanical preload that induces a hydrodynamic wedge to generate more load support and direct stiffnesses. Three metal shims inserted under the bump strip layers and in contact with the bearing housing create a multiple lobe clearance profile at a very low cost. Shaft speed coastdown measurements reveal the rotordynamic performance of a rotor supported on original GBFs and (modified) shimmed GFBs. The later GFBs determine a raise in the rotor-bearing system natural frequency, as expected, and also act to delay the onset speed of large-amplitude subsynchronous motions. Predictions of imbalance response implementing linearized bearing force coefficients are in good agreement with measured amplitudes of synchronous response for both GFB configurations, original and modified.

Test Response of a Turbocharger Supported on Floating Ring Bearings: Part I — Assessment of Subsynchronous Motions

2003 ◽  
Author(s):  
Chris Holt ◽  
Luis San Andre´s ◽  
Sunil Sahay ◽  
Peter Tang ◽  
Gerry La Rue ◽  
...  
Keyword(s):  
Ambient Temperature ◽  
Test Data ◽  
Natural Frequencies ◽  
Comprehensive Analysis ◽  
Experimental Results ◽  
Inlet Pressure ◽  
Rotor Speed ◽  
Test Response ◽  
Feed Pressure ◽  
Feed Temperature

Measurements of casing acceleration on an automotive turbocharger running to a top speed of 115 krpm and driven by ambient temperature pressurized air are reported. Waterfall acceleration spectra versus rotor speed show the effects of increasing lubricant inlet pressure and temperature on the turbocharger rotordynamic response. A comprehensive analysis of the test data forwards regimes of speed operation with two subsynchronous whirl motions (rotordynamic instabilities). Increasing the lubricant feed pressure delays the onset speed of instability for the most severe subsynchronous motion. However, increasing the lubricant feed pressure also produces larger synchronous displacements. The effect of lubricant feed temperature is minimal on the onset and end speeds of rotordynamic instability. Nevertheless, operation with a cold lubricant exhibits lower amplitudes of motion, synchronous and subsynchronous. The experimental results show the subsynchronous frequencies of motion do not lock (whip) at system natural frequencies but continuously track the rotor speed. No instabilities (subsynchronous whirl) remain for operating speeds above 90 krpm. Bearings greatly influence turbocharger (TC) rotordynamic performance.

Experimental Response of Simple Gas Hybrid Bearings for Oil-Free Turbomachinery

2006 ◽  
Vol 128 (3) ◽  
pp. 626-633 ◽  
Author(s):  
Deborah A. Osborne ◽  
Luis San Andre´s
Keyword(s):  
High Speed ◽  
Damping Ratio ◽  
Dynamic Force ◽  
Test Results ◽  
Low Friction ◽  
Foil Bearings ◽  
Feed Pressure ◽  
Micropower Generators ◽  
Lift Off ◽  
Stiffness And Damping

Gas film bearings offer unique advantages enabling successful deployment of high-speed microturbomachinery (<0.4 MW). Current applications encompass micropower generators, air cycle machines and turbo expanders. Mechanically complex gas foil bearings are in use; however, their excessive cost and lack of calibrated predictive tools deters their application to mass-produced systems. The present investigation provides experimental results for the rotordynamic performance of a small rotor supported on simple and inexpensive hybrid gas bearings with static and dynamic force characteristics desirable in high-speed turbomachinery. These characteristics are adequate load support, stiffness and damping coefficients, low friction and wear during rotor startup and shutdown, and most importantly, enhanced rotordynamic stability. The test results evidence the paramount effect of feed pressure on early rotor lift-off and substantially higher threshold speeds of rotordynamic instability. Higher supply pressures also determine larger bearing direct stiffnesses, and thus bring an increase in the rotor-bearing system critical speed albeit with a reduction in damping ratio.

On the Coupling of Foil Bearing Supported Rotors: Part 1 — Analysis

2007 ◽  
Author(s):  
Hooshang Heshmat ◽  
James F. Walton ◽  
Crystal A. Heshmat
Keyword(s):  
Dynamic Characteristics ◽  
High Speed ◽  
Ball Bearing ◽  
Dynamic Performance ◽  
Rotor Systems ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Flexible Rotors ◽  
Coupling Dynamic ◽  
Bearing System

The expanded application of high-speed rotor systems operating on compliant foil bearings will be greatly enhanced with the ability to adequately couple multiple shaft systems with differing bearing systems and dynamic performance. In this paper the results of an analytical tradeoff study assessing coupling dynamic characteristics and their impact on coupled rotor-bearing system dynamics are presented. This analysis effort was completed in an effort to establish the form of characteristics needed to couple foil bearing supported rotors to ball bearing supported rotors, other foil bearing supported rotors as well as coupling rigid and flexible rotors both supported on foil bearings. The conclusions from this study indicate that with appropriate coupling design, a wide array of foil bearing supported rotor systems may be successfully coupled.

Experimental Response of Simple Gas Hybrid Bearings for Oil-Free Turbomachinery

2003 ◽  
Author(s):  
Deborah A. Wilde ◽  
Luis San Andre´s
Keyword(s):  
High Speed ◽  
Damping Ratio ◽  
Dynamic Force ◽  
Test Results ◽  
Power Generators ◽  
Foil Bearings ◽  
Feed Pressure ◽  
Micro Power ◽  
Lift Off ◽  
Stiffness And Damping

Gas film bearings offer unique advantages enabling successful deployment of high-speed micro-turbomachinery (&lt; 0.4 MW). Current applications encompass micro power generators, air cycle machines and turbo expanders. Mechanically complex gas foil bearings are in use; however, their excessive cost and lack of calibrated predictive tools deter their application to mass-produced systems. The present investigation provides experimental results for the rotordynamic performance of a small rotor supported on simple and inexpensive hybrid gas bearings with static and dynamic force characteristics desirable in high-speed turbomachinery. These characteristics are adequate load support, stiffness and damping coefficients, low friction and wear during rotor startup and shutdown, and most importantly, enhanced rotordynamic stability. The test results evidence the paramount effect of feed pressure on early rotor lift off and substantially higher threshold speeds of rotordynamic instability. Higher supply pressures also determine larger bearing direct stiffnesses, and thus bring an increase in the rotor-bearing system critical speed albeit with a reduction in damping ratio.

Thermal Management and Rotordynamic Performance of a Hot Rotor-Gas Foil Bearings System—Part II: Predictions Versus Test Data

2011 ◽  
Vol 133 (6) ◽  
Author(s):  
Luis San Andrés ◽  
Keun Ryu ◽  
Tae Ho Kim
Keyword(s):  
Test Data ◽  
Computational Models ◽  
Energy Transport ◽  
Structural Model ◽  
Companion Paper ◽  
Test System ◽  
Forced Response ◽  
Rotor Speed ◽  
Foil Bearings ◽  
System Operating

Implementation of gas foil bearings (GFBs) in microgas turbines relies on physics based computational models anchored to test data. This two-part paper presents test data and analytical results for a test rotor and GFB system operating hot. A companion paper (Part I) describes a test rotor-GFB system operating hot to 157°C rotor OD temperature, presents measurements of rotor dynamic response and temperatures in the bearings and rotor, and includes a cooling gas stream condition to manage the system temperatures. The second part briefs on a thermoelastohydrodynamic (TEHD) model for GFBs performance and presents predictions of the thermal energy transport and forced response, static and dynamic, in the tested gas foil bearing system. The model considers the heat flow from the rotor into the bearing cartridges and also the thermal expansion of the shaft and bearing cartridge and shaft centrifugal growth due to rotation. Predictions show that bearings’ ID temperatures increase linearly with rotor speed and shaft temperature. Large cooling flow rates, in excess of 100 l/min, reduce significantly the temperatures in the bearings and rotor. Predictions, agreeing well with recorded temperatures given in Part I, also reproduce the radial gradient of temperature between the hot shaft and the bearings ID, largest (37°C/mm) for the strongest cooling stream (150 l/min). The shaft thermal growth, more significant as the temperature grows, reduces the bearings operating clearances and also the minimum film thickness, in particular, at the highest rotor speed (30 krpm). A rotor finite element structural model and GFB force coefficients from the TEHD model are used to predict the test system critical speeds and damping ratios for operation at increasing shaft temperatures. In general, predictions of the rotor imbalance show good agreement with shaft motion measurements acquired during rotor speed coastdown tests. As the shaft temperature increases, the rotor peak motion amplitudes decrease and the system rigid-mode critical speed increases. The computational tool, benchmarked by the measurements, furthers the application of GFBs in high temperature oil-free rotating machinery.

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