Power Loss in High-Speed Micro Turbomachinery: An Experimental Study

2012 ◽  
Author(s):  
James F. Walton ◽  
Hooshang Heshmat ◽  
Michael Tomaszewski
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Ambient Pressure ◽  
Asperity Contact ◽  
Static Structure ◽  
Power Sources ◽  
Rotor Systems ◽  
Foil Bearings ◽  
Turbogenerator Rotor ◽  
Loss Models

In the paper the authors present the results of a study to investigate the windage and foil bearing losses in modern high-speed micro-turbomachinery such as motors, turboexpanders and turbogenerator rotor systems. Areas investigated include clearance between rotor and static structure; surface roughness; and ambient pressure conditions. Comparisons between experiments and theoretical windage loss models show excellent correlation at high speeds. Testing also indicated that some optimum rotor stator gaps are possible to minimize windage loss and that surface roughness can significantly impact windage. It was also shown that for rotor systems with foil bearings, at lower speeds rapid deceleration occurs. This is most likely due to the reduction in film thickness and onset of asperity contact between rotor and bearing surfaces. As expected ambient pressure also impacts windage losses. The theoretical rotor windage loss models, their range of applicability and key limitations of those loss models are discussed. While bearing losses are not included in theoretical windage loss models, it was shown that they do need to be considered, especially when developing very high speed motor/generators. Approaches to properly account for the wide array of losses in order to develop high power density power sources are recommended.

Numerical analysis of high-speed wheel/rail adhesion under interfacial liquid contamination using an elastic-plastic asperity contact model

2016 ◽  
Vol 231 (1) ◽  
pp. 63-74
Author(s):  
Bing Wu ◽  
Tao Wu ◽  
Zefeng Wen ◽  
Xuesong Jin
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Present Model ◽  
Temperature Fields ◽  
Elastic Model ◽  
Asperity Contact ◽  
Roughness Parameters ◽  
Slip Ratio ◽  
Elastic Plastic ◽  
Train Speed

The objective of this paper is to investigate the high-speed wheel/rail adhesion under interfacial liquids contamination using a numerical model. This model considers the rheological property of interfacial liquids, elastic-plastic deformation of microasperities contact and the temperature across the film thickness. The pressure and the temperature fields can be obtained. The effects of train speed, surface roughness parameters, characteristic shear stress, and the slip ratio are investigated. Furthermore, the present model is compared with the elastic model and the elastic-plastic model without considering the thermal effect. The numerical results show that the train speed and temperature affects the wheel/rail adhesion significantly.

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.

Lubricant Free Foil Bearings Pave Way to Highly Efficient and Reliable Flywheel Energy Storage System

2016 ◽  
Author(s):  
Hooshang Heshmat ◽  
James F. Walton
Keyword(s):  
Energy Storage ◽  
High Speed ◽  
Ambient Pressure ◽  
Storage System ◽  
High Surface ◽  
Mean Free Path ◽  
Energy Storage System ◽  
Flywheel Energy Storage ◽  
Flywheel Energy Storage System ◽  
Foil Bearings

Advanced compliant foil bearings capable of operating in low ambient pressures associated with soft vacuum are now paving the way to a new type of flywheel energy storage system. Many conventional flywheel energy storage system design approaches use active magnetic bearings with backup bearing technologies to meet the need for high speed operation in a low ambient pressure environment. Low ambient pressures are needed to overcome the power loss limitations associated with windage at high surface speeds. However, bearing technologies that rely on active control tend to be large, are dynamically soft which necessitates backup bearings and require a power supply which consumes some of the stored power to maintain rotor levitation. In this paper the authors will demonstrate both theoretically and experimentally the ability of advanced 5th generation compliant foil bearings to support large flywheel rotors weighing in excess of 900 N and which can operate to speeds in excess of 40,000 rpm. Testing conducted at pressures as low as 7 kPa demonstrates the ability of foil bearings to operate in low ambient pressures consistent with flywheel energy storage system needs for low windage loss. The authors will also present a hypothesis and the mechanisms involved in a hydrodynamic phenomenon that allows a foil bearing to operate successfully when the mean free path of the air molecules is exceedingly large due to low ambient pressures.

On the Coupling of Foil Bearing Supported Rotors: Part 2 — Experiment

2007 ◽  
Author(s):  
Michael J. Tomaszewski ◽  
James F. Walton ◽  
Hooshang Heshmat
Keyword(s):  
High Speed ◽  
Dynamic Performance ◽  
Experimental Program ◽  
Motor Drive ◽  
Combined System ◽  
Rotor Systems ◽  
Foil Bearings ◽  
Foil Bearing ◽  
Rotor Bearing ◽  
Full Speed

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 a successful experimental program are presented. Test results are presented for three different foil bearing coupled rotor systems. First, a coupled 32 kW, 60,000 rpm induction motor drive supported on compliant foil bearings was coupled to an identical 32 kW 60,000 rpm generator rotor and operated to full speed. Next, a high-speed 30,000 rpm capable ball bearing mounted precision spindle was driven to full speed when coupled to a 32 kW foil bearing supported drive motor. Third, the 32 kW, 60,000 rpm foil bearing based motor drive was coupled to a foil bearing supported rotor having a bending critical speed at approximately 29,000 rpm. This combined system was operated successfully to 60,000 rpm. Results of this experimental test program confirm the rotor-bearing system dynamic analysis and demonstrate the feasibility of coupling foil bearing supported rotors to a wide array of other rotor-bearing systems.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

scholarly journals Interactive Effects in Two-Droplets Combustion of RP-3 Kerosene under Sub-Atmospheric Pressure

Processes ◽  
2021 ◽  
Vol 9 (7) ◽  
pp. 1229
Author(s):  
Hongtao Zhang ◽  
Zhihua Wang ◽  
Yong He ◽  
Jie Huang ◽  
Kefa Cen
Keyword(s):  
Burning Rate ◽  
Atmospheric Pressure ◽  
High Speed ◽  
Ambient Pressure ◽  
Interactive Effects ◽  
Propagation Time ◽  
High Speed Camera ◽  
Single Droplet ◽  
Fuel Droplets ◽  
Spacing Distance

To improve our understanding of the interactive effects in combustion of binary multicomponent fuel droplets at sub-atmospheric pressure, combustion experiments were conducted on two fibre-supported RP-3 kerosene droplets at pressures from 0.2 to 1.0 bar. The burning life of the interactive droplets was recorded by a high-speed camera and a mirrorless camera. The results showed that the flame propagation time from burning droplet to unburned droplet was proportional to the normalised spacing distance between droplets and the ambient pressure. Meanwhile, the maximum normalised spacing distance from which the left droplet can be ignited has been investigated under different ambient pressure. The burning rate was evaluated and found to have the same trend as the single droplet combustion, which decreased with the reduction in the pressure. For every experiment, the interactive coefficient was less than one owing to the oxygen competition, except for the experiment at L/D0 = 2.5 and P = 1.0 bar. During the interactive combustion, puffing and microexplosion were found to have a significant impact on secondary atomization, ignition and extinction.

Characteristic properties of AlTiN and TiN coated HSS materials

2015 ◽  
Vol 67 (2) ◽  
pp. 172-180 ◽  
Author(s):  
Mumin Sahin ◽  
Cenk Misirli ◽  
Dervis Özkan
Keyword(s):  
Surface Roughness ◽  
Tensile Strength ◽  
High Speed ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Wear Properties ◽  
Content Type ◽  
X Ray ◽  
Number Of Cycles ◽  
Future Work

Purpose – The purpose of this paper is to examine mechanical and metallurgical properties of AlTiN- and TiN-coates high-speed steel (HSS) materials in detail. Design/methodology/approach – In this study, HSS steel parts have been processed through machining and have been coated with AlTiN and TiN on physical vapour deposition workbench at approximately 6,500°C for 4 hours. Tensile strength, fatigue strength, hardness tests for AlTiN- and TiN-coated HSS samples have been performed; moreover, energy dispersive X-ray spectroscopy and X-ray diffraction analysis and microstructure analysis have been made by scanning electron microscopy. The obtained results have been compared with uncoated HSS components. Findings – It was found that tensile strength of TiAlN- and TiN-coated HSS parts is higher than that of uncoated HSS parts. Highest tensile strength has been obtained from TiN-coated HSS parts. Number of cycles for failure of TiAlN- and TiN-coated HSS parts is higher than that for HSS parts. Particularly TiN-coated HSS parts have the most valuable fatigue results. However, surface roughness of fatigue samples may cause notch effect. For this reason, surface roughness of coated HSS parts is compared with that of uncoated ones. While the average surface roughness (Ra) of the uncoated samples was in the range of 0.40 μm, that of the AlTiN- and TiN-coated samples was in the range of 0.60 and 0.80 μm, respectively. Research limitations/implications – It would be interesting to search different coatings for cutting tools. It could be the good idea for future work to concentrate on wear properties of tool materials. Practical implications – The detailed mechanical and metallurgical results can be used to assess the AlTiN and TiN coating applications in HSS materials. Originality/value – This paper provides information on mechanical and metallurgical behaviour of AlTiN- and TiN-coated HSS materials and offers practical help for researchers and scientists working in the coating area.

scholarly journals Aerodynamic Losses in Turbines with and without Film Cooling, as Influenced by Mainstream Turbulence, Surface Roughness, Airfoil Shape, and Mach Number

2012 ◽  
Vol 2012 ◽  
pp. 1-28 ◽  
Author(s):  
Phil Ligrani
Keyword(s):  
Surface Roughness ◽  
Mach Number ◽  
Film Cooling ◽  
Total Pressure ◽  
High Speed ◽  
Density Ratio ◽  
Aerodynamic Loss ◽  
Pressure Losses ◽  
Loss Coefficients ◽  
Exit Mach Number

The influences of a variety of different physical phenomena are described as they affect the aerodynamic performance of turbine airfoils in compressible, high-speed flows with either subsonic or transonic Mach number distributions. The presented experimental and numerically predicted results are from a series of investigations which have taken place over the past 32 years. Considered are (i) symmetric airfoils with no film cooling, (ii) symmetric airfoils with film cooling, (iii) cambered vanes with no film cooling, and (iv) cambered vanes with film cooling. When no film cooling is employed on the symmetric airfoils and cambered vanes, experimentally measured and numerically predicted variations of freestream turbulence intensity, surface roughness, exit Mach number, and airfoil camber are considered as they influence local and integrated total pressure losses, deficits of local kinetic energy, Mach number deficits, area-averaged loss coefficients, mass-averaged total pressure loss coefficients, omega loss coefficients, second law loss parameters, and distributions of integrated aerodynamic loss. Similar quantities are measured, and similar parameters are considered when film-cooling is employed on airfoil suction surfaces, along with film cooling density ratio, blowing ratio, Mach number ratio, hole orientation, hole shape, and number of rows of holes.

A Comprehensive Study on Surface Roughness in Machining of AISI D2 Hardened Steel

2012 ◽  
Vol 576 ◽  
pp. 60-63 ◽  
Author(s):  
N.A.H. Jasni ◽  
Mohd Amri Lajis
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
End Milling ◽  
Cutting Speed ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Radial Depth ◽  
Aisi D2 ◽  
Coated Carbide

Hard milling of hardened steel has wide application in mould and die industries. However, milling induced surface finish has received little attention. An experimental investigation is conducted to comprehensively characterize the surface roughness of AISI D2 hardened steel (58-62 HRC) in end milling operation using TiAlN/AlCrN multilayer coated carbide. Surface roughness (Ra) was examined at different cutting speed (v) and radial depth of cut (dr) while the measurement was taken in feed speed, Vf and cutting speed, Vc directions. The experimental results show that the milled surface is anisotropic in nature. Surface roughness values in feed speed direction do not appear to correspond to any definite pattern in relation to cutting speed, while it increases with radial depth-of-cut within the range 0.13-0.24 µm. In cutting speed direction, surface roughness value decreases in the high speed range, while it increases in the high radial depth of cut. Radial depth of cut is the most influencing parameter in surface roughness followed by cutting speed.

Effect of Pressure on Bubble Growth Within Liquid Droplets at the Superheat Limit

1982 ◽  
Vol 104 (4) ◽  
pp. 750-757 ◽  
Author(s):  
C. T. Avedisian
Keyword(s):  
Vapor Bubble ◽  
Bubble Growth ◽  
High Speed ◽  
Ambient Pressure ◽  
Organic Liquid ◽  
Liquid Droplets ◽  
Growth Data ◽  
Two Phase ◽  
Photographic Evidence ◽  
Good Agreement

A study of high-pressure bubble growth within liquid droplets heated to their limits of superheat is reported. Droplets of an organic liquid (n-octane) were heated in an immiscible nonvolatile field liquid (glycerine) until they began to boil. High-speed cine photography was used for recording the qualitative aspects of boiling intensity and for obtaining some basic bubble growth data which have not been previously reported. The intensity of droplet boiling was found to be strongly dependent on ambient pressure. At atmospheric pressure the droplets boiled in a comparatively violent manner. At higher pressures photographic evidence revealed a two-phase droplet configuration consisting of an expanding vapor bubble beneath which was suspended a pool of the vaporizing liquid. A qualitative theory for growth of the two-phase droplet was based on assuming that heat for vaporizing the volatile liquid was transferred across a thin thermal boundary layer surrounding the vapor bubble. Measured droplet radii were found to be in relatively good agreement with predicted radii.

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