Performance of textured foil journal bearing considering the influence of relative texture depth

Both foil structure and surface texturing have been widely used to improve bearing performance. However, there is little research on their combination, namely, textured gas foil bearing. This paper adopts the Reynolds equation as the pressure governing equation of bump-type foil journal bearing to study the influence of textures located on the top foil. The Newton-Raphson iterative method and the perturbation method are employed to obtain static and dynamic characteristics, respectively. Thereafter, based on three texture distribution types, further analysis about the effect of the relative texture depth and the textured portion is carried out. The results indicate that an appropriate arrangement of textures could improve the performance of gas foil bearing. For #1 texture distribution, the maximum increment of load capacity could exceed 10% when ω = 1.4 × 105 r/min, ε = 0.2.

A review of thermohydrodynamic aspects of gas foil bearings

In recent times, gas foil bearings have become popular for commercial use in the aircraft and space industry, turbocompressors, turbine generators and in the more complex fields of turbochargers and turboexpanders. The gain in popularity for gas foil bearings is due to their features such as contamination-free zone, wide temperature range, higher stability and higher reliability characteristics as compared to other types of bearings. However, several challenges have come across while analysing the gas foil bearing behaviour at different working conditions. The current paper presents an overview of the work done in the past few decades for developing numerical models and listing the efforts of several researchers around the world to conduct the experimental investigation for predicting and analysing thermohydrodynamic behaviour of gas foil bearings at different operating conditions. It is expected that the current paper will help readers to thoroughly understand the hydrodynamic and thermal aspects of gas foil bearings.

Design guidelines for bump-type compliant conical foil bearing

The integral bump foil strip cannot optimize the performance for the compliant conical foil bearing (CFB) as the uneven distribution of structural stiffness. To maximize the bearing characteristics, this paper proposed different bump foil schemes. Firstly, the anisotropy of CFB was studied based on the nonlinear bump stiffness model, and the circumferentially separated foil structure was proposed. Moreover, an axially separated bump foil structure with the variable bump length was introduced to make the axial stiffness distribution more compliant with the gas pressure. In addition, the effect of foil thickness was also discussed. The results show that CFB with integral bump foil exhibits obvious anisotropy, and the suggested installation angle for largest load capacity and best dynamic stability are in the opposite position. Fortunately, a circumferential separated bump foil can improve this defect. The characteristics of CFB with axial separated foil structure can be improved significantly, especially for that with more strips and the variable bump half-length design. The suitable bump and top foil thickness should be set considering the improved supporting performance and proper flexibility. The results can give some guidelines for the design of CFB.

Design analysis and performance evaluation of a novel Multi-Cantilever Foil Bearing

This study gives an explanation to design analysis and performance evaluation of a novel multi-cantilever foil bearing (MCFB). The aim of this study is to develop a theoretical model that will explain the working principles of the cantilever foil bearing. A theoretical derivation of structural and vibration models were developed to find structural stiffness, equivalent viscous damping and maximum deflection. Findings show that the theoretical results of structural models have an equivalent structural stiffness of 58.59kN/mm, equivalent viscous damping of 0.599kNs/m and maximum deflection of 0.5675mm. The equivalent viscous damping is computed at a near zero circumferential coordinate (0.0350). The results obtained from vibration models show an equivalent structural stiffness of 58.74kN/mm, equivalent viscous damping of 0.228kNs/m and maximum deflection of 0.5675mm. Theoretical viscous damping coefficient varies from 0.23kNs/m at 24Hz to 0.026kNs/m at 200Hz when determined at maximum deflection of 0.5675mm and phase angle of 0.0350. This means the higher the frequency, the lower the viscous damping coefficient. The validation was done over frequency range 24-200Hz and at amplitude of 50mm at a 450 phase angle. The models were found to have compared well with experimental results in the prediction of equivalent viscous damping coefficient. The models can be relied upon to analyze the behaviour of MCFB and it can also form a theoretical background for the design and manufacture of Multi-Cantilever Foil Bearing.

Design and experimental verification of the vehicle compressor rotor system with inhomogeneous foil bearings

In this paper, the design and experimental verification of the rotor system with gas foil bearings are carried out with a vehicle compressor developed in our laboratory. The designed rotating speed 100,000 rpm with 50 g/s mass flow and 1.8 pressure ratio. The journal foil bearing with inhomogeneous bump foil is designed and tested by a push-pull device to evaluate the structure stiffness of bump foil. The result shows that the stiffness curves of two bearings with the same manufacturing process are not consistent, which indicates the uncertainly in the manufacture of foil bearings and it is necessary to obtain the foil stiffness data by experiment. A multi-disc model is established to simulate the impeller in the finite element model (FEM) for the vehicle compressor is too short to ignore the impeller width. The stiffness and damping coefficients of foil bearings are used to proceed rotordynamic analysis. The vibration experiments indicate that with the operating speed enhancement, the center orbit falls smaller. When the rotating speed increases to about 60,000 rpm, two sub-synchronous frequency occur and remain at 150 and 307 Hz finally. Two radial acceleration peaks appear at 9736 and 25,828 rpm respectively, which are close to the critical speed of damped Campbell diagram. The compressor performance map shows that the pressure ratio of the compressor is slightly lower than the design value due to the eccentricity of the foil bearing, which can be solved by increasing the operating speed. This paper provides some reference value for the design and experiment of vehicle compressor supported by the foil bearings.

Thermo-elastohydrodynamic analysis of the inhomogeneous foil bearing with misalignment

Purpose The misalignment is generally inevitable in the process of machining and assembly of rotor systems with gas foil bearings, but the exploration on this phenomenon is relatively less. Therefore, the purpose of this paper is to carry out the thermo-elastohydrodynamic analysis of the foil bearing with misalignment, especially the inhomogeneous foil bearing. Design/methodology/approach The rotor is allowed to misalign in two non-rotating directions. Then the static and dynamic performance of the inhomogeneous foil bearing is studied. The thermal-elastohydrodynamic analysis is realized by combining the Reynolds equation, foil deformation equation and energy equation. The small perturbation method is used to calculate the dynamic coefficients, then the critical whirl ratio is obtained. Findings The gas pressure, film thickness and temperature distribution distort when the misalignment appears. The rotor misalignment can improve the loading capacity but rise the gas temperature at the same time. Furthermore, the rotor misalignment can affect the critical whirl ratio which demonstrates that it is necessary to analyze the misalignment before the rotordynamic design. Originality/value The value of this paper is the exploration of the thermo-elastohydrodynamic performance of the inhomogeneous foil bearing with misalignment, the analysis procedure and the corresponding results are valuable for the design of turbo system with gas foil bearings.

Investigation of rotor–gas foil bearing system and its application for an ultra-high-speed permanent magnet synchronous motor

In this study, an ultra-high-speed rotor–gas foil-bearing system is designed and applied to a permanent magnet synchronous motor. Gas foil journal bearings and gas foil thrust bearings are used to provide journal and axial support to the rotor, respectively. The bearings are analyzed theoretically considering the nonlinear deflection of the top foil, and the static and dynamic characteristics are obtained with which the rotor dynamic performances of the tested rotor are calculated using the finite element method. During the experiment, the permanent magnet synchronous motor can operate stably at 94,000 r/min, which demonstrates a great dynamic performance of the gas foil bearings and the stability that it provides to the entire system. The sub-synchronous vibration also occurs when the rotating speed reaches 60,000 r/min and as the speed keeps rising, the amplitude of such vibration increases, which will contribute to the destabilization of the rotor–gas foil-bearing system. Finally, the axial force of the rotor is calculated theoretically as well as measured directly by four micro force sensors mounted in the thrust end cover of the permanent magnet synchronous motor. The experimental results presented in this article are expected to provide a useful guide to the design and analysis of the rotor–gas foil-bearing system and high-speed permanent magnet synchronous motor.