Transcript No Slide Title

32nd Turbomachinery Research Consortium Meeting
Tribology Group
Rotordynamics Laboratory
Luis San Andres
Mast-Childs Professor
Turbomachinery Laboratory
Mechanical Engineering Department
Texas A&M University
May 2012
http://rotorlab.tamu.edu
1
Tribology Group
Mission:
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
2
Students Tribology Group
Top: Feng Yu
Bottom
Owen
Jose
Sung-Hwa
Zhang Hernandez
Jeung
Yujiao
Alain
Joshua
Tao
Anderson Norsworthy
Gary
Bradley
Stephanie
Simerskey
Qing Liu
3
Analysis/test product & design validation
Thermal energy transport for bearing
systems in turbochargers
Honeywell Turbocharging Technologies
(09/10-09/12)
Oil inlet
CASING
TB
Shaft (journal)
$ 208k
TJ
RING
Efficient energy transport by oil
flow determines TC performance
100%
24 %
65%
Heat to ring
Heat from shaft
Drag Power 35%
(inner & outer~0)
17 %
Heat to casing
Heat to fluid (o)
Heat
to fluid (i)
8%
Heat to fluid (i+o)
83 %
76 %
high speed (240 krpm)
4
Analysis: product verification & design validation
Modeling thrust foil bearings for PV & CV Turbos
Borg-Warner (2011-2012) $ 90.4 k
Needs: more reliable & + power efficient TCs,
lighter oils (0-5W) and higher inlet temperatures
(~150C).
Y
Bearing pad with
top foil and
underspring
Direction of rotor
Spinning, 
Line weld

r
Oil free TCs dispense with contaminated
engine oil to increase reliability.
P
X
P
T
Support
disk
Deliverable: Predictive tool for ready
integration into B&W engineering
design flow. Test validation at B&W (Germany)
W (Load)
r
Rotor collar
Gas film
Underspring
Top foil
5
2010-12 TRC funding
Measurement of leakage in a novel all metal noncontacting annular seal at high temperature
TRC (10-12) $ 74.8k (2 years)
Cold air inlet
Insulation
Pressurization Vessel
Air inlet
Shaft
Bearing Assembly
Seal
Test seal
Centering spring
HALO™ Seal
Rotor
Exhaust duct
Motor
Labyrinth seal
High temperature seal test rig
(300 C=572 F)
HALOTM seal
Project progress
status follows
6
2010-12 TRC funding
Computational model for tilting pad
journal bearings
TRC (10-12) $ 70.4k (2 years)
Carter & Childs,
ASME GT2008-50069
Technical
presentation
follows
For high load bearings (>
150 psi), improve
correlation to
experimental force
coefficients by adding
pad-pivot flexibility and
fluid energy transport &
thermal effects
Test TAMU TPB (Wilkes)
New Model
YY
New Model
XX
XX
Test
Test
rotor speed 13.1 krpm
YY
7
2011-12 TRC funding
Automated Analysis of XLTRC2 Time
Transient Responses in
Nonlinear Rotor Bearing Systems
TRC (11-12) $ 34.8k (1 year)
1 × fn
2 × fn
3 × fn
100
0
X
10
15
20
speed (kRP M)
25
30
10
20
30
Rotor speed [krpm]
35
40
40
Technical presentation follows
1X
3 × fn
2 × fn
1 × fn
Vertical response (x)
2
0
5
24
100
-100
½3 WFR ½WFR
13
0
Rotor speed [krpm]
0
35
100
Response (um)
Amplitude [µm]
Vertical response (x)
Manage output
of XLTRC2 time
response of NL
rotor-bearing
motions &
characterize
frequency and
modal content
0WFM _X
200
400
600
WFM _Y
800
Frequency [Hz]
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2011-12 TRC funding: Gas bearings for MTM
Metal Mesh Foil Bearings: Operation
at High Temperature
TRC (11-12) $ 36.6k (1 year)
State of the art predictive tools
benchmarked to test data
Technical presentation follows.
Report TRC-BC001-12
Oil free TM research past funding
TRC (2003-2009) $ 312 k
NSF (2003-2006) $ 255.5k
NASA GRC (2007-2009) $ 284.6k
Capstone (2007) $ 64.7 k
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2011-12 TRC funding: Linear/Nonlinear SFDs
SFD TESTING & ANALYTICAL METHODS DEVELOPMENT
Large load (500 lbf) SFD test rig
Pratt & Whitney (08/08-12/12)
$ 436k TRC (12) $ 39.k (1 year)
Static loader
Shaker assembly
(Y direction)
Technical presentation follows
Report TRC-SFD-01-12
Shaker assembly
(X direction)
SFD test
bearing
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Other industrial project
Computational analysis of textured gas face seals for
steam turbines
CIATEQ A.C. (Mexico) (2010-12) Sponsors1 grad student
Replace carbon
rings to
increase
turbine
reliability.
Typical steam turbine
for lubrication
system mechanical
drive
Non-contacting gas face
seal with textured
pattern
Model novel
textured face seal
geometries and
GUI for whole seal
cartridge
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Invited submissions (May 31)
NSF China-TAMU program
Xi’an Jiaotong University
•
DESIGN AND OPERATION OF LUBRICATED HIGH SPEED SPINDLES:
COUPLED SYSTEM THERMO MECHANICAL AND DYNAMICS
EFFECTS
•
NOVEL THRUST FOIL BEARINGS FOR OIL-FREE
MICROTURBOMACHINERY
More collaborative research programs
expected with Asian OEMs, and KOSEF (Korea
Science Foundation), NSF-China, CONACYTMexico, Brazil Education Ministry.
12
The rankings
2012: 15th among all
institutions
U.S. News and World Report Ranking of Mechanical Engineering
Graduate Programs among Public Institutions, 2005 - 2012
School
2012
Rank
School
2010/11
Rank
School
2009
Rank
School
2008
Rank
School
2007
Rank
School
2006
Rank
Rank
2005
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
3 Illinois
3 Georgia Tech
3 Georgia Tech
3 Georgia Tech
4 Georgia Tech
4 Georgia Tech
3 Illinois
Michigan
4 Georgia Tech
4 Georgia Tech
5 Purdue
5 Purdue
6 UT Austin
6 UT Austin
7 UCLA
7 Penn State
8 Penn State
Minnesota
10 UC San Diego
Wisconsin
12 Maryland
Virginia Tech
14 Texas A&M
Ohio State
Wisconsin
9 UCLA
Purdue
Purdue
6 Minnesota
6 UT Austin
UT Austin
8 Penn State
7 Penn State
UCLA
UCLA
Minnesota
UC San Diego
Wisconsin
Wisconsin
Minnesota
Virginia Tech
Virginia Tech
13 Texas A&M
Ohio State
12 Texas A&M
Illinois
Illinois
4 Illinois
5 Purdue
5 Purdue
5 Purdue
6 UCLA
6 UT Austin
6 UT Austin
7 Minnesota
7 Texas A&M
UT Austin
8 Minnesota
Wisconsin
10 Texas A&M
Virginia Tech
Penn State
9 Texas A&M
Minnesota
Penn State
10 Ohio State
11 Virginia Tech
Penn State
UCLA
UCLA
12 Texas A&M
Virginia Tech
Wisconsin
Maryland
Ohio State
Ohio State
UC San Diego
UC San Diego 14 Ohio State
Maryland
13 Maryland
UC San Diego
13 Ohio State
Maryland
Wisconsin
Virginia Tech
15 UC San Diego
UC Santa Barbara
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March 16, 2012
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
Do more
morewith
withless
nothing!
Diversity students 2012
2 PhD (1F)
6 MS (1F, 1H)
2 UGS (1F, 2AM)
Graduating 08/2012
PhD Thomas
Chirathadam (SwRI)
MS Yujiao Tao
MS Jose Hernandez
(CIATEQ, Mx)
MS Feng Yu
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Performance
Funding 2010-2012
$ 208.3k (Honeywell)
+ 97.2k (Pratt & Whitney)
+ 90.4k (Borg Warner)
+ 146.2k (TRC-2011)
542.1k +
$ 68.0k software licenses
Research expenditures
$ 246.4k (FY 11)
$ 182.2k (FY 12)
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Scholarship
08
09
10
11
12
Total
2011-2012
Journal (peer reviewed)
5
6
11
6
2
8
Conference (peer reviewed)
6
7
7
5
5
10
Conference (NOT peer reviewed)
2
2
2
1
1
3
3
4
4
Book Chapters
Accepted/awaiting publication
• 2011 BEST Rotordynamics Paper Award – IGTI Structures and
Dynamics Committee
San Andrés, L., and Delgado, A., “A Novel Bulk-Flow Model for Improved
Predictions of Force Coefficients in Grooved Oil Seals Operating
Eccentrically,” ASME Paper GT2011-45274.
• 2010 Best Paper Award for ASME Journal of Tribology (2011 IJTC
Conference, LA)
Kim, T. H., and San Andrés, L., 2010, “Thermohydrodynamic Model
Predictions and Performance Measurements of Bump-Type Foil Bearing for
Oil-Free Turboshaft Engines in Rotorcraft Propulsion Systems,” ASME Journal
of Tribology, 132, p. 011701
Total: FIVE Best paper awards 2002-2012
16
2012 TRC reports
TRC-SFD-01-12
Force Coefficients for a Large Clearance Open Ends SFD
with a Central Feed Groove: Test Results and Predictions
TRC-BC001-12
Measurements of Rotordynamic Response in a High
temperature Rotor Supported on two Metal Mesh Foil
Bearings
In the works after n+1 revisions
Summer 2012:
Reports on computational model for tilting pad bearings
(Y. Tao, M.S. Thesis) and NL rotordynamics XLTRC2
modeling (Q.Liu)
17
2012 TRC proposals
Automated analysis of time transient
responses in nonlinear rotor bearing
systems (Year II)
Computational model for tilting pad
journal bearings (Year III)
Linear-nonlinear force coefficients for
SFDs (Year II)
Making a wet (foamy) seal and estimating
its dynamic forced coefficients
Engineered analysis for pocket damper
seals and combined labyrinth-brush
seals
# years
Cost
2
$ 41,484
4
$ 40,984
2
$28,470
2
$ 44,984
2
$40,984
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Questions:
Luis San Andres: [email protected]
More information at
http://rotorlab.tamu.edu
All presentations and annual report available
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Graduate Program in Mechanical Engineering
•Enrollment --- with 387 graduate students (fall 2011; almost all
full-time students); the 7th largest and one of the most diverse
mechanical engineering graduate programs in the U.S.
•Faculty --- 54 T/TT faculty (http://meen.tamu.edu/, spring
2012), including 4 endowed chair professors, 20 professors, 11
associate professors*, and 19 assistant professors*
•Ranking --- 7th among U.S. public institutions and 15th overall
(U.S. News & World Report, 2012)
•Diversity --- 78 (20%) women; 214 (55%) Ph.D. students (with
M.S. degrees), or 250 (65%) including direct Ph.D. students;
students from 23 states in the United States and 18 other
countries (fall 2011)
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Project in negotiation
Samsung Techwin (S Korea) (2 years) $160 k
Predictive model for thrust collars in helically
geared compressors.
(+ experimental benchmarking at TurboLab: Childs)
Bull gear
Expected + use in
drive trains for
wind turbines
Thrust
washers
Pinion gear
Pinion gear
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VIRTUAL TOOL for TC rotordynamics
Integration of nonlinear rotordynamics & bearing
performance – reduces time for prototype
development (35%) and saves costs in product
development (30%)
Honeywell Turbocharging Technologies
Predicted shaft motion
Measured shaft motion
Measured Steady-State Waterfall / Y Displacement
RBS with ODminIDmax / Oil Texaco-Havoile Energy 5W30, 150°C, 4bar
Predicted Steady-State Waterfall / Y Displacement
RBS with ODminIDmax / Oil Texaco-Havoline Energy 5W30, 150°C, 4bar
0.07
0.07
Subsynchronous Components
Subsynchronous Components
Synchronous Component
Synchronous Component
0.06
Normalized Nonlinear Response
0.06
0.05
Motion Amplitude
(2001-2009) $600k
0.04
0.03
0.02
0.01
0.05
0.04
0.03
0.02
0.01
0
0
500
1000
1500
2000
2500
3000
3500
Frequency (Hz)
4000
4500
5000
5500
6000
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
Frequency (Hz)
23
Compare leakage: four seal types
Flow Factor [kg-K 0.5/(MPa-m-s)]
40
Labyrinth Seal
Brush Seal
Hybrid Brush Seal
HALO™ Seal
35
30
25
Hybrid Brush Seal
20
15
10
5
0
1.0
2.0
Flow factor

3.0
4.0
Pressure Ratio [Ps/Pe]
5.0
6.0
HALO™ Seal
m T
Ps D
Flow factor Φ for four seal types versus inlet/exhaust pressure
ratio [Ps/Pe] for increasing gas inlet temperatures (300 °C).
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Oil-free Microturbomachinery
when green becomes white
Oil-less
turbocharger
25
Oil-Free Bearings for MTM
PV/CV turbochargers and midsize gas turbines need gas
bearings to secure compact units with improved efficiency in
an oil-free environment.
Applications as portable fuel cells (< 60 kW) to midsize GTs
(< 400 kW) for distributed power, hybrid vehicles, CO2 waste
heat and compression systems.
2025 mandate on + efficiency for IC vehicle engines: Materials
and oil-free bearing systems could enable 55 miles/gallon.
Gas Bearings allow
• weight reduction, lower number of parts
• higher temperatures & no cooling
• improved overall engine efficiency & system availability
26
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Gas Bearings for MTM
What are the needs?
Make READY technology for industrial
application by PUSHING development to
• make out of the shelf item with proven
results for a wide range of applications;
• engineered product with well known
manufacturing process;
• known (verifiable) performance with
proven laboratory and field experiences
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Project in limbo
GE O&G (Italy) (1 year) $100 k
Enhanced model for prediction of leakage and force
coefficients in pocket damper seals
GE O&G interest in
improving reliability of
annular seals in
subsea compressors,
including operation
under wet conditions.
GT2011-4556
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Oil-free MTM at TAMU
• 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.
Cooperation with NASA GRC, KIST, Capstone
Software Licenses
BEST PAPER AWARDS
2011 IJTC J. Tribology (with KIST)
2008 IGTI S&D - Rotordynamics
2005 IGTI S&D - Rotordynamics
2003 IGTI S&D - Rotordynamics
Honeywell, Borg-Warner,
Becker-Turbo,
Capstone MT, Barber-Nichols,
NASA, SNECMA, Dresser-Rand,
SWRI, R&D Dynamics,
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KIST, Bosch
The future in the works
30