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Tribology GroupRotordynamics Laboratory
Luis San AndresMast-Childs Professor
Turbomachinery Laboratory
33rd Turbomachinery Research Consortium Meeting
http://rotorlab.tamu.edu
May 22, 2013
Access to presentations and proposals at
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Tribology GroupMission: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
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2013 Students/Scholars
Joshua Brooks
JieyunZHang
SangshinPark
Gary Bradley
Joshua Norsworthy
TayuyaKinoshita
AndriyZahorulk
o
Bottom
Sung-HwaJeung
WeilianShan
XiaowanShan
YingkunLi
Qing LiuTop:
Missing Travis Cable, Jerry Haripin, Mathew Hilton
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• Turbocharger Bearing Systems Honeywell Turbo Technologies
• Gas Foil Bearings for Oil-Free TurbosBorg-Warner Turbochargers
• Novel Squeeze Film DampersPratt & Whitney Engines
• Thrust collars for integrally geared compressorsSamsung Techwin
Turbomachinery Research Consortium:• Nonlinear Rotordynamics – Data Analysis • Gas Pocket Damper Seals & Brush Seals• Wet Seals for Subsea Compression• Tilting Pad Bearings – Effects of pad flexibility
CollaborationsCIATEQ (Mx) & KIST (Korea)Gas face seals, Metal mesh foil bearings
Research projects (2012-2014)http://rotorlab.tamu.edu
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SFD TESTING & ANALYTICAL METHODS DEVELOPMENTLarge load (500 lbf) Pratt & Whitney (2008-13)
Static loader
Shaker assembly (Y direction)
Shaker assembly (X direction)
SFD test bearing
TRC (11-13)
Linear/Nonlinear SFDs
BEST PAPER AWARD 2011 IGTI Rotordynamics
TRC-SFD-01-13
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Model for lubricated thrust collars in integrally geared compressors. Samsung Techwin (2 years)
Bull gear
Pinion gear
Thrust washers
Pinion gear
Expected use in drive trains for wind turbines
Analysis/test product & design validation
(+ experimental benchmarking at Turbo Lab: Childs)
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Honeywell Turbocharging Technologies (2001-10)
Virtual tool for TC rotordynamics
gy , ,
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plitu
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Subsynchronous ComponentsSynchronous Component
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pons
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Subsynchronous ComponentsSynchronous Component
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0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000Frequency (Hz)
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pons
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Predicted shaft motion Measured shaft motion
Integration of nonlinear rotordynamics & bearing performance – reduces time for prototype development (35%) and saves costs in product development (30%)
Analysis/test product & design validation
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Thermal energy transport for bearing systems in turbochargers
Honeywell Turbocharging Technologies (10-13)
Efficient energy transport by oil flow determines TC performance
TB
TJ
Shaft (journal)
RING
CASING
Oil inletTB
TJ
Shaft (journal)
RING
CASING
Oil inletTB
TJ
Shaft (journal)
RING
CASING
Oil inlet
Heat from shaft
Drag Power (inner & outer~0)
100%
Heat to casing
Heat to fluid (i+o)Heat to fluid (i)
Heat to fluid (o)Heat to ring
65%
35%
24 % 17 %
83 %
8 %
76 %
high speed (240 krpm)
Analysis/test product & design validation
BEST PAPER AWARD2012 IGTI Microturbomachinery & TCs
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Modeling thrust foil bearings for PV & CV Turbos Borg-Warner Turbo (2012)
Delivered 01/13: Predictive tool for ready integration into B&W engineering design flow.
Need: more reliable & + power efficient TCs, lighter oils (0-5W) and higher inlet temperatures (~150C).
Oil free TCs dispense with contaminated engine oil to increase reliability.
W (Load)
Rotor collarr
Top foil
Gas film
Underspring
P
X
Y
Supportdisk
Bearing pad with top foil and underspring
Line weld
Direction of rotorSpinning,
r
P
T
W (Load)
Rotor collarr
Top foil
Gas film
Underspring
P
X
Y
Supportdisk
Bearing pad with top foil and underspring
Line weld
Direction of rotorSpinning,
r
P
T
Analysis/test product & design validation
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InsulationShaft
Bearing Assembly
Exhaust duct
Air inlet
Rotor
Test sealPressurization Vessel Centering spring
Cold air inlet
MotorSeal
High temperature seal test rig (300 C=572 F)
Measurement of leakage in a novel all metal non-contacting annular seal at high temperature.
2010-12 TRC
Labyrinth seal
HALOTM seal
HALO™ Seal
TRC-SEAL-01-13
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Computational model for tilting pad journal bearings
For high load bearings (> 150 psi), XLTPJB© improves correlation to experimental force coefficients by adding pad & pivot flexibility and fluid energy transport & thermal effects
2010-13 TRC
TRC-B&C-01-13 Effect of pivot flexibility on TPJB force performance (static & dynamic)
TRC-B&C-03-13 Effect of pad surface elasticity on TPJB static load performance
Hydrodynamic pressure P
Hot oil flow
Pivot
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Automated Analysis of Time Transient Responses in Nonlinear Rotor Bearing Systems
Manage large output of time response of NL rotor-bearing motions & characterize frequency and modal content
0 5 10 15 20 25 30 35 40
Vertical response (x)
0 10 20 30 40 Rotor speed [krpm]
Am
plitu
de [µ
m]
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1 × fn 2 × fn 3 × fn
Frequency [Hz]0 200 400 600 800
Rot
or s
peed
[krp
m]
2
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24
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1X
1 × fn
2 × fn
3 × fn
Vertical response (x)
½WFR½ WFR3½ WFR3
2011-13 TRC TRC-RD-01-13
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• Added click & run worksheets: multiple cases, multiple loading conditions, multiple bearing configurations, efficient storage of data
• Post-processing tools: analyze tons of data (thousands of data points), make FFTS and waterfalls, filter responses to obtain 1X and any other sub or super-synchronous motions, filtered mode shapes at selected frequencies, etc.
• Set up test rig (flex rotor on JBs) to measure responses and to benchmark predictions of rotor NL dynamics.
Saves time in diagnosing & troubleshooting
TRC-RD-01-13Automated Analysis of Time Transient Responses in Nonlinear RBS
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Oil-free microtubomachinery•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.
BEST PAPER AWARDS2012 IGTI S&D – Bearings & Seals2011 IJTC J. Tribology (with KIST)2008 IGTI S&D - Rotordynamics2005 IGTI S&D - Rotordynamics2003 IGTI S&D - Rotordynamics
Honeywell, Borg-Warner, Beck-Turbo,
Capstone MT, Barber-Nichols, NASA, SNECMA, Dresser-Rand,
SWRI, R&D Dynamics, KIST, AENTL.
Software Licensees
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Metal Mesh Foil Bearings: Operation at High Temperature
Oil free TM research past fundingTRC (2003-2009) $ 312 kNSF (2003-2006) $ 255.5kNASA GRC (2007-2009) $ 284.6kCapstone (2007) $ 64.7 k
State of the art predictive tools benchmarked to test data
2011-12 TRC Gas bearings for MTM
TRC-B&C-02-13Shimmed Foil Bearings: Structural
stiffness and material loss factorTRC-B&C-04 -13
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Design/construct compression systems to handle wet gas conditions- eliminate L/G separators,- reduce weight and parts- increase reliability & efficiency- extend operation hours
Making a wet (foamy) seal and estimating its dynamic forced coefficients.
2012-13 TRCSubsea application with wet gas compression
Progress detailed later (Gary Bradley)
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Stator (segmented)
flow
Combined brush seal -labyrinth seal
2012-13 TRCApplications in power steam turbinesEngineered analysis for pocket damper seals and combined labyrinth-brush seals
FPDS with 4 pockets and 3cavities
PDS with 4 pockets and 3cavities
TRC-SEAL-02-13
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Travis A. Cable Graduate Research Assistant
GUI for simple thrust bearings
A revamping of TRC-B&C-4-96
Ω
h(θ,t)CMAX
α
Thrust Collar
δ
Drive Shaft
Fixed Pad Taper Angle
CMIN
Ro
Ri
L
Tapered SectionUniform
Section
β
θiθo
SupplyExit
Side View
Top View
Ω
h(θ,t)CMAX
α
Thrust Collar
δ
Drive Shaft
Fixed Pad Taper Angle
CMIN
Ω
h(θ,t)CMAX
α
Thrust Collar
δ
Drive Shaft
Fixed Pad Taper Angle
CMIN
Ro
Ri
L
Tapered SectionUniform
Section
β
θiθo
SupplyExit
Ro
Ri
L
Tapered SectionUniform
Section
β
θiθo
SupplyExit
Side View
Top View
Original TRC code by (UG) N. Zirkelback(1996) – Fortran CONSOLE.Solves Reynolds equation using finite elements.Lumped thermal parameter model.
2013: built Excel GUI to interface with 1996-code to calculate thrust bearing performance for multiple shaft speeds.
A freebie for TRC members. Could be updated to model tilting pad thrust bearings.
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2012 TRC reports (overdue)
Automated Analysis of XLTRC2 Time Transient Responses in Rotor Bearing Systems with Nonlinear Supports
TRC-RD-01-13 Qing Liu
A Novel Computational Model for Tilting Pad Journal Bearings with Soft Pivot Stiffnesses TRC-B&C-01-13
Yujiao Tao Gas Seal Leakage at High Temperature: a Labyrinth Seal and an All-Metal
Compliant Seal of Similar Clearances TRC-SEAL-01-13
Alain Anderson Metal Mesh Foil Bearings: Prediction and Measurement of Static and
Dynamic Performance Characteristics TRC-B&C-02-13
Thomas Chirathadam
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A FE Model for Static Load in Tilting Pad Journal Bearings with Pad Flexibility
TRC-B&C-03-13 Yingkun Li
Identification of Structural Stiffness and Material Loss Factor in a Shimmed (Generation One) Bump-Type Foil Bearing
TRC-B&C-04-13 Joshua Norsworthy
On the Forced Performance of an Squeeze Film Damper Operating with Large Amplitude Orbital Motions: Measurements and Assessment of the
Accuracy of the Linearized Force Coefficients Model. TRC-SFD-01-13
Seung-Hwa Jeung Predictions vs. Test Results for Leakage and Rotordynamic Force
Coefficients of a Fully Partitioned Pocket Damper Seals and a Labyrinth Seal – Limitations of the Current Computational Model
TRC-SEAL-02-13 Welian Shan
2013 TRC reports (current)
June 1, 2013 (I hope)
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2013 TRC proposals
$ 44,0001A test rig for evaluation of thrust foil bearings or face seals
$ 37,9661Effect of shimming on the force coefficients of shimmed foil bearings
$ 35,8662Engineered analysis for pocket damper seals & combined labyrinth-brush seals
$ 40,6663Linear-nonlinear force coefficients for SFDs (Year III)
$ 37,0734Computational model for tilting pad journal bearings (Year III)
Cost# years
$ 195.6 k
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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 more with less
Graduating 2013MS Feng Yu MS Gary BradleyMS Alain Anderson MS Sung-Hwa JeungMS Jose Hernandez
Do more with nothing!
Diversity students 20132 PhD (2F)6 MS (3F, 1A)3 UGS
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Old Friends at the Turbomachinery Laboratory
June 10 The influence of thermally induced inputs on the dynamics and design of rotating machines
Patrick Keogh, University of Bath, UK.
Vector and operator norms in rotor response computation
Eric Maslen, James Madison University, USA
Some aspects of rotordynamic forces and aerodynamic instabilities in turbomachinery
Seung Jing Song, Seoul National University, Seoul, Korea
June 11 Foundation identification using modal parameters
Eric Hahn U. South Wales, Australia
Theoretical and experimental analysis of hybrid aerostatic bearings
Mihai Arghir Institut Prime, Université de Poitiers, France
Recent improvements in rotordynamic performance of gas foil bearings for micro turbomachinery
Tae-Ho Kim Kookmin University Seoul, Korea
A special event after Turbo Expo 2013 (San Antonio)A tour de force into the latest developments in
rotordynamics of turbomachinery
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Questions (?)
Luis San Andres: Lsanandres@tamu.edu
http://rotorlab.tamu.eduAll slide shows for presentations and annual report available
Learn more at
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U.S. News and World Report Ranking of Mechanical Engineering Graduate Programs among Public Institutions, 2005 - 2012
2005 2006 2007 2008 2009 2010/11 2012
Rank School Rank School Rank School Rank School Rank School Rank School Rank 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 Michigan 3 Illinois 3 Illinois 3 Georgia Tech 3 Georgia Tech 3 Georgia Tech
4 Georgia Tech 4 Georgia Tech 4 Georgia Tech 4 Georgia Tech Illinois Illinois 4 Illinois
5 Purdue 5 Purdue Purdue Purdue 5 Purdue 5 Purdue 5 Purdue
6 UT Austin 6 UT Austin 6 Minnesota 6 UT Austin 6 UCLA 6 UT Austin 6 UT Austin
7 UCLA 7 Penn State UT Austin 7 Penn State UT Austin 7 Minnesota 7 Texas A&M
8 Penn State Wisconsin 8 Penn State UCLA 8 Minnesota Virginia Tech Penn State
Minnesota 9 UCLA UCLA Minnesota Wisconsin 9 Texas A&M Minnesota
10 UC San Diego UC San Diego Wisconsin Wisconsin 10 Texas A&M Penn State 10 Ohio State
Wisconsin Minnesota Virginia Tech 11 Virginia Tech Penn State UCLA UCLA
12 Maryland Virginia Tech 12 Texas A&M 12 Texas A&M Virginia Tech Wisconsin Maryland
Virginia Tech 13 Texas A&M Ohio State Ohio State 13 Maryland 13 Ohio State Wisconsin
14 Texas A&M Ohio State UC San Diego UC San Diego 14 Ohio State Maryland Virginia Tech
Ohio State Maryland UC San Diego 15 UC San Diego
UC Santa BarbaraMarch 16, 2012
The rankings 2012: 15th among all institutions
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Scholarship
33Accepted/awaiting publication
11Book Chapters
2222Conference (NOT peer reviewed)
1156577Conference (peer reviewed)
666116Journal (peer reviewed)
Total 2012-2013
1312111009
Total: SEVEN Best paper awards 2002-2013.
ASME IGTI (June 2013) 2012 Best Paper Award, Structures & Dynamics Committee, Ryu, K., and San Andrés, L., 2012, ”Effect of Cooling Flow on The Operation of a Hot
Rotor-Gas Foil Bearing System,” ASME J. Eng. Gas Turbines Power, 134.2012 Best Paper Award, Microturbines, Turbochargers, & Small
Turbomachines CommitteeSan Andrés, L.., Barbarie, V., Bhattacharya, A., and Gjika, K., 2012, “On the Effect of
Thermal Energy Transport to the Performance of (Semi) Floating Ring Bearing Systems for Automotive Turbochargers,” ASME J. Eng. Gas Turbines Power, 134.
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Funding 2012-2013$ 158.6k (Samsung)+ 97.2k (Pratt & Whitney) + 196.2k (TRC-2012)452.0k +
$ 60.0k software licenses
Research expenditures$ 279.7k (FY 12)$ 241.1k (FY 13)
Performance
Not bad considering how much I complain …
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Other industrial projectComputational analysis of textured gas face seals
for steam turbinesCIATEQ A.C. (Mexico) (2010-13) funds 1 MS student
steam turbine & lubrication system mechanical drive
Replace carbon rings to
increase turbine
reliability. Model novel
textured face seal
geometries and GUI for whole seal cartridgeNon-contacting gas face
seal with textured pattern