Presentation on theme: "Tribology Group Rotordynamics Laboratory May 2012"— Presentation transcript:
1 Tribology Group Rotordynamics Laboratory May 2012 32nd Turbomachinery Research Consortium MeetingTribology GroupRotordynamics LaboratoryLuis San AndresMast-Childs ProfessorTurbomachinery LaboratoryMechanical Engineering DepartmentTexas A&M UniversityMay 2012
2 Tribology Group Mission: To advance state of the art in fluid film bearings for high performance turbomachineryTypes of funded research projects:Engineering science fundamentals & development of computational engineering tools,Experimental – Bearing & Seal parameter identificationTest-product verification & design validationEducation
3 Students Tribology Group Top:Feng YuOwen ZhangJose HernandezSung-Hwa JeungGary BradleyBottomYujiao TaoAlainAndersonJoshuaNorsworthyStephanie SimerskeyQing Liu
4 Analysis/test product & design validation Thermal energy transport for bearing systems in turbochargersHoneywell Turbocharging Technologies(09/10-09/12) $ 208kEfficient energy transport by oil flow determines TC performance
5 Modeling thrust foil bearings for PV & CV Turbos Analysis: product verification & design validationModeling thrust foil bearings for PV & CV TurbosBorg-Warner ( ) $ 90.4 kNeeds: 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.Deliverable: Predictive tool for ready integration into B&W engineering design flow. Test validation at B&W (Germany)
6 2010-12 TRC funding Project progress status follows Measurement of leakage in a novel all metal non-contacting annular seal at high temperatureTRC (10-12) $ 74.8k (2 years)HALO™ SealLabyrinth sealHigh temperature seal test rig(300 C=572 F)HALOTM sealProject progress status follows
7 TRC fundingComputational model for tilting pad journal bearingsTRC (10-12) $ 70.4k (2 years)For high load bearings (> 150 psi), improve correlation to experimental force coefficients by adding pad-pivot flexibility and fluid energy transport & thermal effectsASME GTCarter & Childs,Technical presentation followsTest TAMU TPB (Wilkes)New ModelYYNew ModelXXXXYYTestTestrotor speed 13.1 krpm
8 2011-12 TRC funding Technical presentation follows Automated Analysis of XLTRC2 Time Transient Responses in Nonlinear Rotor Bearing SystemsTRC (11-12) $ 34.8k (1 year)Manage output of XLTRC2 time response of NL rotor-bearing motions & characterize frequency and modal contentTechnical presentation follows
9 2011-12 TRC funding: Gas bearings for MTM Metal Mesh Foil Bearings: Operation at High TemperatureTRC (11-12) $ 36.6k (1 year)State of the art predictive tools benchmarked to test dataTechnical presentation follows.ReportTRC-BC001-12Oil free TM research past fundingTRC ( ) $ 312 kNSF ( ) $ 255.5kNASA GRC ( ) $ 284.6kCapstone (2007) $ 64.7 k
11 Non-contacting gas face seal with textured pattern Other industrial projectComputational analysis of textured gas face seals for steam turbinesCIATEQ A.C. (Mexico) ( ) Sponsors1 grad studentReplace carbon rings to increase turbine reliability.Model novel textured face seal geometries and GUI for whole seal cartridgeNon-contacting gas face seal with textured patternTypical steam turbine for lubrication system mechanical drive
12 Invited submissions (May 31) NSF China-TAMU program Xi’an Jiaotong UniversityDESIGN AND OPERATION OF LUBRICATED HIGH SPEED SPINDLES: COUPLED SYSTEM THERMO MECHANICAL AND DYNAMICS EFFECTSNOVEL THRUST FOIL BEARINGS FOR OIL-FREE MICROTURBOMACHINERYMore collaborative research programs expected with Asian OEMs, and KOSEF (Korea Science Foundation), NSF-China, CONACYT-Mexico, Brazil Education Ministry.
14 Tribology Group Students Prepared for global competencyLearn communication skills (written & oral)Training in teams that work and deliverReady for open-ended multidisciplinary problems with no unique answerExperience in research tied to industrial needsLearn of compelling need for professional integrityDo more with lessDiversity students 20122 PhD (1F)6 MS (1F, 1H)2 UGS (1F, 2AM)Graduating 08/2012PhD Thomas Chirathadam (SwRI)MS Yujiao TaoMS Jose Hernandez (CIATEQ, Mx)MS Feng YuDo more with nothing!
16 Scholarship0809101112TotalJournal (peer reviewed)5628Conference (peer reviewed)7Conference (NOT peer reviewed)Book Chapters13Accepted/awaiting publication42011 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 GT2010 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, pTotal: FIVE Best paper awards
17 2012 TRC reports TRC-SFD-01-12 TRC-BC001-12 Force Coefficients for a Large Clearance Open Ends SFD with a Central Feed Groove: Test Results and PredictionsTRC-BC001-12Measurements of Rotordynamic Response in a High temperature Rotor Supported on two Metal Mesh Foil BearingsIn the works after n+1 revisionsSummer 2012:Reports on computational model for tilting pad bearings (Y. Tao, M.S. Thesis) and NL rotordynamics XLTRC2 modeling (Q.Liu)
18 2012 TRC proposals# yearsCostAutomated analysis of time transient responses in nonlinear rotor bearing systems (Year II)2$ 41,484Computational model for tilting pad journal bearings (Year III)4$ 40,984Linear-nonlinear force coefficients for SFDs (Year II)$28,470Making a wet (foamy) seal and estimating its dynamic forced coefficients$ 44,984Engineered analysis for pocket damper seals and combined labyrinth-brush seals$40,984
19 Questions: More information at http://rotorlab.tamu.edu Luis San Andres:More information atAll presentations and annual report available
21 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 T/TT faculty (http://meen.tamu.edu/, spring ), 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 (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)
22 Project in negotiation Samsung Techwin (S Korea) (2 years) $160 kPredictive model for thrust collars in helically geared compressors.(+ experimental benchmarking at TurboLab: Childs)Bull gearExpected + use in drive trains for wind turbinesThrust washersPinion gearPinion gear
23 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 ( ) $600kPredicted shaft motionMeasured shaft motion
24 Compare leakage: four seal types Hybrid Brush SealHALO™ SealFlow factorFlow factor Φ for four seal types versus inlet/exhaust pressure ratio [Ps/Pe] for increasing gas inlet temperatures (300 °C).
25 Oil-free Microturbomachinery when green becomes whitewhiteOil-lessturbocharger
26 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 allowweight reduction, lower number of partshigher temperatures & no coolingimproved overall engine efficiency & system availability26
27 Gas Bearings for MTM What are the needs? Make READY technology for industrial application by PUSHING development tomake 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 experiences27
28 Project in limbo GE O&G (Italy) (1 year) $100 k Enhanced model for prediction of leakage and force coefficients in pocket damper sealsGTGE O&G interest in improving reliability of annular seals in subsea compressors, including operation under wet conditions.
29 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 efficiencyValidation of performance – static and dynamic – on dedicated high speed test rigs.Cooperation with NASA GRC, KIST, CapstoneSoftware LicensesBEST PAPER AWARDS2011 IJTC J. Tribology (with KIST)2008 IGTI S&D - Rotordynamics2005 IGTI S&D - Rotordynamics2003 IGTI S&D - RotordynamicsHoneywell, Borg-Warner,Becker-Turbo,Capstone MT, Barber-Nichols,NASA, SNECMA, Dresser-Rand,SWRI, R&D Dynamics,KIST, Bosch