Hydrodynamic journal bearing program Quarterly progress report no. 1, 29 May - 29 Jul. 1965
Test assembly design requirements for space power systems journal bearings
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Technique for improving hydrodynamic gyro bearings
Conical or spherical, spirally grooved grease bearings have an inclined surface which is machined inboard of the grooved surface. The indentation and inclined surface provide a reservoir for forced out lubricant, and when rotation begins, centrifugal force returns the lubricant to the grooved area.
Broussard, P., Jr.↗
Experiments with hydrodynamic journal bearings of various materials and designs in sodium at temperatures at 800 F
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Anderson, W. J.↗
Experiments on the stability of various water-lubricated fixed geometry hydrodynamic journal bearings at zero load.
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Schuller, F. T.↗
Design of various fixed-geometry water-lubricated hydrodynamic journal bearings for maximum stability
This publication is the result of over 260 fractional-frequency-whirl stability tests on a variety of fixed-geometry journal bearings. It is intended principally as a guide in the selection and design of antiwhirl bearings that must operate at high speeds and low loads in low-viscosity fluids such as water or liquid metals. However, the various fixed-geometry configurations can be employed as well in applications where other lubricants, such as oil, are used and fractional-frequency whirl is a problem. The important parameters that effect stability are discussed for each bearing type, and design curves to facilitate the design of optimum-geometry bearings are included. A comparison of the stability of the different bearing configurations tested is also given.
Schuller, F. T.↗
Mystery of Foil Air Bearings for Oil-free Turbomachinery Unlocked: Load Capacity Rule-of-thumb Allows Simple Estimation of Performance
The Oil-Free Turbomachinery team at the NASA Glenn Research Center has unlocked one of the mysteries surrounding foil air bearing performance. Foil air bearings are self-acting hydrodynamic bearings that use ambient air, or any fluid, as their lubricant. In operation, the motion of the shaft's surface drags fluid into the bearing by viscous action, creating a pressurized lubricant film. This lubricating film separates the stationary foil bearing surface from the moving shaft and supports load. Foil bearings have been around for decades and are widely employed in the air cycle machines used for cabin pressurization and cooling aboard commercial jetliners. The Oil-Free Turbomachinery team is fostering the maturation of this technology for integration into advanced Oil-Free aircraft engines. Elimination of the engine oil system can significantly reduce weight and cost and could enable revolutionary new engine designs. Foil bearings, however, have complex elastic support structures (spring packs) that make the prediction of bearing performance, such as load capacity, difficult if not impossible. Researchers at Glenn recently found a link between foil bearing design and load capacity performance. The results have led to a simple rule-of-thumb that relates a bearing's size, speed, and design to its load capacity. Early simple designs (Generation I) had simple elastic (spring) support elements, and performance was limited. More advanced bearings (Generation III) with elastic supports, in which the stiffness is varied locally to optimize gas film pressures, exhibit load capacities that are more than double those of the best previous designs. This is shown graphically in the figure. These more advanced bearings have enabled industry to introduce commercial Oil-Free gas-turbine-based electrical generators and are allowing the aeropropulsion industry to incorporate the technology into aircraft engines. The rule-of-thumb enables engine and bearing designers to easily size and select bearing technology for a new application and determine the level of complexity required in the bearings. This new understanding enables industry to assess the feasibility of new engine designs and provides critical guidance toward the future development of Oil-Free turbomachinery propulsion systems.
DellaCorte, Christopher↗
Research Capabilities for Oil-Free Turbomachinery Expanded by New Rotordynamic Simulator Facility
A new test rig has been developed for simulating high-speed turbomachinery shafting using Oil-Free foil air bearing technology. Foil air journal bearings are self-acting hydrodynamic bearings with a flexible inner sleeve surface using air as the lubricant. These bearings have been used in turbomachinery, primarily air cycle machines, for the past four decades to eliminate the need for oil lubrication. More recently, interest has been growing in applying foil bearings to aircraft gas turbine engines. They offer potential improvements in efficiency and power density, decreased maintenance costs, and other secondary benefits. The goal of applying foil air bearings to aircraft gas turbine engines prompted the fabrication of this test rig. The facility enables bearing designers to test potential bearing designs with shafts that simulate the rotating components of a target engine without the high cost of building actual flight hardware. The data collected from this rig can be used to make changes to the shaft and bearings in subsequent design iterations. The rest of this article describes the new test rig and demonstrates some of its capabilities with an initial simulated shaft system. The test rig has two support structures, each housing a foil air journal bearing. The structures are designed to accept any size foil journal bearing smaller than 63 mm (2.5 in.) in diameter. The bearing support structures are mounted to a 91- by 152-cm (3- by 5-ft) table and can be separated by as much as 122 cm (4 ft) and as little as 20 cm (8 in.) to accommodate a wide range of shaft sizes. In the initial configuration, a 9.5-cm (3.75-in.) impulse air turbine drives the test shaft. The impulse turbine, as well as virtually any number of "dummy" compressor and turbine disks, can be mounted on the shaft inboard or outboard of the bearings. This flexibility allows researchers to simulate various engine shaft configurations. The bearing support structures include a unique bearing mounting fixture that rotates to accommodate a laserbased alignment system. This can measure the misalignment of the bearing centers in each of 2 translational degrees of freedom and 2 rotational degrees of freedom. In the initial configuration, with roughly a 30.5-cm- (12-in.-) long shaft, two simulated aerocomponent disks, and two 50.8-cm (2-in.) foil journal bearings, the rig can operate at 65,000 rpm at room temperature. The test facility can measure shaft displacements in both the vertical and horizontal directions at each bearing location. Horizontal and vertical structural vibrations are monitored using accelerometers mounted on the bearing support structures. This information is used to determine system rotordynamic response, including critical speeds, mode shapes, orbit size and shape, and potentially the onset of instabilities. Bearing torque can be monitored as well to predict the power loss in the foil bearings. All of this information is fed back and forth between NASA and the foil bearing designers in an iterative fashion to converge on a final bearing and shaft design for a given engine application. In addition to its application development capabilities, the test rig offers several unique capabilities for basic bearing research. Using the laser alignment system mentioned earlier, the facility will be used to map foil air journal bearing performance. A known misalignment of increasing severity will be induced to determine the sensitivity of foil bearings to misalignment. Other future plans include oil-free integral starter generator testing and development, and dynamic load testing of foil journal bearings.
Howard, Samuel A.↗
High Speed Bearing Wear Rate Measurements for Spacecraft Active Thermal Control Fluid Pumps with a Novel Pin on Disk Apparatus
A novel pin on disc tribometer was designed and constructed to generate a high-speed, wear coefficient database for hydrodynamic bearings that are typically used in canned motors found in the active thermal control circuits of robotic and inhabited spacecraft. The primary motivation for this work was the premature failure of the active external thermal control pump on the International Space Station in 2010. During the failure investigation of this incident, the root cause was postulated to be high speed wear of the bearings. Although a detailed forensic analysis gave credibility to this theory, the lack of wear coefficient data at relevant conditions prevented validation of this finding. The database generated from the new Extreme Environment Tribometer (EET) enabled a closure calculation within 5% of the observed wear from inspections of the failed hardware. Testing in anhydrous ammonia and surrogate fluid was performed to provide a means for simplified testing in the future and to populate a preliminary database for the design of future active thermal control systems on spacecraft. The EET and test techniques developed for the measurement of high-speed wear coefficients are available to future system designers.
thermal control↗
Load Capacity Estimation of Foil Air Journal Bearings for Oil-Free Turbomachinery Applications
This paper introduces a simple "Rule of Thumb" (ROT) method to estimate the load capacity of foil air journal bearings, which are self-acting compliant-surface hydrodynamic bearings being considered for Oil-Free turbo-machinery applications such as gas turbine engines. The ROT is based on first principles and data available in the literature and it relates bearing load capacity to the bearing size and speed through an empirically based load capacity coefficient, D. It is shown that load capacity is a linear function of bearing surface velocity and bearing projected area. Furthermore, it was found that the load capacity coefficient, D, is related to the design features of the bearing compliant members and operating conditions (speed and ambient temperature). Early bearing designs with basic or "first generation" compliant support elements have relatively low load capacity. More advanced bearings, in which the compliance of the support structure is tailored, have load capacities up to five times those of simpler designs. The ROT enables simplified load capacity estimation for foil air journal bearings and can guide development of new Oil-Free turbomachinery systems.
DellaCorte, Christopher↗
The fabrication and test of a dual spin gas bearing reaction wheel
The design and fabrication of a dual spin gas bearing reaction wheel are discussed. Numerical analyses, data, and conclusions from performance tests are reported. The unique feature of the reaction wheel is the dual gas bearing concept in which two sets of self-acting hydrodynamic bearing are used to obtain stictionless operation and low noise around zero speed and to accommodate the momentum range from plus 6.8 N-m-s to minus 6.8 N-m-s with the potential for long life inherent in gas bearings.
Opper, R. L.↗
Cantilever mounted resilient pad gas bearing
A gas-lubricated bearing is described, employing at least one pad mounted on a rectangular cantilever beam to produce a lubricating wedge between the face of the pad and a moving surface. The load-carrying and stiffness characteristics of the pad are related to the dimensions and modulus of elasticity of the beam. The bearing is applicable to a wide variety of types of hydrodynamic bearings.
Etsion, I.↗
Stability characteristics of gyroscopes with hydrodynamic-grooved rotor bearings
Two degree of freedom gyroscopes stability with hydrodynamic grooved rotor bearings, describing parallel and conical whirling rotor oscillations
Miura, H.↗
Radial Clearance Found To Play a Key Role in the Performance of Compliant Foil Air Bearings
Compliant foil air bearings are at the forefront of the Oil-Free turbomachinery revolution, which supports gas turbine engines with hydrodynamic bearings that use air instead of oil as the working fluid. These types of bearings have been around for almost 50 years and have found a home in several commercial applications, such as in air cycle machines, turbocompressors, and microturbines, but are now being aggressively pursued for use in small and midrange aircraft gas turbine engines. Benefits include higher operating speeds and temperatures, lower maintenance costs, and greater reliability. The Oil-Free Turbomachinery team at the NASA Glenn Research Center is working to foster the transition of Oil-Free technology into gas turbine engines by performing in-house experiments on foil air bearings in order to gain a greater insight into their complex operating principles. A research program recently undertaken at Glenn focused on the concept of radial clearance and its influence on bearing performance. The tests were conducted on foil bearings with different radial clearances. As defined for a foil bearing, radial clearance is a measure of the small amount of shaft radial motion that is present from play that exists in the elastic support structure, such as between the top and bump foils and the bump foils and bearing shell (see the drawing). With an insufficient amount of radial clearance, the bearing imparts a high preload on the shaft, which when excessive, can reduce the loadcarrying capability of the bearing. On the other hand, systems using foil bearings with excessive radial clearance may experience rotordynamic instabilities because of low bearing preload. Therefore, without a more thorough understanding of radial clearance, it is difficult to accurately predict the performance of a given bearing design. The test program demonstrated that there is a direct correlation between radial clearance and the performance of foil air bearings. As shown in the graph, an optimum radial clearance exists that will maximize the amount of load that the bearing is capable of supporting. With respect to this optimum, two different performance regimes were observed that are a function of the amount of radial clearance. Tests showed that bearings with radial clearances below the optimum in regime I were susceptible to sudden seizure, a failure mode indicative of thermal runaway caused by high preload. The high preload is in response to an insufficient amount of radial clearance available to accommodate the thermal growth of the bearing and shaft. However, radial clearances greater than the optimum in regime II resulted in low bearing preloads that did not cause any heat-related problems, and the failure mode was due to fluid-film breakdown. In fact, bearings operating with radial clearances twice as much as the optimum suffered a decrease in the maximum load capacity of only about 20 percent. Therefore, special attention has to be given to the range of operating conditions expected in the bearing/shaft system since changes in temperature, centrifugal, and hydrodynamic effects can all affect radial clearance. This enhanced understanding of foil air bearing behavior will greatly aid our efforts to transition Oil-Free technology to future aircraft engines.
Radil, Kevin C.↗
Steady-state and transient analysis of a squeeze film damper bearing for rotor stability
A study of the steady-state and transient response of the squeeze film damper bearing is presented. Both the steady-state and transient equations for the hydrodynamic bearing forces are derived. The bearing equivalent stiffness and damping coefficients are determined by steady-state equations. These coefficients are used to find the bearing configuration which will provide the optimum support characteristics based on a stability analysis of the rotor-bearing system. The transient analysis of rotor-bearing systems is performed by coupling the bearing and journal equations and integrating forward in time. The effects of unbalance, cavitation, and retainer springs are included in the analysis. Methods of determining the stability of a rotor-bearing system under the influence of aerodynamic forces and internal shaft friction are discussed with emphasis on solving the system characteristic frequency equation and on producing stability maps. It is shown that for optimum stability and low force transmissability the squeeze bearing should operate at an eccentricity ratio epsilon 0.4.
Barrett, L. E.↗
Design and application of squeeze film dampers for turbomachinery stabilization
The steady-state transient response of the squeeze film damper bearing was investigated. Both the steady-state and transient equations for the hydrodynamic bearing forces are derived; the steady-state equations were used to determine the damper equivalent stiffness and damping coefficients. These coefficients are used to find the damper configuration which will provide the optimum support characteristics based on a stability analysis of the rotor-bearing system. The effects of end seals and cavitated fluid film are included. The transient analysis of rotor-bearing systems was conducted by coupling the damping and rotor equations and integrating forward in time. The effects of unbalance, cavitation, and retainer springs are included. Methods of determining the stability of a rotor-bearing system under the influence of aerodynamic forces and internal shaft friction are discussed.
Gunter, E. J.↗
Changes in Hardware in Order to Accommodate Compliant Foil Air Bearings of a Larger Size
Compliant foil air bearings are at the forefront of the Oil-Free turbomachinery revolution of supporting gas turbine engines with air lubricated hydrodynamic bearings. Foil air bearings have existed for almost fifty years, yet their commercialization has been confined to relatively small, high-speed systems characterized by low temperatures and loads, such as in air cycle machines, turbocompressors and micro-turbines. Recent breakthroughs in foil air bearing design and solid lubricant coating technology, have caused a resurgence of research towards applying Oil-Free technology to more demanding applications on the scale of small and mid range aircraft gas turbine engines. In order to foster the transition of Oil-Free technology into gas turbine engines, in-house experiments need to be performed on foil air bearings to further the understanding of their complex operating principles. During my internship at NASA Glenn in the summer of 2003, a series of tests were performed to determine the internal temperature profile in a compliant bump- type foil journal air bearing operating at room temperature under various speeds and load conditions. From these tests, a temperature profile was compiled, indicating that the circumferential thermal gradients were negligible. The tests further indicated that both journal rotational speed and radial load are responsible for heat generation with speed playing a more significant role in the magnitude of the temperatures. As a result of the findings from the tests done during the summer of 2003, it was decided that further testing would need to be done, but with a bearing of a larger diameter. The bearing diameter would now be increased from two inches to three inches. All of the currently used testing apparatus was designed specifically for a bearing that was two inches in diameter. Thus, my project for the summer of 2004 was to focus specifically on the scatter shield put around the testing rig while running the bearings. Essentially I was to design a scatter shield that would be able to accommodate the three inch bearing and that would also meet all safety requirements. Furthermore, the new scatter shield also had to house a heater, used for high-speed and temperature testing. Using Solidworks, a computer aided modeling program, I was able to accomplish the task set out for me and designed the new scatter shield. Furthermore, I also guided the fabrication process. As a result of this containment shield being designed, the Oil-Free turbomachinery team now has the ability to test bearings of larger diameters. Finally, it is expected that these tests will provide information useful for the validation of future analytical modeling codes.
Zeszotek, Michelle↗
Stability characteristics of gyroscopes with hydrodynamic-grooved rotor bearings
Stability characteristics of two degree of freedom gyroscope having hydrodynamic grooved journal rotor bearings, discussing frequency of self excited oscillation
Miura, H.↗
Comparison of Code Predictions to Test Measurements for Two Orifice Compensated Hydrostatic Bearings at High Reynolds Numbers
Rotordynamic coefficients obtained from testing two different hydrostatic bearings are compared to values predicted by two different computer programs. The first set of test data is from a relatively long (L/D=1) orifice compensated hydrostatic bearing tested in water by Texas A&M University (TAMU Bearing No.9). The second bearing is a shorter (L/D=.37) bearing and was tested in a lower viscosity fluid by Rocketdyne Division of Rockwell (Rocketdyne 'Generic' Bearing) at similar rotating speeds and pressures. Computed predictions of bearing rotordynamic coefficients were obtained from the cylindrical seal code 'ICYL', one of the industrial seal codes developed for NASA-LeRC by Mechanical Technology Inc., and from the hydrodynamic bearing code 'HYDROPAD'. The comparison highlights the difference the bearing has on the accuracy of the predictions. The TAMU Bearing No. 9 test data is closely matched by the predictions obtained for the HYDROPAD code (except for added mass terms) whereas significant differences exist between the data from the Rocketdyne 'Generic' bearing the code predictions. The results suggest that some aspects of the fluid behavior in the shorter, higher Reynolds Number 'Generic' bearing may not be modeled accurately in the codes. The ICYL code predictions for flowrate and direct stiffness approximately equal those of HYDROPAD. Significant differences in cross-coupled stiffness and the damping terms were obtained relative to HYDROPAD and both sets of test data. Several observations are included concerning application of the ICYL code.
Keba, John E.↗