Showing papers on "Thrust bearing published in 2018"

Lubricant Effects on White Etching Cracking Failures in Thrust Bearing Rig Tests

Abstract: White etching cracking (WEC) is a subsurface bearing failure mechanism influenced by a number of factors, including lubricant composition. Certain metal-containing lubricants have been repo...

Numerical analysis of water-lubricated thrust bearing with groove texture considering turbulence and cavitation

Abstract: This paper aims to establish the mathematical models for the water-lubricated thrust bearing with groove texture considering turbulence and cavitation and numerically analyze the influence of rotary speed, texture depth, groove number and groove width on the static performance of the bearing.,The turbulent Reynolds equation and the Jakobsson–Floberg–Olsson cavitation model are adopted for the analysis. The Payvar–Salant algorithm and Finite difference schemes are used to discretize the governing equations. To illustrate the influence of turbulence, the performance of the bearing predicted by the turbulent and laminar models are compared.,According to the results, the load capacity and the friction force calculated by the turbulent model are greater than those obtained by laminar model, and the deviation between them gradually increases with the increased rotary speed. So, the turbulent effect should be fully considered for high-speed water-lubricated bearing with surface texture. There exists a peak value for the load capacity of the water-lubricated thrust bearing in respect to the texture depth, the number of grooves and the groove width ratio, while the friction force varies slowly with those parameters. Well-designed groove texture can improve the performance of the water-lubricated thrust bearing.,This paper proposes a mathematical model considering turbulent and cavitation effect for water-lubricated thrust bearing with surface texture. This model can be complementary to conventional laminar model which is used to analyze the performance of textured bearing at low rotary speed.

An experimental investigation of a microturbine simulated rotor supported on multileaf gas foil bearings with backing bump foils

Abstract: Two multileaf gas foil journal bearings with backing bump foils and one set of gas foil thrust bearings were designed, fabricated, and used in a 100 kW class microturbine simulated rotor system to ...

Performance investigation of micro-pocketed textured pad thrust bearing

Abstract: Purpose The purpose of this paper is to conceive a new surface texture incorporating a tiny shape among the micro-pockets (with circular, rectangular, trapezoidal and triangular cross-sections) and dimples (cylindrical, hemispherical and ellipsoidal) for exploring to enhance the maximum possible performance behaviors of sector shape pad thrust bearing. Design/methodology/approach Numerical simulation of hydrodynamically lubricated sector shape textured pad thrust bearing has been presented incorporating thermal and cavitation effects. The coupled solution of governing equations (Reynolds equation, film thickness expression, viscosity–temperature relation, energy equation and Laplace equation) has been achieved using finite difference method and Gauss–Seidel iterative scheme. Findings With new textured pads, higher load-carrying capacity and lower coefficient of friction are obtained in comparison to plain sector shape pad. Texture pattern comprising square cross-sectional pockets yields higher load-carrying capacity and lower coefficient of friction in comparison to other cross-sectional shapes (circular, trapezoidal and triangular) of pockets considered herein. Originality/value This study reports a new texture, which involves micro-pockets of square cross-sectional shapes to improve the performance behavior of sector shape pad thrust bearing. About 75 per cent increase in load carrying capacity and 42 per cent reduction in coefficient of friction have been achieved with pad having new texture in comparison to conventional pad.

Oil film shape prediction of hydrostatic thrust bearing under the condition of high speed and heavy load

Abstract: Purpose Hydrostatic thrust bearing is a key component of the vertical CNC machining equipment, and often results in friction failure under the working condition of high speed and heavy load. The lubricating oil film becomes thin or breaks because of high speed and heavy load and it affects the high precision and stable operation of the vertical CNC machining equipment; hence, it is an effective way of avoiding friction failure for achieving the oil film shape prediction Design/methodology/approach For the hydrostatic thrust bearing with double rectangular cavities, researchers solve the deformation of the friction pairs in hydrostatic bearing by using the computation of hydrodynamics, elasticity theory, finite element method and fluid-thermal-mechanical coupled method. The deformation includes heat deformation and elasticity deformation, the shape of gap oil film is got according to the deformation of the friction pairs in hydrostatic bearing, and gets the shape of gap oil film, and determines the influencing factors and laws of the oil film shape, and achieves the prediction of oil film shape, and ascertains the mechanism of friction failure. An experimental verification is carried out. Findings Results show that the deformation of the rotational workbench is upturned along its radial direction under the working condition of high speed and heavy load. However, the deformation of the base is downturned along its radial direction and the deformation law of the gap oil film along the radius direction is estimated; the outer diameter is close but the inner diameter is divergent wedge. Originality/value The conclusion can provide a theoretical basis for the oil film control of hydrostatic thrust bearing and improve the stability of vertical CNC machining equipment.

Design Optimization of an Automotive Turbocharger Thrust Bearing Using a CFD-Based THD Computational Approach

Abstract: In a quest to reduce fuel consumption and emissions of automotive combustion engines, friction losses from many different sources need to be minimized. For modern designs of turbochargers commonly used in the automotive industry, reduction of friction losses results in better efficiency and also contributes to a faster transient response. The thrust bearing is one of the main contributors to the mechanical losses of a turbocharger. Therefore, it is crucial to optimize the design of the thrust bearing so that it has minimum friction losses while keeping sufficient thrust carrying capacity. One of the main challenges of turbocharger thrust bearing design, is that rotation speed is not fixed: the turbocharger may have a rotation speed which varies between 0 to as much as 250 kRPM. Moreover, the thrust bearing generates considerable heat, which changes the temperature of the oil film and its surroundings. In the present work, the design of the thrust bearing of an automotive turbocharger has been optimized. A CFD-based Thermohydrodynamic (THD) computational approach has been developed, taking into consideration heat dissipation, conjugate heat transfer throughout the bearing domain including the surrounding parts, as well as shear thinning and cavitation in the lubricant domain. An optimizer has been coupled to the CFD solver, with the aim of identifying bearing designs with reduced friction losses. Two bearing concepts have been evaluated: a taper-land design—which is a commonly applied thrust bearing concept—as well as a pocket bearing design. The resulting optimum pocket designs exhibit improved performance, in comparison to the optimum taper-land design. The present results indicate that (a) the pocket design concept can substantially contribute to further reducing the friction losses of a turbocharger, and (b) optimal design parameters of pocket bearings depend on the specific application (size, operating conditions), therefore detailed calculations should be performed to verify optimum performance.

Towards robust design optimization of automotive turbocharger rotor-bearing systems

Abstract: In the competitive automotive market, the performance of turbochargers is constantly being pushed towards their theoretical optimum. One of the key components of the turbocharger is the rotor-bearing system, which determines the friction losses and noise output and furthermore affects the overall turbocharger efficiency, reliability and cost. In order to fulfil the demands of the automotive market, developing methods to optimize the rotor-bearing system is the focus of this study, where particular attention is paid to taking into account the product-to-product variations that are inevitable in cost-effective mass-produced parts, as well as the variations in turbocharger operating conditions. First, a model of the rotor-bearing system was developed to predict the rotordynamic response over the operating range. The model is constructed in a step-by-step fashion, starting with a simple test case: a Laval rotor supported by plain journal bearings. As the behavior of the rotor-bearing system varies over its rotation speed range, run-up simulations were performed by a time-transient multi-physical model. In this model, several sub-models are coupled: a rotordynamic sub-model, a thermo-hydrodynamic submodel and a thermal network model. Once a satisfactory correlation was found between numerical simulation results and measurement results, the test case progressed to a Laval rotor with floating ring bearings instead of plain journal bearings. Correspondingly, the bearing model was extended to include the dynamics of the floating ring and its two oil films. The resulting run-ups showed a response consisting of a critical speed, an oil whirl and an oil whip. Analysis of a turbocharger rotor-bearing system was subsequently performed, showing a more complex response, consisting of multiple critical speeds and the co-existence of sub-synchronous whirling modes. The effect of the rotor-bearing operating conditions, unbalance configuration, the thrust bearing and the bearing cylindricity were investigated. Most of the trends are correctly predicted by the model, however the correlation between measurement results and simulation results was clearly inferior to the case of the Laval rotor, most likely due to the uncertainties in the actual turbocharger geometry and the actual unbalance distribution. Lastly, an optimization of a Laval rotor-bearing system was performed. The resulting robust optimum design ensures optimum rotor-bearing performance, even at the most severe operating conditions and even if all manufacturing tolerances represent the worst case scenario. Particularly the uncertainties in rotor unbalance and oil supply temperature were found to have a significant influence on the optimum design.

Measured and Predicted Operating Characteristics of a Tilting-Pad Journal Bearing with Jacking-Oil Device at Hydrostatic, Hybrid, and Hydrodynamic Operation

Abstract: Jacking-oil pockets are applied in many journals and thrust bearing applications in order to provide a hydrostatic oil film force that ensures a wear free run-up following a successful lift-off procedure. However, all components of the jacking-oil system have to be carefully designed in order to limit costs and prevent significant disturbance of hydrodynamic operation after deactivation of lift-oil. Experimental data and predictions for a four-pad tilting-pad journal bearing in load between pivot configuration are presented. Dynamic processes of the lift-off procedure as well as characteristic parameters of stationary conditions are studied. Moreover, hydrodynamic operation and hybrid lubrication providing a combined hydrodynamic and hydrostatic pressure distribution are investigated for sliding speeds up to 20 m/s. Analyzes of lift-off procedure prove that characteristic parameters such as lift-off pressures and vertical lift displacements are considerably influenced by manufacturing tolerances and misalignments. The comparison of hydrodynamic and hybrid lubrication provides a significant increase of load carrying capacity by additional jacking-oil supply at the maximum journal speed. In summary, results of measurements and predictions correlate well for all three investigated lubrication conditions.

Tribological research on the development of White Etching Cracks (WECs)

Abstract: The aim of the presented research activities was to identify mechanical, thermal, and chemical factors possibly linked to the formation of WECs (White Etching Cracks). By means of a systematic variation of various influencing parameters, the significance of each of those was investigated. It is hoped that, once the parameters promoting WECs have been identified, the physical and chemical mechanisms responsible for WEC can be thoroughly understood in the near future. This would allow to prevent costly premature bearing failures, e. g. given in wind turbines. Four research centers in Kaiserslautern, Munster and Hannover (Institute of Machine Elements, Gears and Transmissions (MEGT), Technische Universitat Kaiserslautern, Materials Testing Group (AWP), Technische Universitat Kaiserslautern, Institute of Physics, Westfalische Wilhelms-Universitat Munster, and Institute for Machine Design and Tribology (IMKT), Leibniz University Hannover) provide their expertise and laboratory facilities for this purpose. At IMKT full bearing investigations with cylindrical roller thrust bearings and model tests with a special ring-roller-ring tribometer were performed under varied test conditions. In a theoretical work package, the stresses induced to the bearing surface were simulated. At “Physikalisches Institut” in Munster surfaces of the bearing washers (and rolling elements) were analysed applying Time-of-Flight secondary ion mass spectrometry (ToF-SIMS) to determine the actual respective chemical composition of the tribofilms. At MEGT component tests were carried out on a three-axis dynamic test rig with radially loaded cylindrical roller bearings. The internal bearing dynamics and, above all, the associated distribution of frictional energy were analysed by means of multi-body simulation. The AWP concentrated on synthesized multi-axial dynamic stresses aimed at mirroring the stresses in a rolling contact apllied on laboratory test specimens to investigate crack initiation and growth in depth.

Inertia Effect on the Load Capacity of Large Water-Lubricated Thrust Bearing

Abstract: With an assumption that the profile of the velocity is not affected by the inertia force, a numerical model based on an extended Reynolds equation, which takes the full inertia effect and turbulenc...

Investigation on inner flow field characteristics of groove textures in fully lubricated thrust bearings

Abstract: Purpose The purpose of this study is to investigate the inner flow field characteristics of groove textures in thrust bearings. Cavitation and vortex are studied simultaneously to enrich the theories of surface texture. Design/methodology/approach Navier–Stokes equations are solved using computational fluid dynamics. The MIXTURE model is adopted to study the gas–liquid mixture flow under the cavitation condition. Findings Re number, the depth ratio as well as the area ratio of the groove texture and the bottom shape are all influencing factors of the inner flow field characteristics. When cavitation region and vortex region occupy the bottom of the groove texture, these do not overlap because of the pressure gradient. The positive pressure gradient in the non-cavitation region introduces nonlinearity into the velocity profiles, which affects the load-carrying capacity and friction. Originality/value Cavitation and vortex are studied simultaneously only in this study. The characteristics of the textured thrust bearing can be analyzed and explained with the combined effect of cavitation and vortex.

Tribological Study on Tailored-Formed Axial Bearing Washers

Abstract: To enhance tribological contacts under cyclic load, high performance materials are required. Utilizing the same high-strength material for the whole machine element is not resource-efficient. In order to manufacture machine elements with extended functionality and specific properties, a combination of different materials can be used in a single component for a more efficient material utilization. By combining different joining techniques with subsequent forming, multi-material or tailored components can be manufactured. To reduce material costs and energy consumption during the component service life, a less expensive lightweight material should be used for regions remote from the highly stressed zones. The scope is not only to obtain the desired shape and dimensions for the finishing process, but also to improve properties like the bond strength between different materials and the microscopic structure of the material. The multi-material approach can be applied to all components requiring different properties in separate component regions such as shafts, bearings or bushes. The current study exemplarily presents the process route for the production of an axial bearing washer by means of tailored forming technology. The bearing washers were chosen to fit axial roller bearings (type 81212). The manufacturing process starts with the laser wire cladding of a hard facing made of martensitic chromium silicon steel (1.4718) on a base substrate of S235 (1.0038) steel. Subsequently, the bearing washers are forged. After finishing, the surfaces of the bearing washers were tested in thrust bearings on an FE-8 test rig. The operational test of the bearings consists in a run-in phase at 250 rpm. A bearing failure is determined by a condition monitoring system. Before and after this, the bearings were inspected by optical and ultrasonic microscopy in order to examine whether the bond of the coat is resistant against rolling contact fatigue. The feasibility of the approach could be proven by endurance test. The joining zone was able to withstand the rolling contact stresses and the bearing failed due to material-induced fatigue with high cycle stability.

Characterization of static air foil thrust bearing performance: an elasto-gasdynamic analysis for aligned, distorted and misaligned operating conditions

Abstract: The performance of air foil thrust bearings (AFTBs) is studied for aligned, distorted and misaligned operating conditions on the basis of a very detailed numerical model for the foil sandwich. The exact geometry of the bump foil is modeled by a Reissner–Mindlin-type shell theory. A penalty-type contact formulation including frictional effects is applied for the contact between top foil and bump foil as well as between bump foil and base plate. The minimal film thickness within the thrust bearing is used as a criterion for comparing different air foil thrust bearings with rigid thrust bearings. If the rotor disk and the base plate are perfectly parallel (aligned conditions), AFTBs are proved to have always a lower load capacity than (optimized) rigid thrust bearings due to unequal bump foil deformations and top foil sagging effects. This finding is in contradiction to previous works based on simplified foil models, which claimed AFTBs to be superior to rigid thrust bearings. Furthermore, for both operating conditions—thermally induced distortions of the rotor disk as well as misalignment—an individual pad of an AFTB is found to be unable to effectively compensate for the disturbance in the gap function. Consequently, a tailoring of the stiffness distribution in the AFTB is shown to be of limiting effect. Instead, the overall compliance of the pads in an AFTB is demonstrated to be the essential reason for the superior behavior of AFTBs to rigid thrust bearings under misaligned conditions.

Precision design of hydrostatic thrust bearing in rotary table and spindle

Abstract: According to the increasing needs of rotary table and spindle to satisfy high-precision machining requirements, the accuracy of rotary table and spindle becomes an important issue due to the error ...

Numerical analysis and experimental research on load carrying capacity of water-lubricated tilting-pad thrust bearings

Abstract: Water-lubricated bearings are expected to be widely used because of convenience, green, safe and energy saving. The purpose of this study is to investigate the load carrying property of water-lubricated tilting-pad thrust bearings. A large amount of numerical analyses are undertaken based on computational fluid dynamics and the optimization method of pivot location and the calculation method of minimum film thickness are summarized. A thrust bearing is designed according to the numerical results and is tested by experiments. The experimental results validate the numerical method and the minimum film thickness to surface roughness ratio corresponding to the change of bearing lubrication regime from mixed lubrication to hydrodynamic lubrication is obtained.