Metal Mesh Gas Bearings Metal Mesh Gas Bearings

Abstract Abstract
MEASUREMENTS OF ROTOR LIFT-OFF AND
BREAK UP TORQUE IN A METAL MESH FOIL BEARING
FOR USE IN AUTOMOTIVE TURBOCHARGERS
Gas bearings enable the commercial success of high speed microturbomachinery operating at high temperatures and virtually friction free. Metal mesh gas foil
bearings are a low cost alternative to replace oil-lubricated bearings in passenger vehicle turbochargers. However, during rotor start up and shut down, the rotor
operates in contact with the foil bearings thus demanding of a large break-up torque to overcome the dry friction. Early rotor lift-off in the bearings enables nearly
friction free operation. Measurements of break-up torque on a metal mesh bearing as a function of shaft speed and static load are obtained in an existing
turbocharger driven test rig. Bearing performance characteristics such as power loss and ultimate load capacity are experimentally determined. The bearing
experiences the highest torque at low shaft speeds, dropping significantly once the rotor lifts off. Increases in static load lead to an increase in bearing break-up
torque and delay rotor lift off to a higher speed.
Experimental Facility Experimental Facility
Gas Bearings
eliminate oil and remove pumping and sealing systems
reduce drag power and heat generation
allow weight reduction
improve overall system efficiency & reliability
enable higher and lower temperature capability
Experimental Experimental Results Results (cont (cont d) d)
Conclusions Conclusions
TEXAS A&M UNIVERSITY, MECHANICAL ENGINEERING
COLLEGE STATION, TX 77843
T
L
Brian Rice
UG Research Assistant
Luis San Andrs
Mast-Childs Professor
Metal Mesh Foil Gas Bearings
readily available at low cost
material compactness provides control of stiffness
enable high temperature operation
Rotordynamic measurements of a metal-mesh gas
foil bearing mounted on a turbocharger rotor
- Lift-off speed and torque during start-up and shut-down
- Drag torque for increasing rotor speed and static loads
- Ultimate load capacity
- Rotor temperature for increasing static load
Research Objective Research Objective
Future applications
http://www.grc.nasa.gov/WWW/Oilfree/turbocharger.htm www.microturbine.com
http://www.miti.cc/newsletters/150hpcom
pressozr.pdf
Turbochargers
Turbo compressor
Micro gas turbine
Keun Ryu
Thomas Chirathadam
Graduate Research Assistants
Mass [g] 278.2
Cartridgelength[mm] 35.9
Cartridgeouter diam. [mm] 54.2
Cartridgeinner diam. [mm] 42.2
Meshlength[mm] 30.5
Meshthickness [mm] 8
Topfoil diam. [mm] 28.1
Topfoil thickness [mm] 0.127
J ournal diam. [mm] 28.05
Speedrange[rpm] 0- 70,000
Pressurerange [psi] 0- 125
TorqueArmLength[mm] 119.2
Table 1. Mainparameters of MMFB bearingandtest rig
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www.turbomagazine.com/features/0110tur_
1994_toyota_supra/photo_09.html
Experimental Experimental Results Results
Figure 1. Turbocharger test rig
[2]
Figure 2. Schematic view of
test rig [2]
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Terminology Terminology
Gas bearing compliant, self-acting film bearing uses
air as the working lubricant.[1]
Break-up torque Applied shaft torque to overcome
dry-friction (contact) and allow shaft rotation with gas film.
Lift-off speed Rotor speed at which thin gas film
evolves to support load acting on bearing and without
rubbing.
Load (W) capacity The maximum load that the
bearing can withstand at a particular speed until sliding
contact occurs with sudden rise in drag torque [1].
Power loss The mechanical loss of energy caused by
the sliding friction between the top foil and test rotor.

b
Break-up friction coefficient

g
Gas film friction coefficient (idem)
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Figure 3. Rotor start-up/shut-down cycle over a
40 second interval, 13 N static load (vertical).
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Air supply pressure
into turbine is
manually increased
until rotor overcomes
the dry friction and
begins to rotate freely.
Rotor runs up to 40
krpmand then coasts
down.
Drag torque is large
and peaks at rotor
speed of ~2 krpm. A
sharp drop in torque
indicates rotor lift-off,
while sharp increase
evidences touch-
down.
Maximum power loss
due to friction occurs
at start-up and
gradually decreases
as lifted rotor speeds
up.
References References
[1] DellaCorte, C., 1997, A New Foil Air Bearing Test Rig for Use to 700 C
and 70,000 rpm,NASA TM-107405.
[2] San Andrs, L., and Kim, T.H., 2008, Measurements of Structural
Stiffness and Damping in a Metal Mesh Bearing and Development of a Test
Rig for Foil Gas Bearings,TRC-B&C-5-08.
Figure 4. Bearing torque versus
speed under a 13 N static load.
Drag torque is
maximum at low rotor
speed, prior to rotor
lift-off. The bearing
torque at top speeds,
>40 krpm, drops to
18% of the torque at
start-up.
Figure 5. Bearing torque versus
applied load at 40 krpm
Figure 6. Bearing ultimate load
capacity versus rotor speed
Figure 7. Temperature of rotor free end versus applied
load. Operation at 40 krpm
Bearing drag torque
increases linearly with
applied load (includes
the bearing weight) at
a speed of 40 krpm
(rotor lifted off).
Rotor runs up to 40
krpmand is statically
loaded. Rotor
decelerates by closing
air supply into turbine.
Ultimate load
capacity determined
from sudden increase
in torque at a rotor
speed that is
proportional to applied
load.
Rotor temperature is
proportional to applied
load in gas film
operating region.
1)During a rotor start-up/shut-down cycle, bearing torque drops
significantly at rotor lift-off and raises sharply at touch-down.
Break-up torque during start-up is ~34% larger than that at shut-
down.
2)Once rotor lifts, torque decreases as rotor speed increases
demonstrating operation in cushion of gas film. Within 30-
40krpm, torque is a minimum.
3)Friction coefficient reduced by ~six times once rotor lifts as
opposed to operation with rubbing contact.
4)Gas film operating torque and rotor temperature increase linearly
with respect to applied static load.
5)Ultimate load capacity increases proportionally as rotor speed
increases.
Metal mesh foil bearings perform best at high speeds where the
gas film can support higher loads and no dry friction occurs. At
low speeds metal mesh foil bearings show high friction. The
challenge is to design a bearing that reduces both break-up
torque and drag torque during gas film operation. Further
research on solid lubricant coatings could achieve the goal.
Gas film operation region
WBEARING=2.73 N
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= 0.055
Once rotor lifts-off, operation with a gas
film reduces friction 82 % (~ 6 times)
55 N-mm
10 N-mm
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Coast down
Run up
Friction coeff.
Acknowledgment Acknowledgment
This study is supported by National Science Foundation under REU#0552885 program.
The support of NASA(agreement NNX07P98A)and Honeywell Turbo Technologies are
also acknowledged.
2
Torque
D
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=
UNIVERSITY OF VIRGINIA,
AEROSPACE ENGINEERING
Charlottesville, VA 22903