Orientador: Katia Lucchesi Cavalca Dedini / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-25T11:01:37Z (GMT). No. of bitstreams: 1 Machado_TiagoHenrique_D.pdf: 3995652 bytes, checksum: f00b87b92c83f91394b947dc2de4ccee (MD5) Previous issue date: 2014 / Resumo: Este trabalho tem como objetivo identificar os parâmetros de um modelo de desgaste em mancais hidrodinâmicos, um dos problemas típicos e inerentes ao funcionamento repetido de máquinas rotativas, o qual pode ser acentuado em partidas e paradas ou durante a passagem pela velocidade crítica do rotor. Desta forma, é proposto um modelo matemático capaz de representar este desgaste em termos de alguns de seus principais parâmetros, que para este trabalho são: profundidade máxima e posição angular. O cálculo da distribuição de pressão e, consequentemente, das forças hidrodinâmicas geradas pelo filme de óleo, é feito através do método dos volumes finitos, adaptado para situações onde o filme de óleo é descontínuo. Na modelagem do sistema rotor-mancais, o modelo do rotor é representado pelo método clássico dos elementos finitos e os mancais são aproximados por coeficientes dinâmicos de rigidez e amortecimento, a fim de representar tais efeitos inerentes ao filme de óleo. A identificação dos parâmetros característicos escolhidos para representar o desgaste é feita a partir da resposta dinâmica, em coordenadas direcionais, do sistema rotor-mancais no domínio da frequência. Esta identificação é realizada através de um método de busca que visa minimizar uma função objetivo, a qual, por sua vez, compara a resposta obtida numericamente com a resposta experimental proveniente de uma bancada de testes instrumentada. Através da comparação com os dados experimentais provenientes desta bancada, os resultados apresentados mostram que o modelo de desgaste desenvolvido neste trabalho é capaz de representar, de forma satisfatória, o comportamento de um mancal desgastado, assim como a resposta do sistema rotativo na presença desse tipo de falha. Com relação ao processo de identificação, o método de busca empregado mostra-se suficientemente robusto para identificar os parâmetros do desgaste real nas diferentes configurações empregadas nos mancais montados na bancada de testes / Abstract: The present work aims to identify the wear parameters of hydrodynamic bearings, one of the typical and inherent problems due to repeated use of rotating machineries, which can be accentuated in starts and stops or during the passage through the critical speed of the rotor. Thereby, a mathematical model capable of representing the wear in terms of its main parameters is proposed, which in the present work are the maximum depth and the angular position. The pressure distribution calculation and, consequently, the hydrodynamic forces generated by the oil film are numerically obtained by the finite volume method, adapted for situations where the oil film is discontinuous. In the rotor-bearing system modeling, the rotor model is represented by classic finite element method and the bearings are approximated by dynamic coefficients of stiffness and damping, in order to represent such inherent oil film effects. The identification of the parameters chosen to represent the wear is taken from the dynamic response, in directional coordinates, of the rotor-bearing system in the frequency domain. This identification is accomplished through a search method that aims to minimize an objective function which, in turn, compares the numerical response with the experimental response taken from an instrumented test rig. The results show that the wear model developed in this work is able to satisfactorily represent the behavior of a worn bearing, as well as the response of the rotating system in the presence of this type of failure. With respect to the identification process, the search method proves to be robust enough to identify the real wear parameters into the different configurations employed in the bearings mounted on the test rig / Doutorado / Mecanica dos Sólidos e Projeto Mecanico / Doutor em Engenharia Mecânica

Cette thèse traite de la dynamique non-linéaire multi-contact des ensembles rotor/stator et s’applique en particulier aux tur-bomoteurs d’hélicoptère conçus par Turboméca, groupe Safran. L’amélioration des performances des turbines à gaz pousse les constructeurs à réduire les jeux fonctionnels rotor-stator no-tamment, tout en garantissant robustesse et fiabilité. Cela nécessite de développer des modèles les plus précis possible afin de prévoir et maîtriser des situations à risques telles que les interactions rotor/stator entre les parties fixes et tournantes déclen-chées principalement, dans le cas des turbomoteurs d’hélicoptère, par la perte d’aubes. La partie 1 présente une synthèse bibliographique des principaux phénomènes physiques rencontrés suite à une touche ro-tor/stator en s’appuyant sur l’expérimentation et le calcul. Un bilan sur les différents modèles numériques de gestion du con-tact frottant est détaillé. La dualité entre méthodes temporelles et fréquentielles est aussi abordée comme la méthode de la ba-lance harmonique et les schémas d’intégration temporelle de la famille de Newmark. Il est aussi décrit deux outils d’analyse fréquentielle : le spectrogramme pour analyser l’évolution d’un spectre fréquentiel dans le temps, le full-spectrum pour pren-dre en compte les précessions du rotor. La partie 2 se focalise sur des systèmes dynamiques académiques : un oscillateur forcé à double butées, un rotor de Jeffcott et un rotor à 3 disques avec tous deux une interaction disque/carter. Compte tenu du caractère transitoire du comportement des turbomoteurs, il s’agit de tester des méthodes d’intégration temporelle pas à pas et aussi des lois de contact. Il en ressort que la méthode de Newmark à accélération moyenne, et les lois de contact type « pénalité amortie » combinées à une régularisation de la raideur et de l’amortissement par une fonction arc tangente sont pertinentes. La modélisation de rotor en flexion en ré-gime transitoire et avec plusieurs touches possibles est réalisée avec la méthode des éléments finis et l’intégration des mé-thodes et techniques précédentes. L’ensemble de la modélisation est mise en œuvre sous l’environnement Matlab et se traduit au final par un logiciel nommé ToRoS (Touche Rotor-Stator). Le turbomoteur de l’Ardiden 1H fait l’objet de la dernière partie. Le logiciel ToRoS développé est utilisé pour prévoir la dyna-mique transitoire de sa turbine libre soumise à de multiples touches, consécutifs à un départ d’aubes. Les lois de contacts ap-pliquées dépendent du type de contact : disque/carter, labyrinthe/stator, palier/butée. Durant la descente en vitesse, la ligne d’arbre adopte, en fonction du niveau de balourd, de la vitesse de rotation, des paramètres du contact et du frottement, un comportement avec un contact quasi-permanent en précession directe. / This PhD thesis deals with the nonlinear transient dynamic response of rotor/stator assemblies in the case of multi-contacts, it is applied on Turbomeca’s helicopter turbo-engine. In order to improve gas turbine performances, constructors have to reduce rotor/stator clearances, while continuing to maintain component’s reliability, durability and safety. It implies the development of models to predict and control unsafe situations as, rotor/stator interactions between fixed and rotating parts, mainly triggered by a blade-loss in helicopters turbo-engine case. The first part of this document is concerned with a bibliographical summary of the main physical phenomena observed after a rotor/stator interaction, this is supported by experiments and numerical calculations. A review of the various sliding contact numerical models is presented. The duality between time and/or frequency simulation response methods as, harmonic balance method vs Newmark time integration scheme is discussed. Then two numerical tools for frequency domain analysis are described: the spectrogram to analyze frequency spectrum as a function of the time, the full-spectrum for analyzing the rotor whirl motions. The second part is focused on the time response simulation of some academic systems: an excited oscillator with two end-stops, a Jeffcott rotor and finally a 3 disks rotor both subjected to disk/casing interactions. Given the transient behavior exhibited by turbo-engine rotors following a rotor/stator contact, the purpose is to test several step-by-step time integration scheme combined with different contact laws. This analysis has shown that the Newmark scheme with constant acceleration used with damped contact penalty laws combined to stiffness and damping coefficients smoothed by arctangent functions are relevant. The rotor bending modeling during transient motion considering possible multi-contacts with the stator is realized using the finite element method and the previously reviewed contact modeling methods. The simulation is implemented under Matlab environment and is named ToRoS. (Rotor/Stator Touch). Finally, the developed modeling is applied to the Ardiden 1H turbo-engine. The ToRoS software is used to predict the transient dynamic response of the free power turbine subjected to multi-contacts, after a sudden blade-loss which is modeled by a sudden unbalance. Contact laws are applied and depend on contact type and location: disk/casing, seals, thrust bearing. Depending on the mass unbalance level, the speed of rotation, the contact and friction parameters, the rotor can be in a quasi-permanent contact state in forward whirl while the rotation speed is running-down

This diploma thesis deals with dynamic behaviour of a turbocharger rotor. The subject is a stock turbocharger for commercial vehicles. The research will be mentioned in the first part of the thesis as well as methods of processing. The second, practical part is divided into two divisions. They are both experimental and computational. The aim is finding of rotordynamic behaviour by an experiment and its comparing with a computational model in ANSYS software. Modal and harmonic analysis of a free and fixed subject will be used by both experiment and evaluation. The subject will be fixed where bearings are located during harmonic analysis. All the experimental results will be processed with mathematical and physical methods like FFT analysis or Campbel diagram. There will be two main types of computational models to choose among. These models will be analyzed in detail. The goal of the thesis is to reach results from ANSYS as close as possible with the experimental testing. This includes finding correct material and physical properties, right choice of mesh and right boundary conditions. At the same time the CPU time compared to the model complexity and results accuracy will be considered in a comparison with data obtained by the experiment.

Höhere Drehzahlen, neue Anwendungen in elektrischen Fahrzeugen und der damit verbundene Leichtbau führen zu stärkeren Schwingungsphänomenen in elektrischen Drehfeldmaschinen. Besondere Bedeutung kommt dabei lateralen Rotorschwingungen zu, die sich akustisch bemerkbar machen und im Extremfall sogar zum Versagen des gesamten Systems führen können. In diesem Beitrag wird ein neuartiges Modell vorgestellt, welches rotordynamische Phänomene beliebiger Drehfeldmaschinen in transienten Fahrzuständen unter Berücksichtigung der vollen elektromagnetischen Kopplung abbilden kann. Im vorliegenden Beitrag wird eine FEM-Validierung des vorgeschlagenen Modells präsentiert. Danach wird ein Szenario vorgestellt, bei dem magnetisch angefachte Lateralschwingungen aufklingen. / Higher Speeds, new applications in electric vehicles and the need for lightweight structures lead to increasing occurrence of vibration phenomena in rotating field electrical machines. Lateral rotor oscillations take a particular role in this context, as they produce noise and may cause the entire system to fail in an extreme case. In this contribution, a novel modelling approach is presented, which allows for the fully coupled simulation of transient rotordynamics in all kinds of rotating field machines. This paper includes a FEM-validation of the proposed model. After that a scenario where self-excited lateral oscillations occur is presented.

By using the rotor dynamic capabilities of Simcenter Nastran Rotordynamics, an eigenvalue analysis of 3D-finite element models of the Jeffcott rotor and the overhung rotor were conducted and compared to the results with beam-based, lumped parameter models. The first two critical speeds of the Jeffcott rotor were estimated with variations of 3.9 and 6.4%. The first three critical speeds of the overhung rotor were estimated with 8.5, 6.7 and 6.5% variations, respectively. The Jeffcott rotor was also analysed with different element configurations: Solid elements, axisymmetric Fourier elements, beam/solids and all beam elements. The Fourier elements were the most appropriate option for axisymmetric rotors regarding computational time and accuracy. Tilting pad journal bearings were simulated and validated against data from Vattenfall's facilities in Älvkarleby, where a vertical rotor is connected to two four-pad tilting pad journal bearings. The bearing formulation was defined in a Fortran based subroutine, which acquires the rotor's speed and position to supply a bearing load vector in Simcenter Nastran's transient solver. The experimental rig was also modelled to include the rotor/stator interaction. The force and displacement orbits at the bearings were replicated adequately concerning experimental data, where a maximum deviation of 20.8% and 9.8% were observed for the forces in x and y-directions.  A 3D-finite element model and a beam based finite element model were compared for an actual hydropower unit, which aimed to investigate the mode extraction procedure and how high mass, elastic rotor components influence the system's dynamics. Consistent rotor modes were identified at frequencies within 15% deviation, where the maximum deviation occurred in the upper range frequency pairs. Convergence between the models was observed for the static, lower range frequencies when considering a rigid generator rotor in the 3D finite element model. The outcome is consistent with the model assumptions and underlines that the beam based model cannot capture specific contributions from elastic rotor components. 3D-finite element analysis is a viable option when considering non-axisymmetric and complex rotors. High mass, non-rigid components must be analysed  in this manner as their dynamic contributions may not be captured with other approaches. Intricate and non-rigid supporting structures are also suitable for 3D modelling to properly reflect the stator-rotor interaction. It is a delicate matter to pinpoint when these conditions occur, and modelling decisions must be therefore be substantiated by simulations and experimental validation.

No description available.

Ce mémoire présente une étude théorique et expérimentale de joints annulaires à bague flottante ainsi que de joints rainurés segmentés, destinés à assurer l’étanchéité dynamique au sein de machines tournantes à haute vitesse dans les domaines aéronautique et aérospatial. Des joints annulaires à bague flottante ont été testés sur un banc d’essais dédié au sein de l’institut Pprime pour de multiples configurations de vitesse de rotation et de différence de pression étanchée. La réponse dynamique des joints par rapport aux vibrations du rotor a été étudiée pour différentes amplitudes de l’excitation. Certains résultats issus de cette étude ont été confrontés à une modélisation numérique basée sur les équations de mouvement d’un joint soumis aux forces d’inertie, aux forces hydrodynamiques dans son étanchéité principale et aux forces de frottement à l’étanchéité secondaire. Le coefficient de frottement à l’étanchéité secondaire a été estimé à partir du modèle de Greenwood et Williamson, appliqué au cas d’un régime de lubrification mixte. Les comparaisons réalisées valident le modèle numérique utilisé, qui reproduit le comportement d’un joint soumis à une excitation rotorique donnée. Un autre modèle est proposé pour le cas des joints rainurés segmentés. Les écoulements au sein des différentes parties d’un tel joint ont été modélisés par des méthodes distinctes. Les forces de frottement sont étudiées par un modèle similaire à celui utilisé dans le cas des bagues flottantes. Une étude paramétrique sur différentes caractéristiques géométriques et de fonctionnement du joint a été menée. / This thesis presents a theoretical and experimental study of floating ring annular seals and radial segmented seals. These seals are designed to prevent leakage inside high-speed rotating machinery used in aeronautics and aerospace applications. Floating ring annular seals were tested on a dedicated test rig inside the Institut Pprime. Various rotation speed and pressure difference configurations were used. The behavior of the floating rings when submitted to rotor vibrations was studied for different excitation amplitudes. Results from this study were confronted to a numerical model based on the equations of motion of the seal. The seal is driven by inertia forces, hydrodynamic forces in the main seal and friction forces on the secondary seal. The friction coefficient on the secondary seal was estimated by Greenwood and Williamson’s model for mixed lubrication. The analysis validates the theoretical model, which reproduces the dynamic behavior of a seal driven by a given rotor excitation. Another model was used to study segmented seals. The flow in each part of such a seal was modeled with various methods. Friction forces were studied with a model similar to that used for floating rings. A parametric study was performed on various geometric and operating parameters.

[pt] Este trabalho pretende demonstrar a possibilidade de usar pinos ativos em máquinas rotativas de forma a reduzir as amplitudes de órbitas em situações críticas através de uma investigação analítica com validação experimental. Os pinos funcionam como medida de segurança quando o rotor se torna instável ou começa a oscilar por qualquer razão. Para este propósito, foi realizado um estudo completo da influência da presença dos pinos dentro do mancal de retenção. Quatro pinos foram posicionados em duas bancadas de testes já existentes no laboratório. A atuação deles provém de motores de passo, que os inserem até um determinado comprimento na parte interna do mancal, isto é, a folga radial entre o rotor e a parede do mancal. Primeiramente, uma análise matemática dos fenômenos envolvidos foi desenvolvida, fornecendo as equações necessárias para as simulações numéricas do sistema. Em seguida, foram realizados testes experimentais nas bancadas e informações relevantes foram adquiridas e comparadas com os resultados das simulações. Eles demonstraram estar consistentes, o que ajudou a validar o conceito de inserção de pinos ativos no mancal de segurança, de modo a evitar possíveis condições perigosas, como atrito, roçamento total e efeitos abrasivos. / [en] This work intends to show the possibility of using active pins in rotating machines to reduce amplitudes of orbits at critical situations through an analytical investigation with experimental validations. The pins shall operate as a safety measure when the rotor becomes unstable or starts to oscillate by any reason. To this purpose a thorough study is made of the influence of the presence of pins inside the retainer bearing. Four pins were installed within two existing test rigs in the laboratory. Their actuation comes from step motors, which insert them until a certain length in the inner side of the retainer bearing, or the gap between the rotor and the bearing wall. First, a mathematical approach of the involved phenomena is developed, providing the equations to perform numerical simulations of the system. Then, experiments where performed in the test rigs and relevant data were collected and compared to the simulation results. They showed positive accordance, which helped to validate the concept of properly inserting active pins inside the retainer bearings to avoid possible hazardous conditions, such as, friction, full annular rubbing, and abrasive effects.

De manière générale, les turbomachines sont des machines tournantes permettant la conversion des différents types d’énergie. Ces dernières sont composées d’une partie mécanique en rotation, appelée rotor, interagissant avec un fluide. La rotation a donc un rôle clé pour ces machines et la liaison entre les parties fixes et les parties tournantes, appelée palier, est primordiale pour un fonctionnement fiable et optimal. Les turbomachines supportées par des paliers magnétiques actifs (PMAs) sont de plus en plus utilisées par les industriels notamment grâce à l’absence de contact direct entre parties fixes et parties tournantes, permettant un gain d’énergie et une réduction des émissions de CO2. La plupart du temps, ces machines sont « embarquées » et reposent sur des supports mobiles. Les mouvements générés par ces supports doivent être considérés dans la prévision du comportement dynamique des turbomachines afin d’améliorer les designs en conséquence. Cette thèse est une contribution à l’étude des turbomachines supportées par des PMAs sujettes à de fortes sollicitations extérieures. L’approche est numérique et expérimentale. L’utilisation d’un banc d’essais académique composé d’un système rotor-PMA, aux propriétés d’une turbomachine industrielle, a permis de tester les modèles développés pour des cas de sollicitations extérieures de type séisme et choc, générées grâce à l'excitateur 6-axes de l'equipex PHARE. Il est montré que le modèle permet la bonne prévision du comportement réel de la machine. Cet outil pourra donc être utilisé pour des designs de type industriel. / Turbomachines are rotating machines enabling the conversion of the different types of energy. The latter are composed of a rotating mechanical part, called rotor, interacting with a fluid. Therefore, rotation play a key role in these machines and the mechanical link between the fixed and the rotating parts, called bearing, is essential for reliable and optimal operations. Turbomachines supported by active magnetic bearings (AMBs) are increasingly used by industrial companies, especially thanks to the absence of direct contact between fixed and rotating parts, enabling energy savings and reduction of CO2 emissions. Most of the time, these machines are "on-board" and are fixed on mobile supports. The motions generated by these supports must be considered in the prediction of the dynamic behaviour of turbomachinery in order to improve the designs accordingly. This PhD is a contribution to the study of turbomachines supported by AMBs subjected to strong external base motions. The approach is numerical and experimental. The use of an academic scale test rig comprising a rotor-AMB system, with the properties of an industrial turbomachine, allowed to test the developed models for cases of external solicitations such as earthquake and shock, thanks to the 6-axis shaker of the equipex PHARE. It is shown that the model provides good predictions of the behaviour of the machine for the tested cases. This tool can therefore be used for industrial designs.

Static characteristics and rotordynamic coefficients were experimentally determined for a four-pad tilting-pad journal bearing with ball-in-socket pivots in loadbetween- pad configuration. A frequency-independent [M]-[C]-[K] model fit the measurements reasonably well, except for the cross-coupled damping coefficients. Test conditions included speeds from 4,000 to 12,000 rpm and unit loads from 0 to 1896 kPa (0 to 275 psi). The test bearing was manufactured by Rotating Machinery Technology (RMT), Inc. Though it has a nominal diameter of 101.78 mm (4.0070 in.), measurements indicated significant bearing crush with radial bearing clearances of 99.6 μm (3.92 mils) and 54.6 μm (2.15 mils) in the axes 45º counterclockwise and 45º clockwise from the loaded axis, respectively. The pad length is 101.6 mm (4.00 in.), giving L/D = 1.00. The pad arc angle is 73º, and the pivot offset ratio is 65%. The preloads of the loaded and unloaded pads are 0.37 and 0.58, respectively. A bulk-flow Navier-Stokes model was used for predictions, using adiabatic conditions for the bearing fluid. Because the model assumes constant nominal clearances at all pads, the average of the measured clearances was used as an estimate. Eccentricities and attitude angles were markedly under predicted while power loss was under predicted at low speeds and very well predicted at high speeds. The maximum detected pad temperature was 71ºC (160ºF) and the rise from inlet to maximum bearing temperature was over predicted by 10-40%. Multiple-frequency force inputs were used to excite the bearing. Direct stiffness and damping coefficients were significantly over predicted, but addition of a simple stiffness-in-series model substantially improved the agreement between theory and experiment. Direct added masses were zero or negative at low speeds and increased with speed up to a maximum of about 50 kg; they were normally greater in the unloaded direction. Although significant cross-coupled stiffness terms were present, they always had the same sign. The bearing had zero whirl frequency ratio netting unconditional stability over all test conditions. Static stiffness in the y direction (obtained from steadystate loading) matched the rotordynamic stiffness Kyy (obtained from multiple-frequency excitation) reasonably at low loads but poorly at the maximum test load.