The accuracy of rotordynamic analysis of aeroengine structures is typically limited by a trade-off between the capabilities and the computational cost of the squeeze-film damper (SFD) bearing model used. Identification techniques provide a means of efficiently implementing complex nonlinear bearing models in practical rotordynamic analysis; thus facilitating design optimisation of the SFD and the engine structure. This thesis considers both identification from advanced numerical models and identification from experimental tests. Identification from numerical models is essential at the design stage, where rapid simulation of the dynamic performance of a variety of designs is required. Experimental identification is useful to capture effects that are difficult to model (e.g. geometric imperfections). The main contributions of this thesis are: • The development of an identification technique using Chebyshev polynomial fits to identify the numerical solution of the incompressible Reynolds equation. The proposed method manipulates the Reynolds equation to allow efficient and accurate identification in the presence of cavitation, the feed-groove, feed-ports, end-plate seals and supply pressure. • The first-ever nonlinear dynamic analysis on a realistically sized twin-spool aeroengine model that fulfills the aim of taking into account the complexities of both structure and bearing model while allowing the analysis to be performed, in reasonable time frames, on a standard desktop computer. • The introduction and validation of a nonlinear SFD identification technique that uses neural networks trained from experimental data to reproduce the input-output function governing a real SFD. Numerical solution of the Reynolds equation, using a finite difference (FD) formulation with appropriate boundary conditions, is presented. This provides the base data for the identification of the SFD via Chebyshev interpolation. The identified 'FD-Chebyshev' model is initially validated against the base (FD) model by application to a simple rotor-bearing system. The superiority of vibration prediction using the FD-Chebyshev model over simplified analytical SFD models is demonstrated by comparison with published experimental results. An enhanced FD-Chebyshev scheme is then implemented within the whole-engine analysis of a realistically sized representative twin-spool aeroengine model provided by a leading manufacturer. Use of the novel Chebyshev polynomial technique is repeatedly demonstrated to reduce computation times by a factor of 10 or more when compared to the basis (FD) model, with virtually no effect on the accuracy. Focus is then shifted to an empirical identification technique. Details of the commissioning of an identification test rig and its associated data acquisition system are presented. Finally, the empirical neural networks identification process for the force function of an SFD is presented and thoroughly validated. When used within the rotordynamic analysis of the test rig, the trained neural networks is shown to be capable of predicting complex nonlinear phenomena with remarkable accuracy. The results show that the neural networks are able to capture the effects of features that are difficult to model or peculiar to a given SFD.

Orientador: Helio Fiori de Castro / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-28T11:56:54Z (GMT). No. of bitstreams: 1 Tyminski_NataliaCezaro_M.pdf: 6550021 bytes, checksum: 3fb888c14fc5d24d29f7f155d0e4f2b0 (MD5) Previous issue date: 2015 / Resumo: As unidades geradoras de energia das usinas são formadas por turbinas e turbo-geradores, que são exemplos típicos de máquinas rotativas. Essas maquinas são componentes críticos, pois são essenciais à geração de energia. Sabendo que a análise dinâmica de máquinas rotativas é uma tarefa complexa envolvendo diversos parâmetros a serem analisados, sua realização não deve considerar apenas o rotor, pois seu comportamento dinâmico é influenciado pela interação com os demais componentes do mesmo sistema. O comportamento dinâmico de uma máquina rotativa é, geralmente, representado por um modelo determinístico. Entretanto, sistemas rotativos reais possuem características estocásticas, visto que os inúmeros parâmetros de projetos possuem incertezas inerentes à fabricação e, principalmente, às condições de operações. Desta forma, modelos estocásticos são uma opção importante para representação de sistemas rotativos na fase de projeto, onde se podem prever os efeitos da variação dos parâmetros de projeto. O tema em foco nesta dissertação de mestrado é a aplicação de Inferência Bayesiana para ajustar um modelo de sistema rotativo. Neste trabalho foram analisadas as incertezas nos parâmetros de projeto de um sistema rotativo, e a partir das incertezas obtidas foi possível obter a resposta estocástica do sistema. A primeira analise considera as incertezas dos parâmetros relacionados ao eixo; como o modulo de elasticidade, a massa especifica do material e o coeficiente de proporcionalidade a matriz de rigidez. Na segunda análise, os parâmetros escolhidos foram os parâmetros de desbalanceamento; ângulo de fase, momento de desbalanceamento e posição axial. Em uma terceira abordagem, foi analisado parâmetros dos mancais hidrodinâmicos, folga radial do mancal e temperatura do óleo lubrificante. A partir das incertezas dos referidos parâmetros, foi possível analisar a propagação de incertezas desses parâmetros no cálculo da posição do eixo no mancal e dos coeficientes dinâmicos dos mancais hidrodinâmicos / Abstract: Energy generation plants rely on units such as turbines and turbo-generators, which are common examples of rotating machines. These machines are critical components in these units, once they are essential to the energy generation. The dynamic analysis of rotating machines is a complex task including several parameters to be considered. This analysis requires taking the rotor into account but also the other components, which affect the dynamic behavior of the system. The dynamic behavior of rotating machines is usually represented by a deterministic model. Although, real rotating system have stochastic characteristics once that the parameters on project have uncertainties. In this way, stochastic models are an important option for the representation of these systems, and it's possible predict the variation's parameters. This study aims the application of Bayesian Inference for model updating on rotating systems. The uncertainties of rotating machines parameters were analyzed, and the system stochastic response was obtained. The first analyzed considers the uncertainties of the beam parameters, as the Young¿s modulus, and the proportionality coefficient to the stiffness matrix. In the second analysis, the selected parameters were the unbalance parameters; phase angle, unbalance moment and axial position. In a third approach, it was analyzed parameters of journal bearings, clearance radial and lubricating oil temperature. From the uncertainties of these parameters, it was possible to analyze the propagation of uncertainties of these parameters, to calculate the center line position in the bearing, and the dynamic coefficients of journal bearings / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestra em Engenharia Mecânica

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This thesis investigates and determines the design considerations to be addressed when designing switched reluctance machines (SRMs) operating at high surface-speeds and high-loads. A new method is introduced to the traditional machine design procedure that captures all of the mechanical, thermal and electro-magnetic considerations for such electric machines. This method is applicable to any motor design; however, is most suitable for machines with rotors that sustain mechanical stresses near the rotor core material limits. The method begins by using common application specifications to identify the maximum diameter and length of a rotor through a series of structural analyses. Maximizing rotor diameter and axial length enables designers to evaluate a machine's theoretical mechanical and electro-magnetic performance limits. The design method is structured such that the designer must use theoretical limits as a constraint for assessing future design decisions which ultimately influence machine cost and performance. The proposed design method is applied to a case study example typical of a large electric vehicle traction machine, a 22,000rpm, 150 kW switched reluctance machine, while attempting to adhere with design practices commensurate with automotive mass manufacturing. To achieve this, a parallel connected 12/8 pole topology was finally developed. The thesis research suggest that a 440 MPa yield strength, 0.27mm thickness lamination with 30 turn stator coils is sufficient to meet the specification requirements within a prescribed power electronic converter voltage and current constraints, while satisfying material mechanical and thermal considerations. Detailed analysis of AC effects, performance characteristics, thermodynamics, noise and vibration is presented to simultaneously demonstrate and validate the proposed machine design and design method. / Thesis / Doctor of Philosophy (PhD)

The labyrinth seal is widely used in turbo machines to reduce leakage flow. The stability of the rotor is influenced by the labyrinth seal because of the driving forces generated in the seal. The working fluid usually has a circumferential velocity component before entering the seal; the ratio of circumferential velocity and shaft synchronous surface velocity is defined as pre-swirl rate. It has been observed that pre-swirl rate is an important factor affecting driving forces in the labyrinth seal thus affecting the stability of the rotor. Besides the pre-swirl, the eccentricity, the clearance, and the configuration of tooth locations are all factors affecting the rotordynamic properties of the labyrinth seal. So it is of interest to investigate the exact relationships between those factors and the seal's rotordynamic properties. In this research, three types of labyrinth seals have been modeled: the straight eye seal, the stepped eye seal, and the balance drum seal. For the straight eye seal, a series of models were built to study the influence of eccentricity and clearance. The other two seals each have only one model. All models were built with Solid Works and meshed with ANSYS-ICEM. Flows in those models were simulated by numerically solving the Reynolds-Averaged Navier-Stokes (RANS) equations in the ANSYS-CFX and then rotordynamic coefficients for each seal were calculated based on the numerical results. It had previously been very difficult to generate a pre-swirl rate higher than 60% in a numerical simulation. So three ways to create pre-swirl in ANSYS-CFX were studied and finally the method by specifying the inlet velocity ratio was employed. Numerical methods used in this research were introduced including the frame transfer, the k-ε turbulence model with curvature correction, and the scalable wall function. To obtain the optimal mesh and minimize the discretization error, a systematical grid study was conducted including grid independence studies and discretization error estimations. Some of the results were compared with previous bulk-flow or experimental results to validate the numerical model and method. The fluid field in the labyrinth seal must be analyzed before conducting rotordynamic analysis. The predicted pressure distributions and leakages were compared with bulk-flow results. A second small vortex at the downstream edge of each tooth was found in the straight eye seal. This has never been reported before and the discovery of this small vortex will help to improve seal designs in the future. The detailed flows in discharged region and in chambers were also discussed. Radial and tangential forces on the rotor were solved based on the fluid field results. It is shown that the traditional first-order rotordynamic model works well for low pre-swirl cases but does not accurately reflect the characteristics for high pre-swirl cases. For example compressor eye seals usually have pre-swirl rates bigger than 70% and the second order model is required. Thus a second-order model including inertia terms was built and applied to the rotordynamic analysis in this research. The influence of pre-swirl, eccentricity and clearance were studied using the straight eye seal model. The rotordynamic characteristics of the stepped eye seal and the balance drum seal were studied considering high pre-swirl rates. Some relationships between influencing factors and the four rotordynamic coefficients were concluded. The results also showed that for all the three seals higher pre-swirl leads to higher cross-coupled stiffness which is one of the main factors causing rotor instability. The rotor stability analysis was conducted to study the influence of drum balance seal on the stability. The rotor was designed with typical dimensions and natural frequencies for a centrifugal compressor rotor. The parameters for bearing and aerodynamic force were also set according to general case in compressors to minimize the effects from them. The result shows that the high pre-swirl rate in balance drum seal leads to rotor instability, which confirmed the significant effect of pre-swirl on the seal and the rotor system. / Ph. D.

This project was initiated to more fully understand the dynamic stability of an automotive turbocharger rotor-bearing system using both linear and nonlinear analyses. The capabilities of a commercial Finite Element Analysis (FEA) code (computer program) were implemented in the investigation process. Several different hydrodynamic journal bearings were employed in the study of the turbocharger linearized dynamic stability. The research demonstrates how the linear analysis of a turbocharger rotordynamics can be very beneficial for the design evaluation and maintenance purposes. / Master of Science

A high-speed rotary device was designed to generate shock waves in a transonic blowdown wind tunnel cascade. The rotary device (Rotating Bar Mechanism) will be used in research conducted at Virginia Tech to study the effects of unsteady aerodynamic flow and heat transfer (resulting from upstream shock wave / wake passing) on turbine blades. The rotating bar mechanism (RBM) consists of: a rotor with flexible cable “bars” attached to the rim of the disk, a disk housing, a bearing housing, a driving air turbine, and a turbine mounting housing. The RBM is mounted to the side of the wind tunnel so that only the bars enter and exit the tunnel test section through a small slot. As the bars translate through the test section, the bars create shocks / wakes similar to those shed from the trailing edges of nozzle guide vanes of a transonic turbine. Considerable design effort was required for the RBM due to its relatively high operating speed. As the result of a finite element stress analysis, a unique method of securing the disk to the shaft was developed. This unique method reduced the stress concentration factor at the disk hub from 2.9 to 1.7. In addition to the stress analysis, a rotordynamic study was also performed. The study revealed that the RBM could not be designed to operate below the first natural frequency. A critical speed of 14,000 RPM was predicted for the rotary device. This prediction was later verified by testing. An integral component of the overall design was the development of a computer code to predict the RBM’s speed under various loading conditions. The loading on the device is due primarily to the aerodynamic drag on the flexible cable bars. Since the mechanism was designed to facilitate bars of different diameters, the prediction code was an essential design tool. The speed prediction code was also verified by testing. The RBM was tested to wind tunnel operating speeds in a spin pit filled with argon to verify the mechanical design. Based on test performance, it was concluded that the RBM is suitable to generate shock waves in a transonic wind tunnel. / Master of Science

Torsional vibration is an oscillatory angular twisting motion in the rotating members of a system. It can be deemed quite dangerous in that it cannot be detected as easily as other forms of vibration, and hence, subsequent failures that it leads to are often abrupt and may cause direct breakage of the shafts of the drive train. The need for sufficient analysis during the design stage of a rotating machine is, thus, well justified in order to avoid expensive modifications during later stages of the manufacturing process. In 1998, a project was initiated by the Turbomachinery Research Consortium (TRC) at Texas A&M University, College Station, TX, to develop a suite of computer codes to model torsional vibration of large drive trains. The author had the privilege of developing some modules in Visual Basic for Applications (VBA-Excel) for this suite of torsional vibration analysis codes, now collectively called XLTRC-Torsion. This treatise parleys the theory behind torsional vibration analysis using both the Transfer Matrix approach and the Finite Element approach, and in particular, validates the results generated by XLTRC-Torsion based on those approaches using experimental data available from tests on a 66,000 HP Air Compressor.

Misalignment in turbomachinery has been commonly known to produce twotimes- running-speed (2N) response. This project aimed to investigate the source of the 2N vibration response seen in misaligned vibrating machinery by simulating misalignment through a coupling. Three flexible disc-pack couplings (4-bolt, 6-bolt, and 8-bolt coupling) were modeled, and parallel and angular misalignments were simulated using a finite element program. The stiffness terms obtained from the coupling simulations had 1N, 2N, and 3N harmonic components. The 4-bolt coupling had large 1N reaction components under angular and parallel misalignment. The 6-bolt coupling model only had a 1N reaction component under angular misalignment, and both cases of parallel misalignment showed a strong 2N reaction component, larger than both the 1N and 3N components. The 8-bolt coupling model under angular misalignment produced large 1N reaction components. Under parallel misalignment, it produced 1N, 2N, and 3N components that were similar in magnitude. All the couplings behaved linearly in the range studied. A simple model predicted that the 2N frequency seen in the response is caused by the harmonic (1N) term in the stiffness. The amplitude of the 2N component in the response depends on the amplitude of the 1N term in the stiffness compared to the average value of the stiffness and the frequency ratio. The rotordynamic response of a parallel and angular misaligned system was completed in XLTRC2. When the frequency ratio was 0.5, the system response with the 4-bolt and 6-bolt coupling had a synchronous 1N component that was much larger than the 2N component. The response did not have a 2N component when the 8-bolt coupling was used but the response did have a 1.6N component that was considerably larger than the 1N component. When the frequency ratio was 2, the system response with the 4-bolt and 6-bolt coupling had a synchronous 1N component and a relatively small ½ frequency component. The response with the 8-bolt coupling had a 0.4N component that was larger than the 1N component. A 5-tilting pad journal bearing was also tested to better understand its behavior under misalignment because some experts attribute the 2N response to the nonlinear forces produced by bearings with high unit loads. The response of the 5-tilting pad bearing did not produce any 2N components while the bearing was subjected to unit loads of up to 34.5 bars.

Torsional vibration is an oscillatory angular twisting motion in the rotating members of a system. It can be deemed quite dangerous in that it cannot be detected as easily as other forms of vibration, and hence, subsequent failures that it leads to are often abrupt and may cause direct breakage of the shafts of the drive train. The need for sufficient analysis during the design stage of a rotating machine is, thus, well justified in order to avoid expensive modifications during later stages of the manufacturing process. In 1998, a project was initiated by the Turbomachinery Research Consortium (TRC) at Texas A&M University, College Station, TX, to develop a suite of computer codes to model torsional vibration of large drive trains. The author had the privilege of developing some modules in Visual Basic for Applications (VBA-Excel) for this suite of torsional vibration analysis codes, now collectively called XLTRC-Torsion. This treatise parleys the theory behind torsional vibration analysis using both the Transfer Matrix approach and the Finite Element approach, and in particular, validates the results generated by XLTRC-Torsion based on those approaches using experimental data available from tests on a 66,000 HP Air Compressor.