A device has been built to study fretting corrosion phenomena at a bearing/cartridge interface. The research is a continuation of a larger study funded by the Naval Research Laboratory. Its main objective is to determine the important parameters influencing fretting and fretting corrosion in rolling element bearings. The new device is capable of varying load from zero to 200 N (45 lbf), amplitude of vibration from zero to 500 µm (0.0197 in.), and frequency from 2.5 to 100 Hz for axial relative motion. Five sets of bearings and cartridges can be tested simultaneously at the same amplitude and frequency of vibration. Using this device with 52100 hardened steel bearings mounted in SAE 1020 steel cartridges, five analyses were carried out to investigate how load, frequency, amplitude, and presence of a grease influence the extent of fretting corrosion at the interface. / M.S.

No description available.

The relative motion between a ball bearing outer race and the bearing's cartridge was investigated. The investigation was part of a larger program, the objective of which is to examine the important parameters influencing fretting corrosion in rolling element bearings. The bearing examined was a 320 size, deep grooved, ABEC 7 ball bearing used in a Navy ship service motor-generator unit. Three axes of acceleration signatures were simultaneously recorded from the outer race and cartridge. These acceleration signatures were Fourier transformed, averaged, and integrated twice to obtain displacement frequency spectrums. Corresponding displacements were vectorially subtracted to produce the relative motion between the outer race and the cartridge. Two load cases (0% and 100% load) and two frequency ranges (15 to 500 Hz and 30 Hz to 10 kHz) are examined. The resulting relative motion spectrums were complex with the bearing's forcing frequencies dominating the spectrums below 250 Hz and rotor imbalance causing the highest spectral component of relative displacement (170 µm). / M.S.

Existing thrust measurement systems (TMSs) at NASA Stennis Space Center use strain gauges and flux plates to measure forces produced by a test article. Alignment and calibration can take two weeks or more every time a piece of hardware or test article is changed. Cross axis loading is also problematic because it is impossible to perfectly align the flex plates and strain gauges in the thrust direction. In response to these problems, a magnetically levitated thrust measurement system has been proposed and a 300lb capacity demonstrator has been designed and built. In this design, the magnetic bearings work concurrently as support bearings and force measurement devices. The demonstrator consists of a floating frame that is completely levitated within a fixed frame by four support bearings carrying loads in the x- and y-direction and seven thrust bearings carrying loads in the z- or thrust direction. Joe Imlach of Imlach Consulting Engineering designed the demonstrator and magnetic bearing components, while Virginia Tech's role has been the application of the multipoint calibration technique including code development, the implementation of a 128-channel data acquisition system, and the overall test verification of the TMS demonstrator.A turnbuckle assembly and magnetostrictive actuator are used in series with a conventional load cell for static and dynamic testing, respectively. Both current based and flux based force equations were used to measure the reaction forces at the bearings. The static results using the current based equations including the current based fringing equations resulted in accuracies of 93% of full load, while the static results using the flux based equations including the flux based fringing equations resulted in accuracies of 99.5% of full load. These accuracies can be compared to accuracies of 83-90% seen in previous work using magnetic bearings to measure forces by monitoring currents and to accuracies of about 99% in previous work using magnetic bearings to measure forces by monitoring fluxes. All of the improved accuracies were made possible through the implementation of a calibration technique known as the multipoint method and the implementation of a gap dependent fringing correction factor developed by Joe Imlach. The demonstrator was not outfitted with accelerometers so the inertia of the floating frame could not be accounted for, limiting the scope of dynamic testing. However, the tests confirmed the ability of the demonstrator to measure dynamic loads in general. / Master of Science

Active magnetic bearings have several potential applications in spacecraft design. Based on the gyrostat model, we develop equations that describe the internal torques and forces that occur between the body and one of the attached wheels. We evaluate the transverse torques for the torque--free gyrostat and a gyrostat undergoing attitude maneuvers using momentum wheels and external torques. We then apply these internal forces to a model of an active magnetic bearing system and discuss their effects on the force limit, the actuator slew rate and the equivalent stiffness and damping parameters. As a basis for this study we use the Distributed Spacecraft Attitude Control System Simulator (DSACSS) with a Revolve MBRotor active magnetic bearing system. The results of several numerical simulations show that the magnitude and frequency of the internal torques remain small over the estimated range of motion of the DSACSS--MBRotor gyrostat. As such, the transverse torques caused by the rotational motion remain less than the discussed performance limits. We show that the magnitude of the internal torques can also be minimized by reducing the axial moment of inertia of the wheel. Furthermore, we discuss the equivalent Jeffcott model. By applying a standard Proportional--Integral--Derivative controller to the active magnetic bearing both the equivalent stiffness and damping parameters remain constant. / Master of Science

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

Most tilting pad journal bearing dynamic characteristics estimation methodologies assume perfect shaft tracking by the pads. In other words, they neglect pivot friction. In case of pads having point or line contact that operate under most normal load conditions, the pad tilting is due to a rocking motion which is not greatly influenced by friction. Hence this simplifying assumption might be acceptable. Heavier loading conditions, such as those typically encountered in gearboxes, demand the use of spherical pivots to avoid pivot failure. The spherical pivot is very attractive for this reason, but the tilting motion is rather a sliding action that must occur in the precision ball socket. A valid concern exists for verifying the soundness of assumed shaft tracking by the pads of such bearings. A "fixed test bearing, floating shaft" type of test rig previously built for determining the dynamic characteristics of bearings was accordingly modified to facilitate the testing of shaft tracking for a spherical pivot bearing. This thesis describes the modifications carried out on the rig. The special instrumentation and data acquisition systems implemented to observe the minute pad motion are also discussed. Some preliminary results of the tests are presented for various loading conditions. They show excellent shaft tracking by the pads. More detailed testing and analysis of data is required to fully understand the pad motion and tracking ability of the spherical pivot design. / Master of Science

Analysis tools for predicting the dynamic behavior of a rotor system supported by ball bearings are presented. Two computer programs were developed. The first uses a transfer matrix technique to compute rotor natural frequencies as a function of bearing stiffness. The second is a bearing analysis program which is used to determine ball bearing stiffness as a function of load and speed. High-speed effects as well as combined axial and radial loading are considered. Together, these programs provide the necessary information for constructing the critical speed map of a rotor system. Analysis of an actual rotor system was performed and the results discussed. The importance of the compliance of the bearing housing with respect to the bearing itself is emphasized. / M. S.

Rotordynamic and thermal analyses of compliant flexure pivot tilting pad gas bearings were performed. First, compliant flexure pivot tilting pad gas bearings with pad radial compliance (CFTPBs) were introduced and designed for high-speed oil-free micro turbomachinery. The pad radial compliance was for accommodation of large rotor growth at high speeds. Parametric studies on pivot offset, preload, and tilting stiffness were performed using non-linear orbit simulations and coast-down simulations for an optimum design. Second, coast-down tests for imbalance response and stability of typical rotor-bearing system with a rigid rotor and two CFTPBs designed from the above design studies were conducted over operating speeds up to 55 krpm. Prediction of synchronous rotordynamic responses was made in terms of critical speed for various imbalance modes by using a rotordynamic analysis software (XLTRC), combined with dynamic force coefficients from the perturbation analysis. For stability analyses, a generalized orbit simulation program was developed considering both the translational and angular rotor motions with two different bearings. Linear stability analyses for the conical vibration mode were also performed by using XLTRC and the perturbation analysis based on the Lund method. Predictions of whirl speed showed good agreement to the tests, but the estimated onset speed of instability appeared lower than the measured instability. Finally, a new thermo-hydrodynamic analysis model of a typical rotor-bearing system with CFTPBs was presented, accompanying linear perturbation analyses to investigate thermal effects on the rotordynamic performance. A numerical procedure was established for solving the generalized Reynolds equation, the 3-D energy equation, and the associated boundary conditions at the pad inlet flow and solid walls (rotor and pad) simultaneously. Parametric studies were conducted on nominal clearance and external load. Nominal clearance showed significant influence on temperature fields, and external load had uneven thermal effects among pads. Case studies with heat flux and temperature boundary conditions on the rotor end surface were performed to simulate various working conditions of the bearing. Large rotor thermal growth due to the high rotor temperature showed noticeable influence on rotordynamic performance by increasing direct stiffness and damping coefficients.

Rotordynamic and thermal analyses of compliant flexure pivot tilting pad gas bearings were performed. First, compliant flexure pivot tilting pad gas bearings with pad radial compliance (CFTPBs) were introduced and designed for high-speed oil-free micro turbomachinery. The pad radial compliance was for accommodation of large rotor growth at high speeds. Parametric studies on pivot offset, preload, and tilting stiffness were performed using non-linear orbit simulations and coast-down simulations for an optimum design. Second, coast-down tests for imbalance response and stability of typical rotor-bearing system with a rigid rotor and two CFTPBs designed from the above design studies were conducted over operating speeds up to 55 krpm. Prediction of synchronous rotordynamic responses was made in terms of critical speed for various imbalance modes by using a rotordynamic analysis software (XLTRC), combined with dynamic force coefficients from the perturbation analysis. For stability analyses, a generalized orbit simulation program was developed considering both the translational and angular rotor motions with two different bearings. Linear stability analyses for the conical vibration mode were also performed by using XLTRC and the perturbation analysis based on the Lund method. Predictions of whirl speed showed good agreement to the tests, but the estimated onset speed of instability appeared lower than the measured instability. Finally, a new thermo-hydrodynamic analysis model of a typical rotor-bearing system with CFTPBs was presented, accompanying linear perturbation analyses to investigate thermal effects on the rotordynamic performance. A numerical procedure was established for solving the generalized Reynolds equation, the 3-D energy equation, and the associated boundary conditions at the pad inlet flow and solid walls (rotor and pad) simultaneously. Parametric studies were conducted on nominal clearance and external load. Nominal clearance showed significant influence on temperature fields, and external load had uneven thermal effects among pads. Case studies with heat flux and temperature boundary conditions on the rotor end surface were performed to simulate various working conditions of the bearing. Large rotor thermal growth due to the high rotor temperature showed noticeable influence on rotordynamic performance by increasing direct stiffness and damping coefficients.