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Research Papers: Gas Turbines: Structures and Dynamics

Experimental and Analytical Investigation of High Speed Turbocharger Ball Bearings

[+] Author and Article Information
Ankur Ashtekar, Farshid Sadeghi

Cummins Professor School of Mechanical Engineering,  Purdue University, West Lafayette, IN 47907

J. Eng. Gas Turbines Power 133(12), 122501 (Aug 26, 2011) (14 pages) doi:10.1115/1.4004004 History: Received October 28, 2010; Revised April 11, 2011; Published August 26, 2011; Online August 26, 2011

The objectives of this investigation were to design and construct a high speed turbocharger test rig (TTR) to measure dynamics of angular contact ball bearing rotor system, and to develop a coupled dynamic model for the ball bearing rotor system to corroborate the experimental and analytical results. In order to achieve the objectives of the experimental aspect of this study, a test rig was designed and developed to operate at speeds up to 70,000 rpm. The rotating components (i.e., turbine wheels) of the TTR were made to be dynamically similar to the actual turbocharger. Proximity sensors were used to record the turbine wheel displacements while accelerometers were used to monitor the rotor vibrations. The TTR was used to examine the dynamic response of the turbocharger under normal and extreme operating conditions. To achieve the objectives of analytical investigation, a discrete element ball bearing model was coupled through a set of interface points with a component mode synthesis rotor model to simulate the dynamics of the turbocharger test rig. Displacements of the rotor from the analytical model were corroborated with experimental results. The analytical and experimental results are in good agreement. The bearing rotor system model was used to examine the bearing component dynamics. Effects of preloading and imbalance were also found to have significant effects on turbocharger rotor and bearing dynamics.

Copyright © 2011 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Turbocharger test rig setup

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Figure 2

Rotor and bearing cross-section

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Figure 3

Introduction of imbalance to the rotor

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Figure 4

Proximity sensors in Y axis and Z axis

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Figure 5

Contact between two spherical bodies

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Figure 6

Turbocharger model setup

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Figure 7

LP displacement (μm) at 1000 rpm

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Figure 8

LP displacement (μm) at 5000 rpm

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Figure 9

LP displacement (μm) at 10,000 rpm

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Figure 10

LP displacement (μm) at 20,000 rpm

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Figure 11

Ball-race loads from analytical model for rigid rotor and flexible rotor

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Figure 12

Ball cage impacts from analytical model for rigid rotor and flexible rotor

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Figure 13

Rotor displacement from test rig at 1350 rpm with 20 gm-mm imbalance

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Figure 14

Rotor displacement from test rig at 2700 rpm with 20 gm-mm imbalance

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Figure 15

Ball-Race contact pressure from analytical model at 30,000 rpm

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Figure 16

Ball-cage pocket forces from analytical model at 30,000 rpm

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Figure 17

Ball-Race forces from analytical model for different varying preloading

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Figure 18

Ball angular velocity from analytical model for different preloading

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Figure 19

Inner race motion from analytical model for different preloading

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Figure 20

Cage motion from analytical model at 20,000 rpm for different preloading

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Figure 21

Cage motion from analytical model at 10|000 rpm for different preloading

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Figure 22

Cage motion from analytical model at 2000 rpm for different preloading

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