Design Innovation

Testing of a Small Turbocharger/Turbojet Sized Simulator Rotor Supported on Foil Bearings

[+] Author and Article Information
James F. Walton

 Mohawk Innovative Technology, Inc. 1037 Watervliet-Shaker Road, Albany, NY 12205jwalton@miti.cc

Hooshang Heshmat

 Mohawk Innovative Technology, Inc. 1037 Watervliet-Shaker Road, Albany, NY 12205hheshmat@miti.cc

Michael J. Tomaszewski

 Mohawk Innovative Technology, Inc. 1037 Watervliet-Shaker Road, Albany, NY 12205mtomaszewski@miti.cc

J. Eng. Gas Turbines Power 130(3), 035001 (Mar 26, 2008) (7 pages) doi:10.1115/1.2830855 History: Received October 15, 2004; Revised October 03, 2007; Published March 26, 2008

A small rotor designed to simulate a miniature turbojet engine or turbocharger rotor mounted on compliant foil bearings was tested at speeds in excess of 150,000rpm and temperatures above 260°C(500°F). The simulator rotor-bearing system was operated while positioned in various orientations and was subjected to transient shock impacts exceeding 35g. Subsequent testing was completed to demonstrate the capabilities of miniature thrust foil bearings as well. The tested rotor weighed approximately 400g and used 15mm diameter foil journal bearings and a multipad 25mm diameter double acting thrust foil bearing. Results of the rotor-bearing system dynamics are presented along with experimentally measured natural frequencies, rotor displacements, and thrust load carrying ability. A good correlation between measurement and analysis is observed. Very short rotor acceleration times from rest to maximum speed were also measured. A parallel test simulator has been used to accumulate over 1000 start-stop cycles to demonstrate the life of the bearing and coating. Based on this successful testing, it is expected that the goal of developing oil-free turbochargers and small turbojet engines that operate at high speeds with long life will be achieved.

Copyright © 2008 by American Society of Mechanical Engineers
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Figure 18

Summary plot of rotor response after numerous tests

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Figure 1

Typical small turbojet engine cross section with conventional rolling element bearings

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Figure 2

Compliant foil bearing operating mechanisms

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Figure 3

Rotor-bearing system demonstrator test rig

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Figure 4

Test shaft, journal foil bearings, and partially assembled thrust foil bearings

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Figure 5

Test rig cross section and instrumentation

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Figure 6

Test rig dimensions and arrangement

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Figure 7

Instantaneous Fourier fast transform spectrum of rotor motion when operating at 151,500rpm

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Figure 8

Rig thermal check out run with slave bearings

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Figure 9

Prototype bearing ambient check run data plot

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Figure 10

Initial 15min heated inlet air check run

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Figure 11

2h durability test run with 50°C bearing air

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Figure 12

Cyclic test to 290°C and 150,000rpm

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Figure 13

2h simulated mission test

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Figure 14

Rotor shock response while at 100,000rpm

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Figure 15

Postshock test peak vibration during coastdown

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Figure 16

Comparison of peak rotor vibrations during coastdown for vertical and horizontal shaft orientations

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Figure 17

Peak coastdown vibration after ±90 roll



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