NOTES ON FLUID FILM JOURNAL BEARINGOVERVIEW

Pranabesh De Choudhury, Ph.D. Pran RDA Consulting Inc. Greensburg, PA 15601

OUTLINE Role of Fluid Film Bearing in Rotating Machinery Basics Newtons Law of Friction Plane Slider Bearing Basic Parameters Stiffness and Damping Coefficients of Short Journal Bearing Stability Map of a Short Journal Bearing Hydrodynamic Instability Finite Difference Method Type of Bearings Modeling Bearings Pran Rda Consulting Inc.

OUTLINE (continued) Tilting-Pad Journal Bearing Load on Pad Vs. Load Between Pads Tilting-Pad Bearings Vs. Fixed Geometry Bearings Stiffness and Damping Coefficients of Tilting-Pad Journal Bearing at minimum, average, and maximum clearances Performance Test Results of Five Shoe Tilting-Pad Journal Bearing Effect of Slow Roll Boundary Lubrication References

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Role of Fluid Film Bearing in Rotating Machinery

Provides a fluid film for the rotating shaft from the bearing due to hydrodynamic action of the lubricant Enables the turbo-machinry to operate with low friction loss Prevents rotor damage Hydrodynamic action of the fluid film results in fluid film stiffness and damping, influencing the location of critical speeds. Influences the rotor-bearing stability

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BASICS
Newtons law holds for the lubricant. Inertia effects of the moving oil can be neglected. Lubricant is incompressible. Fluid pressure is independent throughout the film thickness. Curvature of the film with respect to thickness can be neglected. Viscosity of the lubricant is constant throughout the film and is independent of temperatures within the film. Shaft and bearing are rigid with perfectly smooth surfaces in perfect alignment. Pran Rda Consulting Inc.

Newtons Law of Friction

Y

Velocity U

Stationary

FIGURE 1 F = A U/h Where, = Coefficient of viscosity A = Area swept U = Velocity h = Oil film thickness = F/A = U/h = u/y = du/dy > Newtonian Fluid

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MOVING
U

STATIONARY

P/X=0

X=0

X=L

FIGURE 1A

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PLANE SLIDER BEARING

(see Figure 2)
h h3 P h3 P 12 ( V V ) 6 ( U U ) 6 h (U1 + U 2 ) = + + + 2 1 1 2 x x x 6 x z z

(1)

First term on right hand side represents the squeeze, the second the wedge, and the third the stretch effect in the bearing. Relating this to the geometry of the journal bearing in fixed Cartesian coordinate system for a short journal bearing (see figure 3), equation 1 reduces to
h h h3 P +2 = t z 6 z

(2)

Film thickness h is

h = c x cos y sin
This is valid for a journal bearing with no axial misalignment Applying the boundary conditions related to the pressure distribution P

(3)

P ( ,0) = P ( , L) = 0

(4)

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The following equation results

P ( , z ) = h 3 z ( z L ) h ( + 2 ) t h3

(5)

From equation 3

and

h = x sin y cos
h & cos y & sin = x t

(6)

(7)

From equations 5, 6, and 7 the following could be obtained

Fx = Fy =

RL3
2

& cos + y & sin ) ( x sin y cos ) 2( x cos d 3 ( c x cos y sin ) 0

2

(8) (9) (10)

RL3
2

& cos + y & sin ) ( x sin y cos ) 2( x sin d 3 ( c x cos y sin ) 0

. . . . If X=x/c, Y=y/c, X=x/c, Y=y/ c

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Equations 8 and 9 takes the following form

& 2Y & ) sin (Y & + 2X & ) cos RL3 2 ( X Fx = cos d 2 3 2c (1 X cos Y sin ) 0 & 2Y & ) sin (Y & + 2X & ) cos RL3 2 ( X Fy = sin d 2 3 2c (1 X cos Y sin ) 0

(11)

(12)

Assuming small displacements from the equilibrium position represented by x0, y0 the incremental hydrodynamic forces in x and y directions can be written as . . Fx = -(Kxxx+Cxxx+Kxyy+Cxyy)@ x=x0 and y=y0 and . . Fy = -(Kyyy+Cyyy+Kyxx+Cyxx)@ x=x0 and y=y0 where
Fx RL3 Kxx = = X 2c 3
2

sin cos H 0 + 3 cos 2 ( X 0 sin Y0 cos )d H0

4

Fy RL3 2 [3 sin 2 ( X 0 sin Y0 cos ) sin cos H 0 ]d Kyy = = 4 Y 2c 3 H0 0

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Fx RL3 = Cxx = & X 2c 3

2 cos3 d H0
3

Fy RL3 = Cyy = & 2c 3 Y

2 sin 3 d H0
2
3

Fx RL3 [3 sin cos ( X 0 sin Y0 cos ) H 0 cos2 ]d Kxy = = 4 2c 3 Y H0 0

Fy RL3 = Kyx = X 2c 3
Fx RL3 = Cxy = & Y 2c 3 Fx RL3 = Cyx = & X 2c 3
2

[3 sin cos ( X 0 sin Y0 cos ) + Ho sin 2 ]d H0

H0 H0
3

0 0

2 sin cosd 2 sin cosd

3

Where Ho = 1 Xo cos Yo sin Xo = osin0 Yo= - ocos 0 o = Equilibrium eccentricity

(1 )0.5 0 0 = Attitude angle = tan [ ] 4

-1

0 Pran Rda Consulting Inc.

Where, Kxx = Bearing stiffness coefficient in X direction Kxy = Cross coupled stiffness coefficient for force in X direction from Y displacement Kyx = Cross coupled stiffness coefficient for force in Y direction from X displacement Kyy = Bearing stiffness coefficient in Y direction Cxx = Bearing damping coefficient in X direction Cxy = Cross coupled damping coefficient for force in X direction from Y displacement Cyx = Cross coupled damping coefficient for force in Y direction from X displacement Cyy = Bearing damping coefficient in Y direction Figures 4 and 5 show plots of the nondmensional bearing characteristics as a function of the equilibrium eccentricity 0. These fluid film bearing coefficients are essential components in rotor dynamic analysis. Bearings having more complicated geometries are analyzed using numerical methods, e.g., finite difference, or, finite element. .

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Basic Parameters
S = Ns (R/C)2 / P Sommerfeld Number
4 (1 2 ) 2 Ss = Modified S 2 2 2 2 (1 ) + 16 0.5 -1 (1 ) = Attitude angle = tan [ ] 4

= Viscosity in reyns Ns = Revolutions per second R = Journal Radius C = Bearing Radial Clearance = Eccentricity ratio P = Bearing unit load = W/(LD) = Attitude angle

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Eccentricity Ratio Vs. Sommerfeld No.

100

10

1 Sommerfeld No. 0 0.1 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

0.01

0.001

0.0001 Eccentricity Ratio

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Eccentricity Ratio Vs. Attitude Angle

100 90 80 Attitude Angle (degrees) 70 60 50 40 30 20 10 0 0 0.1 0.2 0.3 0.4 0.5 Eccentricity Ratio 0.6 0.7 0.8 0.9 1

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HYDRODYNAMIC INSTABILITY
Hydrodynamic instability in a fluid film journal bearing is caused by hydrodynamic forces generated in the fluid film relative to the shaft displacement causing the shaft in whirling motion. Concept of Half Frequency Whirl
Center of Bearing U
Vcc Path of Journal Center

2a

c-a d

c+a

Vc =2afw

Rate of increase of area in lower half of bearing = Vcd=2afwd Oil transported into lower half = U(c+a) Oil transported out of lower half = U(c-a) Net amount transported into lower half Ua = dnsa = 2afwd fw = ns ns = Journal rotational speed in revolutions per second and fw = Whirl frequency Resonant Whip: At low eccentricity ratios (low load), when the rotational speed is about two times the first critical speed the system builds up a vibration at the first critical speed and gets locked in at that frequency. This form of vibration is referred to as resonant whip. Hydrodynamic instability in general, is caused by cross coupling stiffness in a fixed geometry journal bearing. The threshold of instability could be different for different types of fixed geometry bearings. The bearing geometries In order of increasing stability threshold speed could be Plain liner bearing Pressure dam bearing Elliptical bearing Offset half bearing Lobed bearing (Three Lobes, common)

 The bearing geometries of different fixed geometry bearings could be optimized for a certain application to increase the hydrodynamic stability threshold. Stability threshold in a fixed geometry bearing is dependent on the eccentricity ratio. The lower the eccentricity ratio, the lower the stability threshold. The stability threshold in a fixed geometry bearing is related to the attitude angle. In general, the higher the attitude angle, the lower the stability threshold. The tilting-pad journal bearing has low attitude angle (close to zero). Hence, in general, does not cause hydrodynamic instability.

FINITE DIFFERENCE METHOD (References 1 through 4)

REYNOLDS EQUATION

h P X + Z
3

h h P 6 = U Z X
3

(1)

Z (Axial)

Pi,j

X (Circumferential)

Pi+1,j

hi+1/2,j hi,j-1/2 Pi,j-1 Pi,j hi-1/2,j hi,j+1/2 Pi,j+1

Pi-1,j

P h = X
3

3 I , J +1 / 2

I , J +1

P h X X
I ,J I ,J 3

3 I J 1 / 2

P P X
I ,J

I , J 1

P h = Z Z h h h = X X
3

3 I , J +1 / 2

I , J +1

P h Z Z

I J 1 / 2

P P Z
I ,J

I , J 1

I , J +1 / 2

I , J 1 / 2

Solving for Pi,j

6 P =
I ,J

I , J 1 / 2

h X

i , j +1 / 2

The boundary conditions are: i= 1 i = n+1 j=1 j = n+1 i,j

D + ( ) h L D h ( ) L
2 3 2

i +1 / 2 , j

i +1 / 2 , j

P P +h +h Z Z +h +h h + Z X
i +1 , j 3 i 1 , j i 1 / 2 , j 2 2 3 3 3 i 1 / 2 , j i , j +1 / 2 2 2

3 i , j +1 / 2

P +h X
i , j +1 / 2 2

3 i , j 1 / 2

P X

i , j 1 2

i , j 1 / 2

P1,j = 0 Pn+2,j = Pn,j Pi,1 = Pinlet partial arc Pi,m+1 = Poutlet partial arc If (Pi,j)calculated < Pcavitation Pi,j = Pcavitation

Iteration convergence and extrapolation is documented in complete detail in reference 2.

Reference: Orcutt, F.K., Steady-State and Dynamic Properties of Journal Bearings in Laminar and Superlaminar Flow Regimes Tilting-Pad Bearings, NASA Contractor Report, NASA CR-732, April, 1967.

OB = Center of tilting pad bearing = Angle of pivot point P located from vertical load line OJ = Steady state position of the journal OBOJ = e0 = C0 Location of journal center OJ with respect to bearing center OB 0 = Attitude angle On = Steady state position of pad center OnOJ = e = C Location of pad center On with respect to journal center OJ. is the corresponding pad attitude angle. R = Journal radius C = Assembled radial clearance C = Machined radial clearance Ono = Center of curvature of pad with no tilting Projecting OJOn on OnoP results in ecos = e0cos(180-+0)+C-C Dividing throughout by C e/C cos = e0/C cos(180-+0) + 1 - C/C cos = 0 cos(180-+0 + 1 - C/C

cos = 1 - C/C - 0 cos(-0) This contains three unknowns, , , and 0 , 0 is the independent variable. Second equation is derived from the requirement that the force on the pad passes through the pivot point, which establishes relationship between and . The third relationship is the requirement that the total horizontal force component summed over all the pads is zero.

F sin = 0
All pads This condition is used to determine 0 by trial and error. For a particular case, 0, C/C, and are known. For several assumed values of 0, calculate cos for each pad. Determine the pad forces F. Plot F sin as function of 0. The zero point determines the desired value of 0.

Simplification: When pivot points are located symmetrically with respect to the vertical load line through the bearing center OB, then 0 = 0. Kxx = K cos2 Cxx = C cos2 Kxy = Kyx = K cos sin Cxy = Cyx = C cos sin Kyy = K sin2 Cyy = C sin2 Summation over all the pads making up the bearing gives the bearing spring and damping coefficients.

For symmetry around the X-axis and no pad inertia, the cross coupling terms disappear.

The finite difference method can be used for analyzing Plain liner bearing Pressure dam bearing Elliptical bearing Offset half bearing Lobed bearing (Three Lobes, common)

For analyzing tilting-pad journal bearings, single pad data is generated for the required L/D ratio, this data then is used to assemble for particular number of pads, load position, and preload per requirement.

TYPE OF BEARINGS

 p
Pad Clearance Circle

Pivot

Ob Oj R W Rp Rb

FIVE SHOE TILT PAD BEARING LOAD BETWEEN PADS NO PRELOAD CENTER PIVOT

 p
Pad Clearance Circle

Pivot

Rp Ob Oj R W Rb

FIVE SHOE TILT PAD BEARINGS LOAD BETWEEN PADS WITH PRELOAD CENTER PIVOT

Preload = 1 Cb/Cp = 1 - (Rb-R)/(Rp-R)

Rp Ob Oj R W Pivot Clearance Circle Rb

Pad

FIVE SHOE TILTING PAD BEARING LOAD ON PAD WITH PRELOAD CENTER PIVOT

 p
Pad Clearance Circle

Pivot

Rp Ob Oj R W Rb

FIVE SHOE TILTING PAD BEARING LOAD BETWEEN PADS WITH PRELOAD OFFSET PIVOT

PRESSURE DAM BEARING Ref. API 684 2nd Edition

ELLIPTICAL BEARING Ref. API 684 2nd Edition

OFFSET HALF BEARING Ref. API 684 2nd Edition

PRELOADED MULTI LOBE BEARING Ref. API 684 2nd Edition

Modeling Bearings
Bearings are Modeled Using Stiffness and Damping Characteristics Eight Dynamic Coefficients for Fixed Geometry Bearings (Plain Liner, Lobed Bearings) Four Dynamic Coefficients for Tilting Pad Journal Bearings No Cross Coupled Coefficients Tilt Pad Bearing Coefficients are dependent on Load Orientation Bearing Preload Pivot Offset Bearing Coefficients are Dependent on Sommerfeld Number Sommerfeld Number is Function of: Load Shaft Diameter Bearing Clearance (Range) Shaft Speed Oil Viscosity S= {(NLD)/W}(R/C)2

BEARING STIFFNESS VS. SPEED AND CLEARANCE - THRUST END

1.20E+06 Kyy MinC 1.00E+06 Kxx AvgC S T IF F N E S S ( L B ./IN .) 8.00E+05 Kxx MaxC Kyy AvgC Kxx MinC

6.00E+05

Kyy MaxC

4.00E+05

2.00E+05

0.00E+00 0 2000 4000 6000 8000 SPEED (RPM) 10000 12000 14000 16000

FIVE SHOE TILTING PAD JOURNAL BEARINGS LOAD ON PAD Vs. LOAD BETWEEN PADS
Stiffness in the vertical direction is considerably different from horizontal direction for load on pad configuration. Two distinct peaks may cause problem meeting required margins. For load between pads configuration the stiffness in the vertical and horizontal directions are closer to each other. Chances of having distinct peaks are less. In load on pad configuration the bottom pad carries most of the load. For lightly loaded bearing it will not cause problem, but for heavily loaded bearings it will. Particularly at slow roll. For load on pad configuration the pad thickness may have to be increased to reduce pad deflection due to heavy load application relative to load between pads configuration.

FIVE SHOE TILTING PAD JOURNAL BEARINGS LOAD ON PAD Vs. LOAD BETWEEN PADS (Continued)
Stability considerations Depends on the rotor/bearing configuration and the destabilizing effect of aerodynamic cross coupling. One may be better than other for particular application. Power loss More for load between pads configuration. Temperature rise More for load between pads configuration. Minimum film thickness - More for load between pads configuration. Eccentricity ratio - Less for load between pads configuration.

Tilting Pad Journal Bearings Vs. Fixed Geometry Bearings

Fluid film cross coupling terms present in a fixed geometry bearing causes instability beyond a certain speed for a given rotor-bearing system. The five shoe tilting pad journal bearing does not have the cross coupling terms, as a result it is inherently stable. Destabilizing influences due to oil seals, aerodynamic cross coupling effects etc. can be better controlled by a five shoe tilting pad journal bearing than a fixed geometry bearing. In tilting pad journal bearing the freedom of pad motion and deep recesses between pads give an effective safeguard against foreign particle damage to the pad surface. Freedom of pad motion designed in a tilting pad journal bearing provides misalignment capability not readily available in a fixed geometry bearing.

TILTING PAD JOURNAL BEARING TEST RESULTS PERFORMANCE DATA

EFFECT OF SLOW ROLL BOUNDARY LUBRICATION

During shutdown, large steam turbines are placed on turning gears in order to let the rotor cool uniformly. The turbine is usually driven at 9 to 15 RPM. Any compressor coupled to a turbine during shutdown will also be turning at these slow speeds. Experimental results obtained from a series of tests conducted on five shoe tilting-pad journal bearings are shown here which could be useful in general. Bearing torque (lb.in.) is presented as a function of bearing load (psi) at three different speeds 5, 10, and 20 rpm at a flow rate of 4 GPM. Friction coefficient is presented as a function of Sommerfeld Number. Bearing torque increases as the bearing load is increased at the same speed. Bearing torque is more with decrease in speed for the same bearing load. Friction coefficient increases with increase in Sommerfeld Number. Results could be different with different type of bearings.

Bearing Torque Vs. Bearing Load @ 4 GPM and 5 RPM 500 450 400 350
Bearing Torque (lb.in.)

300 250 200 150 100 50 0 0 50 100

Bearing Load (psi)

150

200

250

Bearing Torque Vs. Bearing Load @ 4 GPM and 10 RPM

500 450 400 350 300 250 200 150 100 50 0 0 50 100 150 200 250 300 350 Bearing Load (psi)

Bearing Torque (lb.in.)

Bearing Torque Vs. Bearing Load @ 4 GPM and 20 RPM

250

200 Bearing Torque (lb.in.)

150

100

50

0 0 50 100 150 200 250 Bearing Load (psi)

Bearing Torque Vs. Bearing Load @ 4 GPM

500
AT 5 RPM

450 400 350 300 250 200 150 100 50 0 0

AT 10 RPM AT 20 RPM

Bearing Torque (lb.in.)

50

100

150 Bearing Load (psi)

200

250

300

Friction Coefficient Vs. Sommerfeld Number @ 4 GPM and 5 RPM

0.17

0.16

0.15 Friction coefficient

0.14

0.13

0.12

0.11

0.1

0.09 0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 Sommerfeld Number x 10E-2

Friction Coefficient Vs. Sommerfeld Number @ 4 GPM and 10 RPM

0.11

0.105

0.1 Friction Coefficient

0.095

0.09

0.085

0.08

0.075

0.07 0 0.05 0.1 0.15 Sommerfeld Number x 10E-2 0.2 0.25 0.3

Friction Coefficient Vs. Sommerfeld Number @ 4 GPM and 20 RPM

0.075

0.07

Friction Coefficient

0.065

0.06

0.055

0.05 0 0.1 0.2 0.3 Sommerfeld Number x 10E-2 0.4 0.5 0.6

Friction Coefficient Vs. Sommerfeld Number @ 4 GPM

0.18
AT 5 RPM

0.16

AT 10 RPM AT 20 RPM

0.14 Friction Coefficient

0.12

0.1

0.08

0.06

0.04 0 0.1 0.2 0.3 0.4 0.5 0.6 Sommerfeld Number x 10E-02

REFERENCES
1. Orcutt, F.K., Steady-State and Dynamic Properties of Journal Bearings in Laminar and Superlaminar Flow Regimes Tilting-Pad Bearings, NASA Contractor Report, NASA CR-732, April, 1967. 2. Orcutt, F.K., Ng, C. W., Vohr, J. H., Arwas E. B., Lubrication Analysis in Turbulent Regime, NASA CR54195, October 1, 1964. 3. Lund, J. W., Spring and Damping Coefficients for the Tilting-Pad Journal Bearing, ASLE, Vol. 7, No. 4, October, 1964, pp. 342-352. 4. Orcutt, F. K., The Steady State and Dynamic Characteristics of the Tilting Pad Journal Bearing in Laminar , and Turbulent Flow Regimes, Journal of Lubrication Technology, Trans. ASME, Series F, Vol. 89, No. 3, July, 1967, pp. 392-404. 5. Lund, J. W., Arwas, E. B., Cheng, H. S., Ng, C. W., Pan, C. H. T., and Sternlicht, B., Rotor-Bearing Dynamics Design Technology, Part III: Design Handbook for Fluid Film Type Bearings, Technical Report AFAPL-TR-65-45, Air Force Aero Propulsion Lab, WPAFB, OH, May, 1965. 6. Lund, J. W., Rotor-Bearing Dynamics Design Technology, Part VII: The Three Lobe Bearing and F;oating Ring Bearing, Technical Report AFAPL-TR-65-45 Part VII, Air Force Aero Propulsion Lab, WPAFB, OH, February, 1968. 7. De Choudhury, Pranabesh , Dynamic Stability of Flexible Rotor-Bearing Systems, Ph.D. Dissertation, University of Virginia, Charlottesville, Virginia, June, 1971. 8. Nicholas, J. C., A Finite Element Dynamic Analysis of Pressure Dam and Tilting-Pad Bearings. Ph.D. Dissertation, University of Virginia, May, 1977 9. De Choudhury, Pranabesh , et.al., A Comparison of Film Temperatures and Oil Discharge Temperature for a Tilting-Pad Journal Bearing, Journal of Lubrication Technology, January 1981, Vol. 103 10. De Choudhury, Pranabesh , et.al., Performance Tests of Five Shoe Tilting-Pad Journal Bearing, ASLE Transactions, Vol. 27, pp 61-66

11. De Choudhury, Pranabesh , et.al., Slow Roll Tests on a Five-Shoe Tilting-Pad Journal Bearing, ASLE Transactions, Vol. 28, pp. 198-202 12. De Choudhury, Pranabesh , et.al., Test Results of Key and Spherical Pivot Five-Shoe Tilt Pad Journal Bearings Part 1: Performance Measurements, Tribology Transactions, Vol. 42 (1999) 3, 541-547 13. De Choudhury, Pranabesh , et.al., Test Results of Key and Spherical Pivot Five-Shoe Tilt Pad Journal Bearings Part 2: Dynamic Measurements, Tribology Transactions, Vol. 42 (1999) 3, 675-680 14. De Choudhury, Pranabesh , et.al., A Flexible Pad Bearing System for a High Speed Centrifugal Compressor, Proceedings of the 21st Turbomachinery Symposium, September 1992, pp. 57-64 15. Rotordynamic Tests of a Flexible Rotor on Flexure Pivot Journal Bearings and Stability Correlation with Frequency Dependent Characteristics, Proceedings of the 31st Turbomachinery Symposium, September 2002, pp. 39-47 16. Rotordynamic and Bearing Upgrade of a High-Speed Turbocharger, Journal of Engineering for Gas Turbines and Power, January 2003, Vol. 125