Professional Documents
Culture Documents
Numerical and Experimental Investigation PDF
Numerical and Experimental Investigation PDF
Numerical and Experimental Investigation PDF
Link to publication
Citation (APA):
Larsen, J. S., Cerda Varela, A. J., & Santos, I. (2014). Numerical and experimental investigation of bump foil
mechanical behaviour. Tribology International, 74, 4656. 10.1016/j.triboint.2014.02.004
General rights
Copyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright owners
and it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights.
Users may download and print one copy of any publication from the public portal for the purpose of private study or research.
You may not further distribute the material or use it for any profit-making activity or commercial gain
You may freely distribute the URL identifying the publication in the public portal ?
If you believe that this document breaches copyright please contact us providing details, and we will remove access to the work immediately
and investigate your claim.
www.elsevier.com/locate/triboint
PII:
DOI:
Reference:
S0301-679X(14)00055-3
http://dx.doi.org/10.1016/j.triboint.2014.02.004
JTRI3249
To appear in:
Tribology International
Abstract
Corrugated foils are utilized in air foil bearings to introduce compliance and damping thus accurate mathematical
predictions are important. A corrugated foil behaviour is investigated experimentally as well as theoretically. The
experimental investigation is performed by compressing the foil, between two parallel surfaces, both statically and
dynamically to obtain hysteresis curves. The theoretical analysis is based on a two dimensional quasi static FE
model, including geometrical non-linearities and Coulomb friction in the contact points and neglects the foil mass. A
method for implementing the friction is suggested. Hysteresis curves obtained via the FE model are compared to the
experimental results obtained. Good agreement is observed in the low frequency range and discrepancies for higher
frequencies are thoroughly discussed.
Keywords:
gas foil bearing, foil structure, nite element method, friction, hysteresis
1. Introduction
The static and dynamic characteristics of compliant
foil bearings are determined by the behaviour of the
uid lm and a exible element underneath the bearing surface altering its compliance. Several congurations are possible to obtain compliance, being the usage
of corrugated bump foils one of the most widely used.
The addition of these compliant elements into the design enables to introduce additional damping to the one
generated in the uid lm. The increase of the energy
dissipation is obtained due to the sliding friction forces,
generated as the bearing surface deforms and induces
displacements in the foil layers. However, the mechanism for obtaining the additional damping characteristics exhibits highly non-linear behaviour, which introduces signicant complexities considering the obtention
of an acceptable level of predictability for this bearing
design.
The challenges related to the technology have generated a signicant number of publications, dealing with
the theoretical modelling and experimental testing of
bump foil bearings. The presentation given here tries to
follow a chronological progression, and focuses on the
Email addresses: josla@mek.dtu.dk (Jon S. Larsen),
acer@mek.dtu.dk (Alejandro C. Varela), ifs@mek.dtu.dk (Ilmar
F. Santos)
Preprint submitted to Tribology International
2. Theoretical Model
a)
A theoretical model of the foil structure has been developed and implemented. It takes into account large
bump foil deections and Coulomb sliding friction. The
model is based on a non-linear FE procedure following
the iterative Newton-Raphson (NR) approach derived in
Appendix A. The foil structure is discretized following
the virtual work principle (VWP) and a bilinear quadrilateral (Q4) iso-parametric plain strain element and the
Green-Lagrange strain measure for large displacements
are implemented.
The mathematical model is quantied in terms of the
residual vector {R} and the tangent matrix [Kt ] which,
combined with the NR approach, solves for the displacement vector {D}. With the exception of the friction elements, the derivation of these quantities are thoroughly described in the literature [22, 23] and for the
sake of briefness omitted here.
wrong. However, by choosing the stiness k to be nonlinear and softening, the reaction force versus deection can be made constant and fullling (1). Choosing
a proper stiness function for k, can even eliminate the
problem of determining the magnitude of the friction
force F when there is no motion xr = 0. This corresponds to (2).
2.1.1. Non-linear Spring Element
The objective is to derive a non-linear spring element to be used in the implicit incremental NR scheme,
which will mimic the behaviour of a friction force. The
schematics and nomenclature of the spring are illustrated in Fig. 2.
The VWP for a general elastic body may be stated as
[23, 22]:
(1)
{} {}dV =
{u} {F}dA +
T
and
Fn F Fn ,
if xr = 0
Fn ,
F =
Fn ,
b)
(2)
{u}T {}dV
V
{u}Ti {p}i .
+
i
(3)
Assuming body forces negligible and writing the internal work as a summation over the elements and assuming the external forces are only applied in nodes (i.e.
deformed
i
j
i
y, v
ui
undeformed
j
x = xj xi uj
x, u
Figure 2: Deformed and undeformed one dimensional spring
Ve
[Kt ] =
{R}
N e d e
=
L
{B0 }
{D}
{D} 0
e
N e
=
{B0 }{B0 }T L0e
(13)
T {d}
= { B}
(6)
ke (u) =
Fn
|u| + s
(15)
where s is introduced to avoid zero division and to obtain a smoothing element force curve. The element stiness and force curves are illustrated in Fig. 3.
Examining the element force curve N e (u) in Fig. 3,
it is clear that the stiness function (15) is a good choice
as it produces a force curve very similar to that of a
L1 L0 (x j u j ) (xi ui ) (x j xi ) u
=
=
L0
(x j xi )
x
(8)
where u = u j ui . By use of (7) and (8), the strain can
now be written as
=
1
(9)
{1 0 1 0}T = {d}T {B0 }
L0
where the strain displacement vector {B0 } is independent of the displacements and hence it is given the zero
subscript. The variation in strain (6) then becomes
= {d}T {B0 }, which inserted into (5) gives
{d}T {B0 }N e L0e = {D}T {P}.
(10)
Stiness, k e
20
15
10
5
0
10.5 0 0.5 1
u
Friction force, N e
= {d}T
1
0.5
0
0.5
1
10.5 0 0.5 1
u
tb
h0
0
l0
S
Parameters
Bump foil thickness, tb
Bump foil height, h0
Bump foil pitch, S
Bump half length, l0
Bump foil width, wb
Youngs modulus of bump foil, E
Poissons ratio of bump foil,
Coecient of friction,
Fn
(16)
|u u s | + s
where u s is set to u in the event of changing sliding
direction.
ke (u u s ) =
Values
0.127 mm
0.9 mm
7.00 mm
3.30 mm
18 mm
2.07 1011 Pa
0.3
0.20
3
2S l0
Q
(1 2 )
E tb
(17)
0.4
Stiness [GN/m3 ]
Dimensionless deecction, w
0
=0
= 0.2
0.2
0.5
3
2
1
0
10
20
30
Walowit
FEM
40
0.1
0.2
0.3
Friction coecient,
Angular extend, 0
10
Stiness [GN/m3 ]
0.3
0.2
= 0.1
=0
2
0
Active bumbs, Nb
Figure 8: Stiness calculated numerically - varying coecients of
friction and number of bumps in the foil strip
for the oscillation around 5 m. In this case, the conned area grows signicantly leading to more Coulomb
damping, and the stiness becomes highly non-linear,
as it changes signicantly at the points where the local
load-displacement coincide with the global hysteresis
loop. Tracking the global hysteresis curve corresponds
to the situation where all contact points are sliding.
This can be seen in Fig. 10. Here a strip of four
bumps, as illustrated in Fig. 10a, is subjected to displacement oscillations upon given a compression of
20 m. The displacement oscillations are of amplitudes
1, 3, 5 m and the corresponding hysteresis curve is
seen in Fig. 10b. In Fig. 10c, the friction forces versus the horizontal displacement for ve selected contact
points are illustrated. These hysteresis loops visually illustrates the amount of energy dissipation taking place
in each of the selected contact points. For the low amplitude of 1 m (green line), it is clear that the movement
6
(a)
(a)
W [N]
60
40
#2#3
#1
#4#5
#6#7
#8
20
(b)
10
15
20
80
25
(b)
W [N]
60
W [N]
60
40
40
20
14
20
16
18
20
22
24
10
15
20
(c)
25
#3
2
F [N]
Figure 9: Theoretical results of a bump strip, given a global compression of approximately 25 m with local oscillations of 1.5 m
amplitude occurring at approximately 5, 10, 15, 20 m during the
loading process. (a) Using a coecient of friction = 0.1 (b) Using
a coecient of friction = 0.2
#5
#6
#7
#8
in sliding points #1 through #5 is zero, meaning that energy is only dissipated in the contact points #6, #7, #8.
For the higher amplitudes of 3 m and 5 m, (red and
blue lines respectively) all the points are sliding when
the local load-displacement curves (Fig. 10b) tracks the
global curve.
It is important to highlight how a relatively small increase in the load amplitude, from 15 N to 20 N, will increase the energy dissipation by approximately 10 times
and at the same time, the energy dissipation only doubles for an amplitude increase from 20 N to 25 N. This
is a consequence of the left most bumps being pinned
for the lowest load amplitudes, and it illustrates the importance of the bump geometry and friction properties
in terms of maximizing the energy dissipation. For instance, the dissipated energy would have been much
higher, for an amplitude of 15 N, if the coecient of
friction had been lower, since this would have prevented
bumps from being pinned.
10
20
30
40
50
4. Experimental Results
In order to validate the implemented numerical model
of the bump foil, its results are compared to experimental results. In this section, the focus is set on the static
as well as the dynamic behaviour of the bump foil. The
data is obtained using an experimental test rig at the
Technical University of Denmark (DTU), designed and
constructed specically for this purpose.
7
whereas dynamic load is obtained by using an electromagnetic shaker, a steel stinger with a diameter of 2 mm
and a piezoelectric load cell, see number 4 in Fig. 11.
4
=
b
200
W [N]
Figure 11: Test setup for characterizing the static and dynamic properties of the bump foil
Nb
=2
100
50
100
150
200
250
Good agreement between the experimental and theoretical results are found when using a coecient of
friction = 0.2 for the simulations. This value corresponds well with common values which is typical in the
range 0.1 < < 0.5 for steel against steel (0.5 in vacuum) and also with the results obtained by e.g [5, 12].
For strips with higher number of bumps, higher global
stiness and larger discrepancies with theoretical results
are observed. The results obtained for a strip with 6
bumps, see Fig. 13, portray these trends. The discrepancies can be attributed to geometrical imperfections of
8
W [N]
400
Nb
In order to check for the inuence of the test rig arrangement on the measured hysteresis curves, the foil
specimen was replaced with a coil spring. Assuming
that the damping contribution from this element is negligible, the setup enabled to determine the baseline damping coming from the test rig. Up to 60 Hz of excitation
frequency, such eect was found to be negligible, compared with the energy dissipation observed when the foil
specimen was tested.
The rst set of results compare the static and dynamic
testing results obtained for a four bump foil strip, see
Fig. 14. The static results are obtained by loading the
foil using calibrated weights, whereas the dynamic ones
correspond to a preload of 40 N and a dynamic loading frequency of 1 Hz. The amplitude of the dynamic
loading is tuned to obtain four dierent displacement
amplitudes. Although the results obtained with a loading frequency of 1 Hz do not have relevance from the
practical point of view, they do enable to establish a direct link between the static results shown in the previous
section and the dynamic ones presented here.
In Fig. 14, the local hysteresis curves follow an almost purely harmonic motion for small displacement
amplitude, and they are placed inside the global loop.
However, when the displacement amplitude surpasses a
threshold value, they start to track the global hysteresis curve. For that condition, two stages can be easily
recognized in both the loading and unloading path of
the cycle, characterized by two dierent slopes for the
curve. These results are qualitatively coincident with
the results from the quasistatic theoretical model shown
before in Fig. 10b, regarding the dependence of the hysteresis loop shape on the motion amplitude. According
to the theoretical model, the high slope behaviour can
be explained by the fact that some bumps of the strip
are sticking, hence the stiness is dominated by elastic deformation of the bumps. When they start to slide,
the hysteresis path switches to a low slope behaviour,
where the stiness is dominated by the friction forces.
Since the local hysteresis curves are amplitude dependant, both the stiness and damping properties are
strongly inuenced by it. Even though for small motion amplitude it could be possible to assume that the
resulting foil displacement is harmonic, once the local
curve hits the global one a highly non-linear motion is
achieved. This behaviour could have signicant eects
when calculating an equivalent linearised damping coecient based on the energy dissipated during one local hysteresis cycle, since such analysis is based on assuming pure harmonic motion for the load displacement
curve.
In order to check for loading frequency dependency
200
20
40
60
80
100
150
Force [N]
Force [N]
100
100
50
50
20
40
20
60
40
60
Displacement [m]
Displacement [m]
Figure 14: Comparison of the static (dashed blue line) and dynamic
testing results, for dierent displacement amplitudes (2 (blue), 4 (red),
8 (green), 12 (black) microns). The applied load frequency is 1 Hz.
The preload is 40 N, and the foil strip contains 4 bumps.
Force [N]
100
50
20
40
60
Displacement [m]
Figure 16: Results of the dynamic testing, for dierent displacement
amplitudes (2 (blue), 4 (red), 8 (green), 12 (black) microns). The
applied load frequency is 10 Hz. The preloads are 40 N and 90 N. The
foil strip contains 3 bumps.
80
100
slip
Force [N]
Force [N]
60
50
stick
40
stick
20
slip
20
40
60
Displacement [m]
20
30
40
Figure 19: Comparison of results for the dynamic testing: local hysteresis loop measured for loading frequency 1 Hz (blue) and 40 Hz
(red). The foil strip contains 3 bumps and the preload is 40 N.
cient was obtained experimentally to 0.4 in the beginning of the slip and dropped signicantly to 0.1
over the acceleration stage where after it remained constant. Their experiments did not deal with the transition between the stick and slip phase. However, the
results may still serve to explain why the global hysteresis curve become narrower at increasing frequency
i.e. higher accelerations close to the transition between
stick and slip.
Other literature in the eld of tribology addresses the
eect of vibration in the normal direction of two mating surfaces over the friction coecient. Chowdhury
and Helali [26] performed an experiment regarding this
issue. A clear trend is observed, regarding the reduction of the friction coecient with both the amplitude
and the frequency of the normal vibration, for dierent
tested materials. These authors relate the observed trend
to an eventual reduction of the eective contact area between the mating surfaces when vibrations are taking
place. This eect may also be relevant for the bump foil
strip, as the normal loads in the contact points is oscillating.
Force [N]
100
50
40
10
Displacement [m]
20
60
Displacement [m]
Figure 18: Results of the dynamic testing, for dierent displacement
amplitudes (2 (blue), 4 (red), 8 (green), 12 (black) microns). The
applied load frequency is 40 Hz. The preloads are 40 N and 90 N. The
foil strip contains 3 bumps.
approach for modelling the friction forces was implemented, based on the usage of non-linear spring elements. The results from the numerical model regarding
load-displacement behaviour have been compared with
theoretical and experimental results coming from the literature, as well as experimental data obtained from a
dedicated test rig.
The numerical model was compared to previously
published analytical results [4]. For the stiness of a
single bump (free-free) good agreement between analytical and numerical results were observed at dierent
coecients of friction. The analytically calculated stiness is commonly used in combination with the simple
elastic foundation model. However, for a strip consisting of several bumps (xed-free), the numerical model
indicated that the analytical method signicantly underestimates the stiness, hence the simple elastic foundation model is generally underestimating the contribution of the structural stiness.
The hysteresis loops obtained numerically, corresponded well with the experimentally obtained hysteresis loops for low load frequencies < 5 Hz and both stiness and damping was found to be highly non-linear.
The numerical model was able to reproduce both the
global load-displacement curves as well as the local
ones, considering smaller vertical displacements around
an equilibrium position. Two distinctive patterns of motion were observed for the local hysteresis loop based
on the theoretical and experimental results. If the vertical displacement perturbations are small enough, then
the hysteresis loop tends to follow a sinusoidal motion,
where the dominant eect corresponds to the bumps
exibility since most of the bumps are pinned due to
friction forces. If the displacement surpasses a threshold value, then the local hysteresis loop tracks the global
one, exhibiting two distinctive slopes associated with
the dominance of the bumps elastic forces or the sliding
friction forces respectively. In this condition, the transition towards sliding friction behaviour greatly enhances
the energy dissipation properties of the foil, and the
resulting vertical displacements deviates signicantly
from the purely harmonic motion.
The experimental determination of the local hysteresis curves for higher loading frequencies revealed that
both the stiness and equivalent damping properties of
the bump are strongly load frequency dependant. At
higher frequencies, the experimental results deviates
signicantly from the theoretical as the hysteresis loops
tend to atten and the energy dissipated per load cycle reduces signicantly. This phenomenon tends to alter the stiness such that it becomes less non-linear but
still of the same approximate magnitude. For small load
based
on
the
(A.1)
If Dni
n
R(Dni+1 ) R(Dni ) +
dR(Dni )
Dni = 0.
dD
(A.2)
dR(Dni )
(A.3)
Kt
dD
then the equilibrium equation (A.2) can be written as
Kt Dni = R(Dni )
(A.4)
(A.5)
or inserting (A.1)
(A.6)
The tangent is then updated with the new displacement Dni = Dni+1 and the procedure is repeated until the
norm of the residual is suciently small. Here, the NR
method was derived for a scalar problem, but it is directly applicable to vector problems.
References
[1] C.-P. R. Ku, H. Heshmat, Compliant foil bearing structural stiness analysis: Part i-theoretical model including strip and variable bump foil geometry, Journal of Tribology 114 (1992) 394
400.
[2] C.-P. R. Ku, H. Heshmat, Structural stiness and coulomb
damping in compliant foil journal bearings: theoretical considerations, Tribology transactions 37 (1994) 525533.
[3] C.-P. R. Ku, H. Heshmat, Structural stiness and coulomb
damping in compliant foil journal bearings: parametric studies,
Tribology transactions 37 (1994) 455462.
[4] J. A. Walowit, J. N. Anno, Modern developments in lubrication
mechanics, Applied Science Publishers London, 1975.
[5] C.-P. R. Ku, H. Heshmat, Compliant foil bearing structural stiness analysis. ii: Experimental investigation, Journal of tribology 115 (1993) 364369.
[6] J. P. Peng, M. Carpino, Coulomb friction damping eects in
elastically supported gas foil bearings, Tribology transactions
37 (1994) 9198.
[7] H. Heshmat, C. P. Ku, Structural damping of self-acting compliant foil journal bearings, Journal of tribology 116 (1994) 7682.
[8] C.-P. R. Ku, H. Heshmat, Eects of static load on dynamic
structural properties in a exible supported foil journal bearing,
ASME Transactions Journal of Vibration Acoustics 116 (1994)
257262.
[9] D. Rubio, L. San Andres, Bump-type foil bearing structural
stiness: Experiments and predictions, ASME Conference Proceedings 2004 (2004) 671679.
[10] D. Rubio, L. San Andres, Bump-type foil bearing structural
stiness: experiments and predictions, Journal of Engineering
for Gas Turbines and Power(Transactions of the ASME) 128
(2006) 653660.
[11] I. Iordano, Analysis of an aerodynamic compliant foil thrust
bearing: method for a rapid design, Journal of tribology 121
(1999) 816822.
[12] L. Rubio, D.and San Andres, Structural stiness, dry friction
coecient, and equivalent viscous damping in a bump-type foil
gas bearing, Journal of engineering for gas turbines and power
129 (2007) 494502.
13