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A Study of The Effect of Various Recess Shapes On Hybrid Journal Bearing Performance Using Computational Fluid Dynamics and Response Sur PDF
A Study of The Effect of Various Recess Shapes On Hybrid Journal Bearing Performance Using Computational Fluid Dynamics and Response Sur PDF
A Study of The Effect of Various Recess Shapes On Hybrid Journal Bearing Performance Using Computational Fluid Dynamics and Response Sur PDF
Fig. 2 Five different recess shapes: (a) rectangular, (b) triangular, (c) circular, (d) elliptical, and (e) annular
Numerical Model
In this analysis, the baseline model is a five-pocketed hybrid
journal bearing with rectangular recess, as shown in Fig. 1. The
stator is shown in Fig. 1(a), and the fluid domain replicating the
air gap between the stator and rotor walls is illustrated in
Fig. 1(b). As shown in the figure, it is a common design for
hybrid bearings and is selected from the literature. All the differ-
ent recess shapes in this study have the same area, with a land
area ratio of 0.2. The numerical model is built using ANSYS CFX.
A 3D-CFD model is created for each recess geometry case. For
all the different geometries considered, the loading force is the
same. Figure 2 illustrates all the recess geometries investigated
in this study.
Operating conditions
Rotational speed N 16,400 rpm
Feeding oil temperature T 20 C Table 3 Comparison of calculated and experimental results
Feeding pressure Pf 7 MPa
Loading force F 10,200 N Method Load force (N) Difference
bulence model, which is k–e in this study. The values of k and e five inlet ports, the outlet oil pressure is the atmosphere pressure,
are derived from the following equations: the total energy is considered, the stator and rotor surfaces are set
" # to be adiabatic walls, and the turbulence model selected is k–e.
The working conditions are shown in Table 1.
@ ðqkÞ @ @ lt @k
þ ðqUi kÞ ¼ lþ þ pk qe þ pkb
@t @Xj @Xi rk @Xj
Mesh Independence Study and Baseline Model Validation.
(4)
In this study, all the different geometry cases are meshed using
" # the same strategy. The main fluid film is meshed using the swept
@ ðqeÞ @ @ lt @e e method. The mesh independence study indicates that 15 layers
þ ðqUi eÞ ¼ lþ þ Gðpk ; qe; peb Þ
@t @Xj @Xi re @Xj k across the fluid film are needed to discretize the space between the
stationary and rotating walls. In the five recesses, unstructured
(5) mesh with inflation layers along all the boundaries is employed.
The five pockets and main fluid film region are connected using
where e represents the turbulence eddy dissipation, pkb and peb are
general grid interface connections. In order to decide a suitable
the buoyancy forces, pk represents the turbulence production due
mesh density, it is necessary to make sure that the solution is inde-
to viscous forces, rk and re are the constants, and lt is the turbu-
pendent of mesh resolution. A mesh independence study is con-
lence viscosity, which is linked to turbulence kinetic energy and
ducted for the baseline model (the bearing model with rectangular
dissipation by the following relationship:
recesses as shown in Table 2). In the mesh independence study,
the numerical results are considered to be independent of mesh
k2
lt ¼ Cl q (6) density when the load force shows little variation as the density
e increases. For the baseline model, the mesh density is increased
gradually by changing the number of element layers across the
thin film. In Table 2, the first mesh has two layers and the last
Boundary Conditions. The boundary conditions used for the mesh has 20 layers. It can be observed that the results for the last
analysis are as follows: the inlet oil pressure is 7 MPa at all the three meshes are very similar. Therefore, the results can be
considered as independent of the mesh density. The fourth mesh eccentricity ratio and attitude angle are selected as design varia-
in the table is selected for the baseline model to ensure the accu- bles in the design of experiments (DOE) process. Table 4 shows
racy as well as save computing time. The resulting mesh density the range chosen for each design variable. The objective functions
is approximately 1.9 106 elements. As shown in Table 2, this is selected are the vertical reaction force and lateral reaction force
the minimum mesh density that gives a mesh-independent solu- on the shaft. The position of the shaft for a given load and work-
tion. Figure 3 shows the mesh of the model with a rectangular ing condition can be obtained by using this response surface
recess. method. Figure 4 shows the overall scheme of this analysis. All
The model with rectangular recesses employed in this study the geometrical shapes of recess studied are compared together
was experimentally tested by Franchek and Childs [1]. Table 3 under the same loading force. All the journal positions are calcu-
presents the comparison between the load capacity derived from lated using the statistical method instead of the traditional iterative
the CFD model and the experimental data from the literature [1]. method, which is time-consuming.
As Table 3 shows, the numerical results are in good agreement The DesignXplorer Systems in ANSYS is used to construct the
with the experimental data. response surface model. Sampling points are selected using the
DOE technique [22]. Central composite design [23] is employed
Response Surface Model. A response surface method is used in this study. Central composite design is very efficient to build a
to obtain the equilibrium position for the journal in this study. The second-order model for the response variables. By using this
technique, a complete three-level factorial experiment design is approach than the normal screening method. After each search, a
avoided, making this response surface model complete quickly. set of candidate points are generated and the point that displays
After solving all the design points in the DOE process, the results the minimum difference with the applied load force is selected as
are used to create a quadratic response surface model. The rela- a refinement point in this study. Then, an additional search is con-
tionship between the reaction force of the fluid film and the shaft ducted based on the refinement point. Through these refinements,
position is then established. A forward stepwise regression the ultimate equilibrium position is then derived. For each recess
method is used to remove the terms that are insignificant in the geometry, the shaft position is derived using the above method.
regression model. A partial F-test is utilized to determine the sig- To validate the response surface method used in this analysis, the
nificance of the individual terms [24]. Based on this surface results for the equilibrium position of the hybrid bearing with rec-
response model, a further optimization scheme is used to find the tangular recesses have been compared with the published data [1],
journal position. In this study, an objective-driven system is used as shown in Fig. 5.
to search for the shaft position. The objectives of the optimization
process are to derive a vertical reaction force that equals the
applied load force and to derive a zero lateral reaction force.
Thus, at this position, the shaft is in equilibrium. To achieve this Results and Discussion
goal, the multi-objective genetic algorithm is used in the response Based on the method discussed previously, the quality of the
surface optimization. This algorithm provides a more refined response surface method and the static performance of the hybrid
bearing for each recess geometry are analyzed. All the different surface response plot for the elliptic recess shows a concave
recess shapes have the same land area ratio of 0.2. shape, which is different from the other plots. A strong interaction
effect exists between the attitude angle and eccentricity ratio.
Equilibrium Position. Table 5 shows the equilibrium position To evaluate the quality of all the response surface models used
of the journal for each geometrical shape of the recess considered in this study, the goodness of fit is analyzed. From Fig. 7, it can be
under the same applied load force of 10,200 N. As shown in the seen that the predicted results are in good agreement with the
table, the eccentricity ratio of the elliptic recess is the largest, observed results. All of the scatter points in the plots are very
while that of the triangular recess shape is the smallest. Therefore, close to the diagonal lines. Therefore, the response surface model
the shape of the recess has a significant effect on the position of fits the data very well. Table 8 shows the coefficient of determina-
the shaft. As the eccentricity ratio is correlated with the minimum tion and adjusted coefficient of determination for each of the
fluid film thickness, the value of hmin is also affected by the shape recess shapes. In the table, all of the coefficients are very close to
of the recess. As a result, the fluid film needed to support the the unit, which indicates that all the regression models used to
shaft during the transient stage would vary with the recess shape. predict the shaft position explain 99% of the response variation
Table 6 shows the variation of the flow rate with respect to differ- about the mean value. Also, the differences between the coeffi-
ent geometric shapes. It can be observed that the flow rate is high- cient of determination and adjusted coefficient of determination
est for the annular recess and lowest for the circular recess. With are very small. So, the regression models of all the geometrical
this table, when designing the recess shape for hybrid bearings, an shapes of the recess are very accurate for predicting the fluid film
appropriate shape can be selected economically by considering reaction force.
the flow rate. From the pumping power perspective, a circular
recess shape is superior since it results in a lower flow rate under Bearing Flow Pattern. Figure 8 shows the fluid film pressure
the same loading conditions, thus requiring less power to pump. distribution on all the different geometric shapes of recess consid-
Table 7 shows the friction torque for each case. As shown in the ered in this study. It can be observed that pressure values are
table, the highest friction torque was generated by the circular higher in the recess area. Among all these shapes, the rectangular
recess, while the lowest friction torque was associated with the and elliptical shapes display little pressure variations inside the
elliptical recess. recess. It can also be observed from Fig. 8(a) that peak values of
pressure occur near the edge of the recess. In the rectangular case,
this location is close to the minimum film thickness, where the
Response Surface Model. Figure 6 shows the surface response convergence region starts to diverge. As shown in the figure,
plots for the response models generated for each of the individual therefore, the occurrence of peak values may be due to the fact
geometric shape of recess. From these figures, it is clear that the that the turbulence intensity of the flow around the minimum fluid
film thickness position is very high, so that a high-pressure spot is phenomenon dynamically. However, in the current steady-state
formed at the end of the convergence region. Once the flow enters model, the low-pressure area is very small compared to the overall
the divergence region of the fluid film, the pressure encounters a bearing land area, thus its effect on the load capacity is limited.
rapid decrease, which leads to a low-pressure spot. The low pres- Therefore, the effect of the low-pressure spot on the rotor surface
sure is also considered as an indication of cavitation, where the can be neglected.
liquid turns into the gas phase due to the low pressure. Liquid cav- Figure 9 shows the temperature distribution on the fluid film for
itation can influence the load capacity, the rotordynamic stability each geometrical shape of the recess. In this study, the supply oil
of the system, and also can cause damage to the stator surface. is set at a temperature of 20 C. It can be noticed that the triangu-
Numerous numerical models can predict the cavitation lar, elliptical, and annular shapes show smaller temperature rise
among all the cases. Also, it can be seen that the temperature of film. It can be seen in the figures that a vortex occurs near the
the oil is increasing as the oil flows out. Therefore, the highest corner region. For the annular recess, two vortices are formed
temperature occurs near the outlet region. Although all the recess near the oil inlet port. This is because the circumferential length
shapes have the same land area ratio of 0.2, different shapes still of annular recess is very small, and thus, the vortex occurs on
significantly affect the temperature distribution in the fluid film both sides of the inlet flow, which will increase the power loss
under the same loading conditions. due to the turbulence. Also, on the left corners, the flow pattern
The flow inside the recess for each case is also compared in is almost the same, except for the rectangular recess shape. In
Fig. 10. The recess shown in the figure is one of the five all other recess shapes, a vortex is followed by a flow distortion
recesses that lies on the vertical axis along the loading direction. near the wall on the left side of the recess. In the rectangular
The streamlines displayed are on the cross section of the fluid recess case, however, there is no flow distortion following the
Fig. 9 Temperature distribution on the rotor surface: (a) rectangular, (b) triangular, (c) circu-
lar, (d) elliptical, and (e) annular
vortex. This maybe due to the fact that, in the axial direction, integrity and not be divided into a small vortex and a flow dis-
the rectangular recess has the maximum length. Therefore, the tortion near the wall. On the other hand, from the power loss
fluid inside the recess can be fully developed in the axial direc- perspective, a smaller vortex may cause less energy loss due to
tion. As a result, the vortex formed near the corner can keep its the high viscosity of the oil.
Table 9 shows the vortex core vorticity, vortex core radius, and Conclusions
vortex core position for each recess shape. The coordinate used
for vortex core position is demonstrated in Fig. 10(a). The origin In this study, the effect of various geometric shapes of recess on
is located at the right corner of each recess. As shown in the table, the performance of a five-pocket hybrid journal bearing under the
for rectangular and triangular recess, the vorticity of the right same loading conditions is analyzed. The recesses considered
corner vortex is smaller, but for the remaining three cases, the vor- include rectangular, triangular, circular, elliptical, and annular
ticity near the left corner is smaller. The vorticity distribution on shape. In addition, a new method based on the response surface
the same plane is also displayed in Fig. 11. As can be observed model is employed to determine the equilibrium position of the
from these figures, the maximum vorticity occurs around the inlet journal for each recess shape. The results show that the geometric
orifice. shape of the recess is critical for bearing performance. In the
surface response model method, the central composite design and following trend: htriangular>hrectangular > hcircular > hannular > helliptical.
multi-objective optimization techniques are used. By comparing Also, the value of lubricant flow rate, Q, is significantly affected by
with the published experimental data, the method proposed in this the recess shape. Under the same loading force, the maximum flow
study to determine the journal position is found to be efficient and rate corresponds to the annular recess and the following pattern
accurate. The fluid film thickness varies with different geometrical is obtained: Qannular > Qelliptical > Qtriangular > Qrectangular > Qcircular.
shapes under the same loading force. According to the numerical The friction torque is critical from the power loss perspective. The
results, the comparison of minimum fluid film thickness shows the results for friction torque corresponding to different recess shapes are
Table 9 The properties of the vortex core near the corner of the recesses
Recess shape Vortex core vorticity (s1) Vortex core radius (mm) Vortex core position (mm)
found to follow this pattern: Tcircular > Ttriangular > Trectangular > Tannular Acknowledgment
> Telliptical. All the different recess shapes have almost the same flow
Gen Fu was selected as one of the 2016 ASME FED Graduate
pattern in which a vortex occurs near the inside corner of the recess.
Scholars of the Year.
The rectangular recess shows a larger vortex near the entrance of the
recess compared to the other geometrical shapes of the recess.
The results suggest that recess shape is a dominant factor
in hybrid bearing design. This study proposed a new design pro- Nomenclature
cess for a 3D-CFD bearing model with the ability to calculate Al ¼ area of the land
equilibrium position and is expected to be useful to bearing Ar ¼ area of the recesses
designers. F ¼ lift force
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