Search Results (17)

In recent years, due to the growing imbalance between energy consumption and available resources, as well as strict CO₂ emission regulations, turbochargers have become increasingly important in applications such as automobiles, ships, and aerospace. Turbochargers can effectively increase the intake volume of engine cylinders, improving fuel combustion efficiency and engine power. In order to meet the growing demand for more energy-efficient, lower-carbon-emission systems, it is necessary to design more compact, efficient, durable, and affordable supercharging systems. Compared with traditional floating ring bearings, rolling bearing turbochargers have become a greater focus of research due to their excellent transient performance, low friction loss, and strong load-bearing capacity. Due to the large number of components, complex structure, lightweight high-load rotor, complicated operating conditions, and unclear nonlinear vibration mechanism of rolling bearing turbochargers, it is necessary to establish a refined model to clarify how factors such as bearing and squeeze film damper parameters and rotor operating parameters affect the system response. Therefore, this study reviews relevant research in this field from the perspectives of modeling and system characteristics and points out directions for future research. Full article

This study presents a detailed experimental comparison of the rotordynamic and thermal performance of automotive turbochargers supported by two distinct hydrodynamic bearing configurations: fully floating ring bearings (FFRBs) and semi-floating ring bearings (SFRBs). While both designs are widely used in commercial turbochargers, they exhibit significantly different dynamic behaviors due to differences in ring motion and fluid film interaction. A cold air-driven test rig was employed to assess vibration and temperature characteristics across a range of controlled lubricant conditions. The test matrix included oil supply pressures from 2 bar (g) to 4 bar (g) and temperatures between 30 °C and 70 °C. Rotor speeds reached up to 200 krpm (thousands of revolutions per minute), and data were collected using a high-speed data acquisition system, triaxial accelerometers, and infrared (IR) thermal imaging. Rotor vibration was characterized through waterfall and Bode plots, while jump speeds and thermal profiles were analyzed to evaluate the onset and severity of instability. The results demonstrate that the FFRB configuration is highly sensitive to oil supply parameters, exhibiting strong subsynchronous instabilities and hysteresis during acceleration–deceleration cycles. In contrast, the SFRB configuration consistently provided superior vibrational stability and reduced sensitivity to lubricant conditions. Changes in lubricant supply conditions induced a jump speed variation in floating ring bearing (FRB) turbochargers that was approximately 3.47 times larger than that experienced by semi-floating ring bearing (SFRB) turbochargers. Furthermore, IR images and oil outlet temperature data confirm that the FFRB system experiences greater heat generation and thermal gradients, consistent with higher energy dissipation through viscous shear. This study provides a comprehensive assessment of both bearing types under realistic high-speed conditions and highlights the advantages of the SFRB configuration in improving turbocharger reliability, thermal performance, and noise suppression. The findings support the application of SFRBs in high-performance automotive systems where mechanical stability and reduced frictional losses are critical. Full article

High-speed rolling bearings exhibit low friction, high mechanical efficiency, low lubrication requirements, and excellent acceleration performance. The replacement of floating ring bearings in turbochargers with rolling bearings is an important tendency for modern turbochargers. However, due to the nonlinearity in rolling bearings, the nonlinear vibration characteristics of the turbocharger rotor system need to be clearly revealed. The turbocharger rotor is modeled by a lumped mass model. The nonlinear rolling bearing model is derived using the Hertz contact theory. The vibration responses of the nonlinear system are obtained by the modified incremental harmonic balance (MIHB) method. The results demonstrate that the MIHB method significantly improves computational efficiency compared to the traditional fourth-order Runge–Kutta method for solving this class of problems while also being capable of obtaining complete solution branches of the system. The stability of the responses is determined by the Floquet theory. Based on the present rotor dynamic model, the conical mode and cylindrical mode are found. Resonance peaks at 4.5 × 10⁴ rpm (conical mode) and 1.1 × 10⁵ rpm (bending mode) are identified as critical vibration thresholds. Moreover, the vibration amplitude results show that the resonance peak of the bending mode is mainly due to the nonlinearity of the rolling bearings, which also causes the amplitude jumping phenomenon. Changing the parameters of the rolling bearing could avoid the resonance peak appearing in the working speed range. The amplitude of the system under different rotating speeds could be suppressed by choosing the appropriate parameters of the rolling bearing. Full article

This study presents an experimental analysis of a turbocharger with semi-floating ring bearings, focusing on hysteresis in subsynchronous vibrations. Four automotive oils (SAE 0W-20, SAE 0W-30, SAE 5W-30, SAE 5W-40) were tested across six oil inlet temperatures from 20 °C to 120 °C during ramp-up and ramp-down cycles to examine the effects of lubricant viscosity and temperature on rotor dynamics. Hysteresis and bifurcation points were observed at distinct rotational speeds in both directions, with subsynchronous components providing insights into rotor–lubrication interactions. This study applies the concept of hysteresis loop width for turbocharger rotors, highlighting its nonlinear dependence on oil temperature, an unexpected and unexplained phenomenon. Additionally, the results suggest that vibration sensors could provide real-time feedback on oil supply conditions, offering potential enhancements for turbochargers and other rotating machinery. Full article

Much research and practical experience have shown that the utilization of textures has an enhancing effect on the performance of dynamic seals and the dynamic pressure lubrication of gas bearings. In order to optimize the performance of floating ring seals, this study systematically analyzes the effects of different texture shapes and their parameters. The Reynolds equation of the gas is solved by the successive over-relaxation (SOR) iteration method. The pressure and thickness distributions of the seal gas film are solved to derive the floating force, end leakage, friction, and the ratio of buoyancy to leakage within the seal. The effects of various texture shapes, including square, 2:1 rectangle, triangle, hexagon, and circle, as well as their parameters, such as texture depth, angle, and area share, on the sealing performance are discussed. Results show that the texture can increase the air film buoyancy and reduce friction, but it also increases the leakage by a small amount. Square textures and rectangular textures are relatively effective. The deeper the depth of the texture within a certain range, the better the overall performance of the floating ring seal. As the texture area percentage increases, leakage tends to increase and friction tends to decrease. A fractal roughness model is developed, the effect of surface roughness on sealing performance is briefly discussed, and finally the effect of surface texture with roughness is analyzed. Some texture parameters that can significantly optimize the sealing performance are obtained. Rectangular textures with certain parameters enhance the buoyancy of the air film by 81.2%, which is the most significant enhancement effect. This rectangular texture reduces friction by 25.8% but increases leakage by 79.5%. The triangular textures increase buoyancy by 28.02% and leakage increases by only 10.08% when the rotation speed is 15,000 r/min. The results show that texture with appropriate roughness significantly optimizes the performance of the floating ring seal. Full article

High-power diesel engine turbochargers predominantly utilize floating ring bearings as their primary supporting components. To further enhance their load capacity, multi-lobe noncircular bearings have been progressively employed. This study focuses on the investigation of noncircular three-lobe SFRBs (semi-floating ring-bearing structures) in marine turbochargers. Employing the half-step center Finite Difference Method (FDM) and the Newton–Raphson iterative procedure, the impact of operational parameters such as the journal speed, external load, oil supply pressure, and oil supply temperature on the static and dynamic characteristics of the inner oil film is analyzed. Subsequently, the accuracy of the theoretical model is validated through a comparative analysis of simulation results obtained from Dyrobes and Fluent. The findings indicate that as the oil supply pressure and temperature increase, the temperature rise and maximum oil film pressure of the three-lobe SFRBs gradually decrease, while the oil film thickness progressively increases, thereby significantly improving the lubrication state. The load capacity of the three-lobe SFRBs is primarily sustained by the bottom tile, where wall friction is most likely to occur. Additionally, within the actual speed range, the stiffness and damping of the three-lobe SFRBs exhibit noticeable nonlinear characteristics. Full article

Floating ring seals are widely used as a leakage control solution for turbomachines because they effectively operate with small clearances between the shaft and seal. The oxidizer pump of the 7 tonf liquid engine in the Korea Space Launch Vehicle II (KSLV-II) operates at high rotational speeds and under cryogenic conditions and has floating ring seals in the bearing cooling path to reduce leakages. In this study, we evaluated the frictional force acting on the nose of the floating ring in the oxidizer pump of the 7 tonf turbopump using numerical analysis, and we investigated the radial force on the floating ring induced by the vibration of the rotor and the flow characteristics around the floating ring seal. Through a comparison of the frictional and floating forces according to the change in the diameter of the floating ring noses, we also estimated the dynamic positioning of the floating ring. In addition, we examined the leakage of the floating ring seals with the rotational speed and gap size of the floating ring, and we used the results as data for designing a floating ring seal. Finally, we performed turbopump real-propellant tests with the floating ring seal of the high and the middle noses, finding that the test result was in good agreement with the results of numerical analysis. Full article

In order to ensure the effective vibration–reduction and vibration–isolation of the steel spring floating plate rail and meet the safe operation requirements of the subway, a Fiber Bragg Grating (FBG) displacement sensor for the deformation monitoring of the subway floating plate is proposed. The sensor adopts double FBGs to realize temperature self-compensation. The elastic ring is used as the elastic conversion structure after the fiber grating is pre-stretched; the two ends are pasted and fixed in the groove in the diameter direction of the ring, which avoids the waveform distortion caused by the full pasting of the fiber grating. The combination of linear bearing and displacement probe rods can increase stability and reduce friction loss so that the sensor has the advantages of high sensitivity and accurate measurement results. The test results and error analysis show that in the range of 0~20 mm, the sensitivity of the sensor is 164.2 pm/mm, the accuracy reaches 0.09% F.S, and the repeatability error and hysteresis error are only 1.86% and 0.99%, respectively. The thermal displacement coupling experiment proves that the sensor has good temperature self-compensation performance. It provides a new technical scheme for the effective monitoring and condition assessment of the built-in steel spring floating plate rail. Full article

Rotor machinery supports are susceptible to fracture arising from multi-period or irregular transient vibration and even the inconspicuous fatigue phenomenon. The novel dynamic model of a rotor mounted on the floating ring squeeze film damper (SFD) was developed. The proposed SFD implements low stiffness and small scale to overcome the deficiency. Based on the theory of hydrodynamic lubrication, the Reynolds equations on the working principle of the floating ring are established. Then, the dynamic characteristics of the rotor system during maneuvers, with the floating ring SFD supports, are subsequently examined by adopting the finite difference method. In addition, the oil film whirl mechanism of the floating ring SFD is demonstrated according to the transient analysis of the fluid–structure interaction model. The results of the SFD simulation reveal that, with increasing eccentricity ratio, both the inner and outer oil film pressure tend to be larger due to the shrinkage of the effective coverage of oil film. The maximum oil film pressure and bearing capacity increase nonlinearly within a certain eccentricity ratio range. Through the comparisons of the results, the vibration suppression effects of the proposed SFD are analyzed. This work will provide the practical reference for the dynamic design of the rotor support system. Full article

Most commercial automotive turbochargers (TC) employ semi-floating ring bearings (SFRB) with axial groove shapes. In order to bring some insights into the role played by the axial groove geometry on the dynamics of TC, this work deals with an experimental study of the rotordynamic behavior of a stock automotive turbocharger operating on SFRB with two different groove shapes, which have the same volume and width, and with the same number of grooves. The rotating machine behavior has been evaluated under different operating conditions using a test bench specially designed to analyze turbochargers. Rotordynamic (RD) characteristics of automotive turbochargers are estimated to evaluate the influence of the axial groove geometry on the machine vibratory behavior. Frequency spectra and orbital plots of the rotor are obtained from accelerometers and proximity probes mounted on the turbocharger. The comparative analysis of the vibrational behavior of automotive turbochargers running on different supporting systems allows the identification of the role played by the axial grooves on the machine rotordynamic performance. The experimental results rendered in this work permit to classify the influence of the axial groove geometry on the turbocharger rotordynamic behavior for several speed and flow conditions. Full article

The floating ring bearing (FRB) has been widely used in the field of high-speed rotating machinery such as turbochargers, aviation engines and so on, because of its simple structure, high efficiency and low power consumption. In order to obtain the best ratio between inter-oil clearance and shaft radius of the floating ring bearing necessitates the design reference of dimensional parameters for the design of floating ring bearings. This study, based on the transfer-matrix method, developed the dynamic model of the floating ring bearing-rotor system, and, using the Runge–Kutta analysis method for floating ring bearings, the influence of oil film relative clearance ratio of floating rings on rotor system stability was analyzed and studied. The optimum clearance ratio between inner oil film and the shaft of floating ring bearings is λ = 0.01. This research can provide some theoretical support for the design of parameters and fault diagnosis of rotor floating ring bearing systems. Full article

The vibration behaviour of turbocharger rotors is influenced by the acting loads as well as by the type and arrangement of the hydrodynamic bearings and their operating condition. Due to the highly non-linear bearing behaviour, lubricant film-induced excitations can occur, which lead to sub-synchronous rotor vibrations. A significant impact on the oscillation behaviour is attributed to the pressure distribution in the hydrodynamic bearings, which is influenced by the thermo-hydrodynamic conditions and the occurrence of outgassing processes. This contribution investigates the vibration behaviour of a floating ring supported turbocharger rotor. For detailed modelling of the bearings, the Reynolds equation with mass-conserving cavitation, the three-dimensional energy equation and the heat conduction equation are solved. To examine the impact of outgassing processes and thrust bearing on the occurrence of sub-synchronous rotor vibrations separately, a variation of the bearing model is made. This includes run-up simulations considering or neglecting thrust bearings and two-phase flow in the lubrication gap. It is shown that, for a reliable prediction of sub-synchronous vibrations, both the modelling of outgassing processes in hydrodynamic bearings and the consideration of thrust bearing are necessary. Full article

The present study theoretically evaluates the stability potential of noncircular geometries when they are adopted in the outer bearing of floating ring bearings (FRB). A numerical study is carried out to evaluate the stability about the static equilibrium position of a balanced, symmetrical, rigid rotor, horizontally placed, and supported at both ends by identical FRBs. In the analysis, the outer bearing of these FRBs is alternatively shaped with common circular bore (CB), two lobe-wave bore (2LWB) or lemon bore (LB), assuming a linearization of the film forces. A minor part of the study consists of partially supporting the results of the above study by means of a nonlinear, transient analysis. Despite limiting to the theoretical aspect, dealt with under several simplifying hypotheses, the investigation highlights the influence of the examined non-circular geometries on the stability of the static equilibrium position, when these geometries are adopted for shaping the outer housing of the FRB. The paper shows that contrasting effects are obtained, depending on the chosen geometrical parameters. In the paper, the acronyms CB, 2LWB, and LB are used to indicate the FRB layouts respectively equipped with outer circular, wave, and lemon bearing. Full article

The paper extents the fluid film bearing database method to arbitrary fixed bearing profiles including floating ring bearings. The method is applied to evaluate rotordynamic response of an automotive turbocharger, modeled as rigid rotor, and of a turbine-generator shaft train for power generation modeled as flexible rotor through the transient transfer matrix method. The methodology claims to render drastically faster evaluation of transient response of rotating systems with nonlinear bearings regardless the complexity of the bearing models implemented. The computational time of transient response is similar to this when short bearing expressions are used. Turbocharger rotordynamic simulation considers the use of nonlinear bearing models as mandatory, and several case studies have to be performed for the definition of key design parameters of floating ring bearings. The bearing database method offers the tool for a severe total time reduction in rotordynamic calculations, with the possibility to implement advanced thermohydrodynamic bearing models to the rotordynamic algorithm as fast as short bearing approximation formulas. Furthermore, the rotordynamic design of large turbine shaft trains is still based on linear harmonic analysis which leads to conservative designs. The database method aims to include the transient response of nonlinear rotor models as a standard procedure in the rotordynamic design of large shaft trains, which nowadays is avoided due to high time cost and complexity. Full article

The current work introduces a new semi-floating ring bearing (SFRB) system developed for improving the rotordynamic and vibration performance of automotive turbochargers (TCs) at extreme operation conditions, such as high temperature, severe external force excitation, and large rotor imbalance. The new bearing design replaces outer oil films, i.e., squeeze film dampers (SFDs), in TC SFRBs with wire mesh dampers (WMDs). This SFRB configuration integrating WMDs aims to implement reliable mechanical components, as an inexpensive and simple alternative to SFDs, with consistent and superior damping capability, as well as predictable forced performance. Since WMDs are in series with the inner oil films of SFRBs, experimentally determined force coefficients of WMDs are of great importance in the design process of TC rotor-bearing systems (RBSs). Presently, the measurements of applied static load and ensuing deflection determine the structural stiffnesses of the WMDs. The WMD damping parameters, including dissipated energy, loss factor, and dry friction coefficient, are estimated from the area of the distinctive local hysteresis loop of the load versus WMD displacement data recorded during consecutive loading-unloading cycles as a function of applied preload with a constant amplitude of motion. The changes in WMD loss factor and dry friction coefficient due to increases in preload are more significant for the WMDs with lower density. The present work shows, to date, the most comprehensive measurements of static load characteristics on the WMDs for application into small automotive TCs. More importantly, the extensive test measurements of WMD deflection versus increasing static loads will aid to anchor predictions of future computation model. Full article