Robust Optimum Design of Thrust Hydrodynamic Bearings for Hard Disk Drives

This paper describes the robust optimum design which combines the geometrical optimization method proposed by Hashimoto and statistical method. Recently, 2.5″ hard disk drives (HDDs) are widely used for mobile devices such as laptops, video cameras and car navigation systems. In mobile applications, high durability towards external vibrations and shocks are essentials to the bearings of HDD spindle motor. In addition, the bearing characteristics are influenced by manufacturing error because of small size of the bearings of HDD. In this paper, the geometrical optimization is carried out to maximize the bearing stiffness using sequential quadratic programming to improve vibration characteristics. Additionally, the bearing stiffness is analyzed considering dimensional tolerance of the bearing using statistical method. The dimensional tolerance is assumed to distribute according to the Gaussian distribution, and then the bearing stiffness is estimated by combining the expectation and standard deviation. As a result, in the robust optimum design, new groove geometry of bearing can be obtained in which the bearing stiffness is four times higher than the stiffness of conventional spiral groove bearing. Moreover, the bearing has lower variability compared with the result of optimum design neglecting dimensional tolerance.

Effects of Dimensional Tolerances on the Friction Power Loss of Hydrodynamic Journal Bearing System

According to the dimensional tolerances on hydrodynamic journal bearing system, a nonlinear oil film force model was established,and the Reynolds' equation was solved by adopting finite difference method. In order to fulfill different dimensional tolerances in the system,adopting 2kfactor design and using the eccentricity ratio corresponding to the stability critical curve,the effects of the friction power loss brought by the dimensional tolerances of the dynamic viscosity,bearing width,bearing diameter and journal diameter were analyzed. The effect on dynamic characteristics of the hydrodynamic journal bearing system was quantitatively analyzed,and the nonlinear dynamic analysis, modeling and calculation methods were studied while considering the manufacturing tolerances. The results show that in contrast to the impacts of the tolerances in journal diameter,dynamic viscosity and bearing width,the bearing diameter tolerance would lead to the rise in the power loss, and the dimensional tolerances have different degrees of impacts on the journal bearing system. The friction power loss decreased as the eccentricity ratio increased, and when the eccentricity ratio was 0. 695 the power loss came to the minimum.The investigation would find the best solution and reduce energy consumption,then control varieties of nonlinear dynamical behavior effectively,and provide a theoretical basis for hydrodynamic journal bearing system in parameter design.

Numerical Simulation and Experimental Research on Passive Hydrodynamic Bearing in a Blood Pump

The current research of hydrodynamic bearing in blood pump mainly focuses on the bearing structure design.Compared with the typical plane slider bearing and Rayleigh step bearing,spiral groove bearing has excellent performance in load-carrying capacity.However,the load-carrying capacity would decrease significantly with increasing flow rate in conventional designs.In this paper,the special treatment is made to the upper spiral groove bearing to make sure that both the circulatory flowing and load-carrying capacity are high.Three-dimensional computational fluid dynamics(CFD) models in the space between rotor and shaft are developed by using FLUENT software.Effects of groove number,film height and groove depth on load-carrying capacity of the spiral groove bearings are investigated by orthogonal experiment design.The experimental results show that film height is the most remarkable factor to the load-carrying capacity.The variation tendency of load-carrying capacity reveals that the best combination of geometry is the one with groove number of 8,film height 0.03 mm and groove depth 0.08 mm.The velocity and pressure distributions in spiral groove bearings are also analyzed,and the analysis result shows that the distributions are in conformity with the design of the blood pump based on the principle of hydrodynamic bearing.The displacement of the rotor with the best combination parameters is tested by using laser displacement sensors,the testing result shows that the suspending performance is satisfactory both in axial and radial directions.This research proposes a bearing design method which has sufficient load-carrying capacity to support rotor as an effective passive hydrodynamic bearing.

Hydrodynamic Lubrication of Elastic Foil Gas Bearing Using Over Relaxation Iteration Method and Non-Dimensional Equation

The purpose is to accurately predict the performance of foil bearing and achieve accurate results in the design of foil bearing structure.A new type of foil bearing with surface microstructure is used as experimental material.First,the lubrication mechanism of elastic foil gas bearing is analyzed.Then,the numerical solution process of the static bearing capacity and friction torque is analyzed,including the discretization of the governing equation of rarefied gas pressure based on the non-dimensional modified Reynolds equation and the over relaxation iteration method,the grid planning within the calculation range,the static solution of boundary parameters and static solution of the numerical process.Finally,the solution program is analyzed.The experimental data in National Aeronautics and Space Administration(NASA)public literature are compared with the simulation results of this exploration,so as to judge the accuracy of the calculation process.The results show that under the same static load,the difference between the minimum film thickness calculated and the test results is not obvious;when the rotor speed of the bearing is 60000 r/min,the influence of the boundary slip effect increases with the increase of the micro groove depth on the flat foil surface;when the eccentricity or the micro groove depth of the bearing increases,the bearing capacity will be strengthened.When the eccentricity is 6µm and 14µm,the viscous friction torque of the new foil bearing increases significantly with the increase of the depth of the foil micro groove,but when the eccentricity is 22µm,the viscous friction torque does not change with the change of the depth of the foil micro groove.It shows that the bearing capacity and performance of foil bearing are improved.

THE STATIC PERFORMANOE AND PARAMETER STUDY OF FLOATING-RING HYDRODYNAMIC THRUST BEARINGS

In this paper, floating--ring thrust bearings are investigated. A mathematical model is established to analyze the static performance of this kind of bearings, such as the load capacity, frictional power loss, temperature rise as well as the angular speed ratio between the floating ring and runner.Meanwhile, a parameter study is also conducted on the characteristics of floating-ring thrust bearings.Finally, the theoretical calculation results are verified by experiments.

EFFECTS OF MANUFACTURING ERRORS ON GAS LUBRICATED JOURNAL BEARING WITH COMPLIANT SURFACE

A theoretical study has been performed to investigate the influence of manufacturing errors on the bearing housing of a gas lubricated journal bearing with compliant surface I in particular on the bearing load capacity. A gas film thickness distribution is presented, in which errors o f both circumferential and axial bearing housing are considered. The influence of the errors on bearing performance is compared between rigid and compliant surface bearings. It was shown that the compliant surface bearings are less sensitive to the manufacturing errors than the rigid surface bearings. Thelefore, the cost of compliant surface bearing could be reduced by setting a larger manufacturing error tolerance.

Computer Aided Analysis of the Performances of a Tilting Pad Gas Journal Bearing

Tilting pad gas journal bearing is one of the most widely used types of aerodynamic bearings due to its inherent excellent stability in high speed applications.A practical method for analyzing and calculating the per- formances of such bearings is presented as well as its rotordynamics based on the computer aided technique.The method of calculation and the philosophy of programming with a microcomputer for the computer aided analysis are highlighted.

Turbulence Models of Hydrodynamic Lubrication

The main theoretical turbulence models for application to hydrodynamic lubrication problems were briefly reviewed, and the course of their development and their fundamentals were explained. Predictions by these models on flow fields in turbulent Couette flows and shear-induced countercurrent flows were compared to existing measurements, and Zhang & Zhang's combined k-ε model was shown to have surpassingly satisfactory results. The method of application of this combined k-ε model to high speed journal bearings and annular seals was summarized, and the predicted results were shown to be satisfactory by comparisons with existing experiments of journal bearings and annular seals.

Itaipu Binacional Hydro Power Plant Thrust Bearing Design Optimization for Higher Efficiency

Hydro generators installed in Itaipu Binacional power plant with 824/737 MVA rated output power （50/60 Hz） belong to the largest ones in the world. Among many unique features, the generators are equipped with the largest hydrodynamic thrust bearings ever built （external diameter 5,200 mm, axial load equals approximately 3,600 t）. This paper is an attempt to propose a new thrust bearing design with the use of the state-of-the-art technologies and simulation techniques that demonstrate a reduction of friction power losses generated by the thrust bearing. This paper is divided into two parts. Within the first one, the original thrust bearing design which was implemented in the generators is described. Related calculation results based on a TEHD （thermo-elasto-hydrodynamic） calculation software used by Alstom will be presented. A comparison between measurement results gathered in the 1980s is given. In the second part, a potential solution of a more beneficial bearing design is described. The proposed thrust bearing design modification is an implementation of Alstom＇s PolypadTM coating. This modern polymer （PEEK） coating material has already been used by Alstom in projects around the world for many years. This coating allows pushing the operating parameters limits toward higher temperatures and lower oil film thicknesses far beyond the limits known for the conventional bearing materials.

Transformation between polar and rectangular coordinates of stiffness and dampness parameters in hydrodynamic journal bearings

The stiffness and dampness parameters of journal bearings are required in rectangular coordinates for analyzing the stability boundary and threshold speed of oil film bearings.On solving the Reynolds equation,the oil film force is always obtained in polar coordinates;thus,the stiffness and dampness parameters can be easily obtained in polar coordinates.Therefore,the transformation between the polar and rectangular coordinates of journal bearing stiffness and dampness parameters is discussed in this study.

Investigation on hydrodynamic lubrication of bearings in a left ventricular assisted device

Formations of clots were found inside the hydrodynamic bearings of the left ventricular assisted devices (LVADs) and caused tremendous risks to the long-term use of these devices. For the hydrodynamic bearings used in the LVAD, not only the lubrication status but also the motion of the blood cells in the bearing will take great effect on the performance of the device. Based on the analysis of the hydrodynamic pressures distribution and the flowing trajectory of red blood cells in the lubrication film, the bearing is designed in a region where enough hydrodynamic pressure is generated to float the rotor to reduce the wear, and the entrainment of red blood cells in the gap of the bearing can be prevented to avoid the formation of clots.

Boundary element method of hydrodynamic characteristics of lubricant in three-leaf dislocated floating-ring bearing

The problem of hydrodynamics of the three-leaf dislocated floating-ring bearing was studied by means of boundary element method.The law including the distribution of pressure on boundary surface(axial,bearing and floating-ring)and its friction loss in different eccentricities was obtained.The results show that the inner friction of three-leaf dislocated bearing increases from 390.875to 1 091.65,and the inner friction of three-leaf dislocated floating-ring bearing increases from 94.2523to 114.5069with eccentricity varying from 0to 0.075in nondimensional.So changing the pressure and flow field of bearing by adding floating-ring is more stability and less wasted work of friction than three-leaf dislocated bearing.

船舶轮缘推进器关键技术研究现状和发展趋势

采用电力直驱模式来完成电能与机械能的无传动转化是高端交通动力装备领域的未来战略性技术之一。轮缘推进器(RDT)作为一种高度集成的电力直驱推进,是近年来研究的热点。文章梳理了船舶轮缘推进器的6项关键技术,包括水力部件设计及优化、电机设计及控制、水润滑轴承的设计和性能强化、系统集成与测试、船体匹配及联合控制以及可靠性评估与智能运维;阐述了各项技术的研究现状和趋势,总结了国内外RDT产品和实船应用情况。研究和应用表明,节能、环保、灵活的轮缘推进器是绿色智能船舶电力推进形式的重要选择,高性能轮缘推进器专用化设计、效能提升和状态监测以及智能运维是轮缘推进器未来重要发展趋势。

取向型微沟槽高速球铣加工制备方法及其减摩性能研究

探究直接利用高速球铣加工工艺制备取向型表面微沟槽织构的方法,并对该类型表面微织构的减摩性能进行研究.鉴于高速球铣加工工艺走刀路径灵活可变、表面材料残留几何尺寸与分布形态具备可控性的特点,利用Matlab仿真对高速球铣加工表面形貌进行预测,通过高速球铣加工试验验证仿真结果,并基于流体动压润滑理论,结合Fluent流体仿真分析与高速环-块摩擦磨损试验,对该类型表面微织构的减摩性能进行分析.当切削参数选用径向切深明显大于每齿进给量的组合时,高速球铣加工表面残留材料能够形成明显的微沟槽形貌,且微沟槽特征的取向可由球头铣刀的走刀路径进行控制;微沟槽承载能力与其取向密切相关,随着微沟槽取向角由90°减小至20°,负压区与正压区范围呈现扩大趋势,油膜内逆流效应逐渐减弱,动压效应逐渐增强,微沟槽承载能力提高了20.64%,表面摩擦系数由0.02845降低至0.02165;然而,当取向角过小时,负压区与正压区的范围过小,不能形成有效的收敛楔,微沟槽承载能力下降,表面摩擦系数上升.通过高速球铣加工工艺能够实现取向型表面微沟槽织构的可控制备,且该类表面的减摩性能与取向角α密切相关,在本文研究范围内,取向角为20°时表现出最小的摩擦系数与最高的油膜承载力.本文研究结果可为表面织构造型方法提供一种新思路,能够为满足零件表面的减摩需求提供很好的解决方法.

高转速工况下箔片气体轴承结构优化

箔片气体动压轴承是一种利用环境气体作为工作介质的自适应式柔性动压轴承,具有高速、高效、耐高温、长寿命等特点,但箔片气体动压轴承在高转速工况下,轴承稳定性低,易发生结构变形,影响使用寿命。为了提高轴承高速工况下的稳定性,对箔片气体动压轴承的波箔与顶箔进行高转速工况下变形量的仿真分析与实验研究。结果表明,三瓣式箔片气体动压轴承在高转速工况下,轴承会发生晃动而产生形变。为了减小变形量,对其进行结构优化,提出了一种三瓣式箔片气体动压轴承的新型结构。对优化后的结构进行高速工况下变形量仿真分析,结果显示最大变形量由原来的0.348 mm降低到0.344 mm,最大变形量下降了0.989%,证明三瓣式箔片气体动压轴承新型结构可以有效控制波箔片的变形量。

三楔气体轴承的动静压特性分析

针对氢燃料电池汽车车载空压机的轴承-转子系统,提出兼具静压和动压特性的三楔式气体轴承.开展轴承动静压耦合作用机制和流场特性、动静态参数研究,并与传统的圆柱气体轴承进行对比.为了计算轴承的流场特性,在Fluent软件的用户自定义函数(UDF)中编写动网格程序,并提出相应的计算流体力学(CFD)瞬态模拟方法来求解轴颈任意偏心位置时的轴承非线性气膜力与动态参数.研究表明,在运行工况变化时,三楔气体轴承动静压效应的强度会不断变化,但始终能通过耦合效应为转子提供有效、稳定的支承.在低转速范围内,静压效应是影响三楔气体轴承性能的主要因素,表现出与圆柱气体轴承相似的支承效果,保证车载压缩机在启停或升速过程中的稳定运转.当转速增大时,三楔气体轴承的动压效应显著增强,能在更低的供气压力下为高速旋转的车载压缩机提供支承.相较于需要外接气源的圆柱气体轴承,三楔气体轴承能在仅利用氢燃料电池汽车供气系统内部气路的情况下为转子提供稳定的支承,适应车载空压机中气体压力有限且须频繁启停、变速的工作环境.

基于CFD的船舶倾斜尾轴承润滑静特性分析

针对船舶尾轴在实际运行过程中存在挠曲变形过大导致尾轴承润滑不良的问题,提出在轴承内孔设计单斜度的倾斜尾轴承结构。利用计算流体力学(CFD)方法,分别建立轴颈倾斜时水平尾轴承和倾斜尾轴承的有限元模型,在相同轴颈倾斜角和偏心率以及不同转速条件下,计算2种结构尾轴承的静特性参数,对比分析同一转速下,不同结构对润滑静特性的影响,以及相同结构时,静特性参数随转速变化的规律。计算结果表明,相同工况下,倾斜尾轴承的最大油膜压力、承载力、摩擦力、摩擦系数和端泄流量均比水平尾轴承更小。随着转速增加,2种尾轴承的最大油膜压力、承载力、摩擦力和端泄流量均不同程度增加,摩擦系数总体呈减小趋势。相关工作可为船舶尾轴承结构的优化设计提供理论参考,便于工程应用。

贫油工况下滑动轴承弹流润滑特性分析

随着风力发电机组的功率增加,滑动轴承在风电齿轮箱中的使用优势逐渐突显。当风力发电机组内的轴承润滑系统堵塞或供油不足时,滑动轴承将长期处于贫油润滑状态。为了研究滑动轴承的贫油润滑特性,基于Reynolds方程和Reynolds边界条件,考虑油膜压力作用下轴套的弹性变形,建立了贫油润滑状态下滑动轴承的计算模型;对比了计入弹性变形和不计入弹性变形的滑动轴承贫油润滑性能;分析了轴套弹性模量和供油量对滑动轴承贫油润滑性能的影响。结果表明,计入弹性变形后的最小油膜厚度位置位于轴套两侧,更加符合实际情况;随着轴套材料弹性模量的增加,轴颈偏心率逐渐减小,最大油膜压力逐渐增加,最小油膜厚度逐渐增加;随着供油量的增加,轴颈偏心率逐渐减小,最大油膜压力逐渐降低,最小油膜厚度逐渐增加。

滚动轴承润滑研究中的几个问题

滚动轴承是高端装备中不可缺少的重要部件,轴承润滑问题的研究为滚动轴承设计、润滑剂选择、轴承可靠服役等提供理论基础。针对滚动轴承润滑相关的几个科学问题,重点概括了滚动轴承润滑数值计算方法及应用,总结了润滑油膜厚度和轴承内部润滑介质流动分布可视化测量技术,阐述了与润滑脂组分相关的机械剪切与温度等参数对润滑特性的影响机制,介绍了滚动轴承固体润滑机制,并从工程设计角度分析了轴承的润滑设计。基于当前研究现状,认为轴承润滑研究应重点面向真实条件下轴承润滑理论计算、与应用工况匹配的先进润滑材料的开发以及轴承润滑评测方法研发3个方面进行发展。

浮环弹性变形对浮环动静压轴承润滑特性的影响

浮环轴承在高速工况下运行时,浮环表面在油膜压力作用下会发生弹性变形,影响轴承润滑性能。针对带有深浅腔的浮环动静压轴承,采用有限元法和有限差分法耦合求解油膜Reynolds方程、能量方程和温黏关系式,采用变形矩阵法求解弹性变形方程,计算浮环弹性变形分布;在浮环平衡的基础上,分析浮环变形对环速比、油膜承载力、端泄流量等润滑特性参数的影响。结果表明:浮环弹性变形分布与油膜压力分布呈现一致性,转速越高,偏心越大,变形越明显;考虑浮环弹性变形,浮环达到平衡状态时,内膜偏心率增加,环速比减小,轴承承载力与摩擦力矩均有所增加;由于浮环变形对内、外膜间隙及流动液阻的不同影响,使得内膜端泄流量增加,外膜端泄流量减少。