Search Results (14)

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

The internal curve hydraulic motor valve plate has a clearance self-compensation performance that can effectively improve the working efficiency of the valve plate. However, the dynamic characteristics of the valve plates require further investigation. This study considers the self-compensating ‘floating’ valve plate as the research object, proposes a dynamic characteristic analysis method for the internal curve hydraulic motor valve plate, and explores the changing rule of oil film thickness and surplus pressing force of the valve plate. The results showed that an increase in the inlet pressure and oil temperature led to an increase in the thickness of the oil film, and the amplitude of the oil film thickness was larger, whereas the rotational speed of the oil film thickness of the valve plate pair was not obvious. When the inlet pressure is lower than 8 MPa, and the oil temperature is in the range of 20–30 °C, the oil film is mainly subjected to the squeezing effect of the valve plate, and the displacement of the valve plate decreased with increasing rotational speed. The inlet pressure is the main factor affecting the displacement of the ‘floating’ valve plate, and when the inlet pressure reaches 8.7 MPa, the valve plate is in hydrostatic balance support. In addition, the surplus pressing force coefficient of the valve plate decreased with increasing inlet pressures. This study provides theoretical support for the design of variable pressing force valve plates for internal curve hydraulic motors by investigating the dynamic characteristics of “floating” valve plates. Full article

In slurry shield tunneling projects, leakage from floating seals frequently leads to abnormal failures of disc cutters. To investigate the leakage characteristics at the floating seal end faces of the cutters, a numerical method is proposed for analyzing the dynamic leakage behavior of the floating seal end faces, considering the effects of wear. The elastohydrodynamic lubrication problem of the floating seal was addressed using the Reynolds equation and the slicing method, leading to the development of a computational model for the pressure and thickness distribution of the oil film on rough surfaces. Based on the Archard wear equation, a dynamic surface roughness model considering wear was established. Furthermore, a numerical model for dynamic leakage of the floating seal end faces in shield machine cutters, incorporating wear effects, was developed. Simulated friction and wear tests of the floating seal end faces, along with cutter seal leakage experiments, were conducted for validation. The results demonstrate that the dynamic surface roughness model considering wear can effectively predict the roughness evolution of worn surfaces. The trend of the theoretical leakage rate is generally consistent with that of the experimental results, verifying the effectiveness of the proposed model. Full article

Hydrodynamic linear guides in machine tools offer a high load capacity and excellent damping characteristics, improving stability, precision, and vibration reduction. This study builds on previous research where floating heights were verified with a simulation model limited to measured floating heights. Advancements include incorporating pressure sensors into a fixed steel rail, enabling simultaneous measurement of oil film pressure and floating heights for a comprehensive understanding of lubrication conditions within the lubrication gap. The experimental results explore the effects of different lubrication methods, providing valuable insights into cavitation and lubrication adequacy. The results demonstrate the feasibility of utilizing pressure sensors to measure oil film pressure within the lubrication gap, providing a nuanced understanding of lubrication dynamics. By measuring both floating heights and pressure measurement, distinctions between hydrodynamic lubrication, mixed friction regions, and instances of lubricant deficiency become readily discernible. The variations in real-time oil film pressure and floating heights help to optimize the lubrication cycle for hydrodynamic linear guides, enhancing system performance and longevity. 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

Oil films on water are an increasingly major contamination problem worldwide. In 2020, we published a novel adsorption and transportation technology for oil–water separation based on biological role models like the floating fern Salvinia. This application provides an unexpected ability for the fast and efficient removal of oil films, particularly in ecologically important freshwater biota. A single small Bionic Oil Adsorber (BOA) with 1 m² functional textile can collect up to 4 L of oil per hour, which equals about 100 m² of oil film from a water surface into a collecting vessel. This is a safe, fast, and sustainable solution for the ubiquitous contaminations of, e.g., fuel oil in freshwater environments. Here, we present updated, new experimental data, and a review of the literature published since. Full article

In the manufacturing and assembly of a toroidal drive mechanism, errors have a great influence on the load sharing of the mechanism. In order to improve the load-sharing characteristics of the mechanism, a floating oil film structure system is designed to support the planetary gear and to compensate for inaccuracies in the manufacturing and assembly of the mechanism parts in this paper. The elasticity and hydrodynamic effect of the floating oil film allow the planetary gear to achieve its own small floatation and produce a certain axial displacement, which compensates for the influence of error and achieves load sharing. To examine the effect of the floating oil film structure, the floating oil film bearing is simulated by FLUENT, the characteristics of the floating oil film are analyzed, and the stiffness and damping coefficients of the floating oil film are calculated. In ADAMS, the method of equivalent replacement of the floating oil film with spring damping is adopted to conduct a dynamic analysis on the toroidal drive mechanism with the floating oil film load-sharing structure, and the results show that the system with a floating oil film structure can effectively compensate the influence of errors and improve the uniform load performance. Full article

In the LF refining process, argon blowing at the bottom of ladle can play an important role in unifying the composition and temperature of molten steel and removing inclusions. However, unreasonable bottom argon blowing process can also cause many problems. Slag entrapment and slag surface exposure may occur, affecting the steel quality. Since the working conditions of different enterprises are very different, corresponding optimization is required for specific parameters. There were some problems in 70t ladle of a steel plant, such as unclear control of bottom argon blowing system in different refining periods, unobvious floating removal effect of inclusions in ladle, high total oxygen content and large fluctuation, etc. In this study, a 1:3 physical model was established according to the similarity principle. Then, on this basis, the experimental schemes with different blowing hole positions and argon flow rates were designed for simulation experiments. By means of mixing time measurement, flow field display and oil film measurement, the optimal argon blowing position was double holes 6, 12 (2/3R), and the included angle between them was 135°. The optimal argon flow rate for wire feeding and soft blowing should be 7.6 L/min (corresponding to the actual production of 180 L/min) and 0.6 L/min (corresponding to the actual production of 15 L/min), respectively. According to this scheme, the industrial experiments showed that the contents of total oxygen and nitrogen in the whole process were reduced, the surface density of inclusions in billet was reduced by 11.81% on average, and calcium sulfide and various inclusions containing aluminum were reduced to varying degrees. Full article

This paper reports the optimization of a two-step atmospheric pressure plasma process to modify the surface properties of a polyurethane (PU) foam and, specifically, to prepare a superhydrophobic/superoleophilic absorbent for the removal of oils and nonpolar organic solvents from water. In particular, in the first step, an oxygen-containing dielectric barrier discharge (DBD) is used to induce the etching/nanotexturing of the foam surfaces; in the second step, an ethylene-containing DBD enables uniform overcoating with a low-surface-energy hydrocarbon polymer film. The combination of surface nanostructuring and low surface energy ultimately leads to simultaneous superhydrophobic and superoleophilic wetting properties. X-ray photoelectron spectroscopy, scanning electron microscopy and water contact angle measurements are used for the characterization of the samples. The plasma-treated PU foam selectively absorbs various kinds of hydrocarbon-based liquids (i.e., hydrocarbon solvents, mineral oils, motor oil, diesel and gasoline) up to 23 times its own weight, while it completely repels water. These absorption performances are maintained even after 50 absorption/desorption cycles and after immersion in hot water as well as acidic, basic and salt aqueous solutions. The plasma-treated foam can remove mineral oil while floating on the surface of mineral oil/water mixtures with a separation efficiency greater than 99%, which remains unaltered after 20 separation cycles. 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

In modern chemical and oil refining complexes, separation processes are among the most popular and energy-intensive. Installations for their implementation should be equipped with nodes for creating vapor (evaporators) and liquid (deflegmators) irrigation. Evaporators of any type (film, thermosiphon, gas lift, cubic) belong to this class of devices. For example, in cubic evaporators, the gas flow is completely formed from flux bubbles that originate on the heat-conducting surface and float in the volume of the cubic liquid located in the apparatus. Due to the accompanying mass exchange, the bubbles are enriched with volatile components during ascent and noticeably increase in volume, and the growth of the bubble is determined, among other things, by the total flow. At the same time, in real bubbling-type equipment, the total mass transfer surface exceeds the cross-section of the device itself by more than two orders of magnitude. Thus, according to, the ratio of the internal cross-sectional area of the apparatus to the developed mass transfer surface is 0.0015–0.002. Based on the analysis of the integral equation of the diffusion boundary layer, it is shown that the presence of a resultant flow of substance through the phase interface (non-equimolarity of the process) in a two-phase gas (vapor)–liquid system leads to the transformation of the structure of the traditional mass transfer equation itself. The use of a new structure obtained for both binary and multicomponent mixtures makes it possible to significantly simplify the approach to the description and generalization of arbitrary mass transfer processes. The innovativeness of the proposed approach lies in its universality for non-equimolar processes. This simplifies the creation of models of any mass transfer devices and entire production lines. In addition, the proposed approach is a good auxiliary tool for various researchers and experimenters. It should also be noted that the separation processes of many products of organic origin during heating are characterized by the appearance of undesirable side reactions (thermal decomposition, condensation, polycondensation, formation of harmful impurities, etc.), which occur most intensively in the heating zones. At the same time, the evaporation and distillation units are subject to requirements for the minimum hydraulic resistance of the structure, the maximum separation capacity (efficiency), and the minimum residence time of the product in the apparatus (equivalent to the minimum holding capacity of the structure). It was noted that the specified requirements are most fully met by film-type devices. 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 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

This work presents the bearing design and analysis of radial semi-floating bush oil lubricated bearings for a typical industrial turbocharger configuration. Initially, the stability analysis for a linear rotor/bearing system is evaluated through eigenvalues and eigenvectors. The stiffness and damping coefficients of the inner oil film are obtained for the linear modeling process. The operating speed range of the turbocharger is high enough, at 21,000 to 24,000 rpm, to be unstable, indicating that the analysis should be and is carried out with nonlinear transient modeling. The nonlinear transient analysis evaluates the rotor and bush limit cycle orbits, rotor dynamics, the forces acting on the rotor and semi-floating bush surfaces, the oil flow through the bearing, the oil temperatures, and the power loss of the two oil films. The optimum design of a set of semi-floating bush bearings for this application depends strongly upon the clearances of the bush and squeeze film damper, usually expressed as the non-dimensional clearance to radius ratio. A typical clearance is evaluated to determine the bearing performance in terms of orbit size, forces acting on the bush and squeeze damper surfaces, oil flow through the bearing, power loss, and thermal heating. The nonlinear transient orbit values are evaluated for frequency content using the FFT to determine which orbits show both the synchronous and sub-synchronous vibration components and the associated rotor modes excited. These results are compared to the linear analysis over the operating speed range. The oil flow through the bearing component is much larger than the squeeze film damper. The forces acting on the bush and squeeze damper surfaces are related to the fatigue life of the bearing. Full article