Gas foil bearings (FB) satisfy many of the requirements noted for novel oil-free turbomachinery. However, FB design remains largely empirical, in spite of successful commercial applications. The mechanical structural characteristics of foil bearings, namely stiffness and damping, have been largely ignored in the archival literature. Four commercial bump-type foil bearings were acquired to measure their load capacity under conditions of no shaft rotation. The test bearings contain a single Teflon-coated foil supported on 25 bumps. The nominal radial clearance is $0.036mm$ for a $38mm$ journal. A simple test setup was assembled to measure the FB deflections resulting from static loads. The tests were conducted with three shafts of increasing diameter to induce a degree of preload into the FB structure. Static measurements show nonlinear FB deflections, varying with the orientation of the load relative to the foil spot weld. Loading and unloading tests evidence hysteresis. The FB structural stiffness increases as the bumps-foil radial deflection increases (hardening effect). The assembly preload results in notable stiffness changes, in particular for small radial loads. A simple analytical model assembles individual bump stiffnesses and renders predictions for the FB structural stiffness as a function of the bump geometry and material, dry-friction coefficient, load orientation, clearance and preload. The model predicts well the test data, including the hardening effect. The uncertainty in the actual clearance (gap) upon assembly of a shaft into a FB affects most of the predictions.

Widespread usage of gas foil bearings (FBs) into microturbomachinery to midsize gas turbine engines requires accurate performance predictions anchored to reliable test data. This paper presents a simple yet accurate model predicting the static and dynamic force characteristics of gas FBs. The analysis couples the Reynolds equation for a thin gas film to a simple elastic foundation model for the top foil and bump strip layer. An exact flow advection model is adopted to solve the partial differential equations for the zeroth- and first-order pressure fields that render the FB load capacity and frequency-dependent force coefficients. As the static load imposed on the foil bearing increases, predictions show that the journal center displaces to eccentricities exceeding the bearing nominal clearance. A nearly constant FB static stiffness, independent of journal speed, is estimated for operation with large loads, and approaching closely the bearing structural stiffness derived from contact operation without rotor spinning. Predicted minimum film thickness and journal attitude angle demonstrate good agreement with archival test data for a first-generation gas FB. The bump-foil-strip structural loss factor, exemplifying a dry-friction dissipation mechanism, aids to largely enhance the bearing direct damping force coefficients. At high loads, the bump-foil structure influences most the stiffness and damping coefficients. The predictions demonstrate that FBs have greatly different static and dynamic force characteristics when operating at journal eccentricities in excess of the bearing clearance from those obtained for operation at low loads, i.e., small journal eccentricity.

Currently, the herringbone groove journal bearing (HGJB) has important applications in miniature rotating machines such as those found in the computer information storage industry. Grooves scribed on either the rotating or stationary member of the bearing pump the lubricating fluid inward thus generating support stiffness and improving its dynamic stability when operating concentrically. The narrow groove theory (NGT), traditionally adopted to model the concentric operation of these bearings, is limited to bearings with a large number of grooves. A finite element analysis is introduced for prediction of the static and rotordynamic forced response in HGJBs with finite numbers of grooves. Results from this analysis are then compared to available experimental data as well as to estimates from the NGT. A bearing geometry parametric study is then conducted to determine optimum rotordynamic force coefficients. A discussion on the temporal variation of the bearing reaction forces and force coefficients for a rotating journal with a small number of grooves is also presented. These changes can be significant at high operating eccentricities, possibly inducing a parametric excitation in rotating systems employing this type of bearing.

Physical models and fast computational programs aim to improve the design and performance of turbocharger (TC) rotordynamics. Most commercial automotive TCs incorporate floating ring bearings (FRBs) owing to their low cost and reduced power losses. However, persistent subsynchronous motions afflict this type of rotor/bearing system, albeit reaching limit cycles that enable their continuous operation. FRBs comprise two fluid films in series and are prone to show one or two subsynchronous instabilities over extended speed ranges of operation. A flow model for prediction of FRB forced response is detailed here. The model incorporates a lumped-parameter thermal energy balance for estimation of the lubricant viscosity and thermal growth of the rotor, bearing and floating ring. The FRB model, fully integrated into a non-linear rotordynamics computational program, predicts the floating ring speed, journal and ring eccentricities, power loss and the rotordynamic force coefficients of the inner and outer films as a function of the load applied at a given rotor speed. Knowledge of the actual load conditions, static and dynamic, and the changes in operating clearance and effective lubricant viscosity are most important for accurate estimation of a TC dynamic forced response. Predictions for the exit lubricant temperature, power losses and floating ring speeds agree well with measurements obtained in an automotive turbocharger test rig. The rotordynamic stability characteristics of the test TC are also highlighted.