Oil film measurement in polytetrafluoroethylene-faced thrust pad bearings for hydrogenerator applications

There is a growing trend in the replacement of the babbit facing in thrust pad bearings with a composite polytetrafluoroethylene (PTFE) surface layer. The PTFE-faced bearings have been shown to allow a greater specific pressure, reduce thermal crowning, and, in some cases, negate the need for an oil-lift (jacking) system. These designs of bearing require new methods for the measurement of oil film thickness both to assist in their development and for plant condition monitoring. In this work, an ultrasonic method of oil film measurement is evaluated for this purpose. An ultrasonic transducer is mounted on the back face of the thrust pad. Pulses are generated and transmitted through the pad material, bonding interlayer, and PTFE surface layer. The proportion of the wave that reflects back from the oil film layer is determined. This is then related to the oil film thickness using a series of calibration experiments and a spring stiffness model. In practice, the reflected signal is difficult to distinguish, in the time domain, from other internal reflections from the pad. Signals are compared with reflections when no oil film is present and processing is carried out in the frequency domain. Experiments have been performed on a full size PTFE-faced thrust pad destined for a hydroelectric power station turbine. The instrumented pad was installed in a test facility and subjected to a range of loading conditions both with and without oil lift. Although there were some problems with the robustness of the experimental procedure, oil films were successfully measured and used to study the effect of the oil-lift system on film formation. © IMechE 2006

A method for the measurement of hydrodynamic oil films using ultrasonic reflection

The measurement of the thickness of an oil film in a lubricated component is essential information for performance monitoring and control. In this work, a new method for oil film thickness measurement, based on the reflection of ultrasound, is evaluated for use in fluid film journal bearing applications. An ultrasonic wave will be partially reflected when it strikes a thin layer between two solid media. The proportion of the wave reflected depends on the thickness of the layer and its acoustic properties. A simple quasi-static spring model shows how the reflection depends on the stiffness of the layer alone. This method has been first evaluated using flat plates separated by a film of oil, and then used in the measurement of oil films in a hydrodynamic journal bearing. A transducer is mounted on the outside of the journal and a pulse propagated through the shell. The pulse is reflected back at the oil film and received by the same transducer. The amplitude of the reflected wave is processed in the frequency domain. The spring model is then used to determine the oil film stiffness that can be readily converted to film thickness. Whilst the reflected amplitude of the wave is dependent on the frequency component, the measured film thickness is not; this indicates that the quasi-static assumption holds. Measurements of the lubricant film generated in a simple journal bearing have been taken over a range of loads and speeds. The results are compared with predictions from classical hydrodynamic lubrication theory. The technique has also been used to measure oil film thickness during transient loading events. The response time is rapid and film thickness variation due to step changes in load and oil feed pressure can be clearly observed

The measurement of lubricant-film thickness using ultrasound

Ultrasound is reflected from a liquid layer between two solid bodies. This reflection depends on the ultrasonic frequency, the acoustic properties of the liquid and solid, and the layer thickness. If the wavelength is much greater than the liquid-layer thickness, then the response is governed by the stiffness of the layer. If the wavelength and layer thickness are similar, then the interaction of ultrasound with the layer is controlled by its resonant behaviour. This stiffness governed response and resonant response can be used to determine the thickness of the liquid layer, if the other parameters are known. In this paper, ultrasound has been developed as a method to determine the thickness of lubricating films in bearing systems. An ultrasonic transducer is positioned on the outside of a bearing shell such that the wave is focused on the lubricant-film layer. The transducer is used to both emit and receive wide-band ultrasonic pulses. For a particular lubricant film, the reflected pulse is processed to give a reflection-coefficient spectrum. The lubricant-film thickness is then obtained from either the layer stiffness or the resonant frequency. The method has been validated using fluid wedges at ambient pressure between flat and curved surfaces. Experiments on the elastohydrodynamic film formed between a sliding ball and a flat surface were performed. Film-thickness values in the range 50-500 nm were recorded, which agreed well with theoretical film-formation predictions. Similar measurements have been made on the oil film between the balls and outer raceway of a deep-groove ball bearing

Noncontacting device to indicate deflection of turbopump internal rotating parts

Phase 2 (development) which was concluded for the ultrasonic Doppler device and the light-pipe-reflectance device is reported. An ultrasonic Doppler breadboard system was assembled which accurately measured runout in the J-2 LOX pump impeller during operation. The transducer was mounted on the outside of the pump volute using a C-clamp. Vibration was measured by conducting the ultrasonic wave through the volute housing and through the fluid in the volute to the impeller surface. The impeller vibration was also measured accurately using the light-pipe probe mounted in an elastomeric-gland fitting in the pump case. A special epoxy resin developed for cryogenic applications was forced into the end of the fiber-optic probe to retain the fibers. Subsequently, the probe suffered no damage after simultaneous exposure to 2150 psi and 77 F. Preliminary flash X-radiographs were taken of the turbine wheel and the shaft-bearing-seal assembly, using a 2-megavolt X-ray unit. Reasonable resolution and contrast was obtained. A fast-neutron detector was fabricated and sensitivity was measured. The results demonstrated that the technique is feasible for integrated-time measurements requiring, perhaps, 240 revolutions to obtain sufficient exposure at 35,000 rpm. The experimental verification plans are included

Evaluation of an ultrasonic method for measurement of oil film thickness in a hydraulic motor piston ring

The efficiency of a hydraulic motor depends on the lubrication performance of the piston ring. If the film is too thin then wear occurs quickly, if it is too thick then oil is lost into the cylinder and efficiency is reduced. In this paper a technique for oil film measurement based on ultrasonic reflection is investigated. This has the potential to be used non-invasively on real components. An ultrasonic pulse will reflect from a thin film interposed between two solids. The proportion of the pulse that is reflected depends on the stiffness of the intermediate layer. If the acoustic properties of the film material are known, then the stiffness can readily be used to determine the film thickness. This principle has been employed for the piston ring lubrication case. A piston/cylinder test bench has been used to evaluate the ultrasonic method. A focusing piezo-electric transducer is mounted outside the cylinder and ultrasonic pulses reflected back from the inner bore. The variation of these pulses as the piston ring passes underneath is investigated and used to determine oil film thickness. Films in the range 0.7 to 1.3 μm were measured; the thickness did not depend strongly on either ring speed or sealed pressure. Several practical aspects were investigated such as, attenuation in the cylinder material, response time, and transducer resolution. Whilst this study demonstrated that film thickness measurement is feasible, there are a number of practical considerations that require further work, principally the focusing and coupling of the ultrasonic transducer and the response time

Viscosity measurement in thin lubricant films using shear ultrasonic reflection

When a shear ultrasonic wave is incident on a solid and liquid boundary, the proportion that is reflected depends on the liquid viscosity. This is the basis for some instruments for on-line measurement of bulk liquid viscosity. In machine elements, the lubricant is usually present in a thin layer between two rubbing solid surfaces. The thin film has a different response to an ultrasonic shear wave than liquid in bulk. In this work, this response is investigated with the aim of measuring viscosity in situ in a lubricating film. The proportion of the wave reflected at a thin layer depends on the layer stiffness. A shear wave is reflected by the shear stiffness of the thin layer. For a thin viscous liquid layer, the stiffness is a complex quantity dependent on the viscosity, wave frequency, and film thickness. This stiffness is incorporated into a quasi-static spring model of ultrasonic reflection. In this way, the viscosity can be determined from shear-wave reflection if the oil-film thickness is known. The approach has been experimentally evaluated on some static oil film between Perspex plates. Predictions of the spring model gave good measurement up to layer thicknesses of around 15 μm. For thicker layers, the shear stiffness reduces to such an extent that almost all the wave is reflected and the difference associated with the layer response is hard to distinguish from background noise

Index to NASA Tech Briefs, 1975

This index contains abstracts and four indexes--subject, personal author, originating Center, and Tech Brief number--for 1975 Tech Briefs

Index to 1981 NASA Tech Briefs, volume 6, numbers 1-4

Short announcements of new technology derived from the R&D activities of NASA are presented. These briefs emphasize information considered likely to be transferrable across industrial, regional, or disciplinary lines and are issued to encourage commercial application. This index for 1981 Tech Briefs contains abstracts and four indexes: subject, personal author, originating center, and Tech Brief Number. The following areas are covered: electronic components and circuits, electronic systems, physical sciences, materials, life sciences, mechanics, machinery, fabrication technology, and mathematics and information sciences