Determination of ball bearing dynamic stiffness

The dynamic radial stiffness characteristics of rolling element bearings are currently determined by analytical methods that have not been experimentally verified. These bearing data are vital to rotating machinery design integrity because accurate critical speeds and rotor stability predictions are highly dependent on the bearing stiffness. A tester was designed capable of controlling the bearing axial preload, speed, and rotor unbalance. The rotor and support structures were constructed to permit critical speeds that are predominantly determined by a 57 mm test bearing. A curve of calculated critical speed versus stiffness was used to determine the actual bearing stiffness from the empirical data. The results of extensive testing are used to verify analytical predictions, increase confidence in existing bearing computer programs, and to serve as a data base for efforts to correct these programs

Rocketdyne LOX bearing tester program

The cause, or causes, for the Space Shuttle Main Engine ball wear were unknown, however, several mechanisms were suspected. Two testers were designed and built for operation in liquid oxygen to empirically gain insight into the problems and iterate solutions in a timely and cost efficient manner independent of engine testing. Schedules and test plans were developed that defined a test matrix consisting of parametric variations of loading, cooling or vapor margin, cage lubrication, material, and geometry studies. Initial test results indicated that the low pressure pump thrust bearing surface distress is a function of high axial load. Initial high pressure turbopump bearing tests produced the wear phenomenon observed in the turbopump and identified an inadequate vapor margin problem and a coolant flowrate sensitivity issue. These tests provided calibration data of analytical model predictions to give high confidence in the positive impact of future turbopump design modification for flight. Various modifications will be evaluated in these testers, since similar turbopump conditions can be produced and the benefit of the modification will be quantified in measured wear life comparisons

Rotor response for transient unbalance changes in a nonlinear simulation

Transient unbalance shifts were determined not to excite a rotor instability in the high pressure turbomachinery of the Space Shuttle Main Engine using the current rotor dynamic models. Sudden unbalance changes of relatively small magnitudes during fast-speed ramps showed stable nonsynchronous motion depending on the resultant unbalance distribution at subsequent high speed dwells. Transient moment unbalance may initiate a limit cycle subsynchronous response that shortly decays, but a persistent subsynchronous with large amplitudes was never achieved. These limit cycle subsynchronous amplitudes appear to be minimized with lower unbalance magnitudes, which indicates improved rotor balancing would sustain synchronous motion only. The transient unbalance phenomenon was determined to be an explanation for synchronous response shifts often observed during engine tests

Housing flexibility effects on rotor stability

Preliminary rotordynamic evaluations are performed with a housing stiffness assumption that is typically determined only after the hardware is built. In addressing rotor stability, a rigid housing assumption was shown to predict an instability at a lower spin speed than a comparable flexible housing analysis. This rigid housing assumption therefore provides a conservative estimate of the stability threshold speed. A flexible housing appears to act as an energy absorber and dissipated some of the destabilizing force. The fact that a flexible housing is usually asymmetric and considerably heavier than the rotor was related to this apparent increase in rotor stability. Rigid housing analysis is proposed as a valuable screening criteria and may save time and money in construction of elaborate housing finite element models for linear stability analyses