Investigation of Sub Synchronous Vibration of Very High Speed Turbocharger Semi-Floating Bearing System: Prediction vs Test

Abstract

Automotive engines are facing increased design focus towards downsizing, higher performance and lower emissions, in the process, challenging turbocharger (TC) technology to their limits. Downsizing of the engine needs smaller compressor and turbine wheels to achieve the critical flow requirements that leads to very high TC operating speeds of more 300k rpm. In general, TC rotor is most commonly supported by hydrodynamic fully floating (RFRB) or semi-floating bearing (SFRB) systems. For such high-speed applications, SFRB could be preferred bearing system where inner and outer bearing clearances act as a plain journal bearing and a squeeze film damper. These hydrodynamic bearings, exhibit non-linear oil whirl/whip phenomena in the inner bearing that leads to higher sub-synchronous vibration and overall deflection of the shaft. Sub-synchronous behavior of the SFRB is evaluated both numerically and experimentally (hot gas stand) for two design variants and results are published in this paper. TCs were run up in hot gas stand and were recorded using NVH Data Acquisition System (DAQ) with frequency analyzers and eddy current displacement sensors. In numerical simulations, multi-body dynamics (MBD) of flexible rotor and housing structures are coupled with elasto-hydrodynamics (EHD) of the inner and outer oil films. The energy equation is considered for calculation of oil film temperature in EHD using thermal boundary condition obtained from 3D FE simulation. Detailed numerical investigation was conducted using EHD joint definitions in the above bearing system. Good agreement was obtained between test and prediction, and finer source characterization was achieved using simulation.