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At least 109 records · Page 6

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NASA NTRS1994

Oscillating-flow regenerator test rig

This report summarizes work performed in setting up and performing tests on a regenerator test rig. An earlier status report presented test results, together with heat transfer correlations, for four regenerator samples (two woven screen samples and two felt metal samples). Lessons learned from this testing led to improvements to the experimental setup, mainly instrumentation as well as to the test procedure. Given funding and time constraints for this project it was decided to complete as much testing as possible while the rig was set up and operational, and to forego final data reduction and analysis until later. Additional testing was performed on several of the previously tested samples as well an on five newly fabricated samples. The following report is a summary of the work performed at OU, with many of the final test results included in raw data form.

Wood, J. G.↗

NASA NTRS1995

Design and development of a high-speed bearing test rig

The development of a high-speed test rig, to be used for compiling an experimental data base of bearing signatures for bearings with known faults, is described. This bearing test rig can be adapted to test oil-film bearings as well as rolling element bearings. This is achieved by mounting the test bearing in one of two special test housings, either of which can be mounted onto a common test shaft which can be driven up to 30,000 rpm. The test bearing housing for rolling element bearings can accommodate proximity displacement transducers, accelerometers, thermocouples, and acoustic emission sensors. The test bearing housing for the fluid-film bearings can accommodate the same instrumentation as well as Bourdon tube-type transducers for measuring oil film pressures around the bearing circumference.

Cockburn, J. A.↗

NASA NTRS1996

Aspirating Seal Development: Analytical Modeling and Seal Test Rig

This effort is to develop large diameter (22 - 36 inch) Aspirating Seals for application in aircraft engines. Stein Seal Co. will be fabricating the 36-inch seal(s) for testing. GE's task is to establish a thorough understanding of the operation of Aspirating Seals through analytical modeling and full-scale testing. The two primary objectives of this project are to develop the analytical models of the aspirating seal system, to upgrade using GE's funds, GE's 50-inch seal test rig for testing the Aspirating Seal (back-to-back with a corresponding brush seal), test the aspirating seal(s) for seal closure, tracking and maneuver transients (tilt) at operating pressures and temperatures, and validate the analytical model. The objective of the analytical model development is to evaluate the transient and steady-state dynamic performance characteristics of the seal designed by Stein. The transient dynamic model uses a multi-body system approach: the Stator, Seal face and the rotor are treated as individual bodies with relative degrees of freedom. Initially, the thirty-six springs are represented as a single one trying to keep open the aspirating face. Stops (Contact elements) are provided between the stator and the seal (to compensate the preload in the fully-open position) and between the rotor face and Seal face (to detect rub). The secondary seal is considered as part of the stator. The film's load, damping and stiffness characteristics as functions of pressure and clearance are evaluated using a separate (NASA) code GFACE. Initially, a laminar flow theory is used. Special two-dimensional interpolation routines are written to establish exact film load and damping values at each integration time step. Additionally, other user-routines are written to read-in actual pressure, rpm, stator-growth and rotor growth data and, later, to transfer these as appropriate loads/motions in the system-dynamic model. The transient dynamic model evaluates the various motions, clearances and forces as the seals are subjected to different aircraft maneuvers: Windmilling restart; start-ground idle; ground idle-takeoff; takeoff-burst chop, etc. Results of this model show that the seal closes appropriately and does not ram into the rotor for all of the conditions analyzed. The rig upgrade design for testing Aspirating Seals has been completed. Long lead-time items (forgings, etc.) have been ordered.

Bharat Bagepalli↗

NASA NTRS1997

Advanced Film Cooling Rig: Development and Test Results

The Advanced Film Cooling Rig (AFCR) test was a program to develop a thermal imaging camera system to measure the effectiveness of multihole film cooling. This system was used to evaluate low-thermal conductivity ceramic test panels incorporating a wide range of multihole cooling geometries. Tests were conducted with a mainstream flow of 600 F at Mach numbers of 0.37 and 1.57. Coolant flow was controlled to give a blowing parameter variation of up to 2.9. Data reduction techniques are given for camera calibration, rig temperature reflection correction, and deriving surface temperatures from video images. Results are presented in terms of overall and film cooling effectiveness distributions. A one-dimensional analysis of a unit film cooling hole was performed to generate film temperature.

Reilly, R. S.↗

NASA NTRS1999

NASA GRC's High Pressure Burner Rig Facility and Materials Test Capabilities

The High Pressure Burner Rig (HPBR) at NASA Glenn Research Center is a high-velocity. pressurized combustion test rig used for high-temperature environmental durability studies of advanced materials and components. The facility burns jet fuel and air in controlled ratios, simulating combustion gas chemistries and temperatures that are realistic to those in gas turbine engines. In addition, the test section is capable of simulating the pressures and gas velocities representative of today's aircraft. The HPBR provides a relatively inexpensive. yet sophisticated means for researchers to study the high-temperature oxidation of advanced materials. The facility has the unique capability of operating under both fuel-lean and fuel-rich gas mixtures. using a fume incinerator to eliminate any harmful byproduct emissions (CO, H2S) of rich-burn operation. Test samples are easily accessible for ongoing inspection and documentation of weight change, thickness, cracking, and other metrics. Temperature measurement is available in the form of both thermocouples and optical pyrometery. and the facility is equipped with quartz windows for observation and video taping. Operating conditions include: (1) 1.0 kg/sec (2.0 lbm/sec) combustion and secondary cooling airflow capability: (2) Equivalence ratios of 0.5- 1.0 (lean) to 1.5-2.0 (rich), with typically 10% H2O vapor pressure: (3) Gas temperatures ranging 700-1650 C (1300-3000 F): (4) Test pressures ranging 4-12 atmospheres: (5) Gas flow velocities ranging 10-30 m/s (50-100) ft/sec.: and (6) Cyclic and steady-state exposure capabilities. The facility has historically been used to test coupon-size materials. including metals and ceramics. However complex-shaped components have also been tested including cylinders, airfoils, and film-cooled end walls. The facility has also been used to develop thin-film temperature measurement sensors.

Robinson, R. Craig↗

NASA NTRS1999

Experimental Analysis of Mast Lifting and Bending Forces on Vibration Patterns Before and After Pinion Reinstallation in an OH-58 Transmission Test Rig

As part of a cooperative research program between NASA Ames Research Center, NASA Glenn Research Center, and the U.S. Army Laboratories, a series of experiments are being performed on the 500 HP OH-58a Transmission Test Rig at NASA Glenn Research Center. The findings reported in this paper were drawn from Phase 1 of a two-phase experiment, and are focused on the vibration response of an undamaged pinion gear and planetary system operating in situ in the transmission test rig. Phase 2 of the experiment, which is reported elsewhere, introduced a seeded fault into the pinion gear and tracked its progress in real-time. Based on methods presented here, further experimental research will be conducted to examine planetary system faults.

Huff, Edward M.↗

NASA NTRS2001

NASA GRC Cryogenic Seal Test Rig Capability

It has been about six years since any cryogenic seal tests were run at NASA GRC (Glenn Research Center). The Cryogenic Components Lab, where the cryogenic seal test rigs are located, has been shutdown due to the impending expansion of the Cleveland Hopkins International Airport. The current plan is to move the Cryogenic Components Lab (CCL), Cells I and 2 to NASA Plumbrook in Sandusky, Ohio. The purpose of this presentation is to inform the seal community of the cryogenic seal test rig capabilities available at NASA GRC for planning of future programs.

Proctor, Margaret↗

NASA NTRS2002

A Comparison Study of Magnetic Bearing Controllers for a Fully Suspended Dynamic Spin Rig

NASA Glenn Research Center (GRC) has developed a fully suspended magnetic bearing system for the Dynamic Spin Rig (DSR) that is used to perform vibration tests of turbomachinery blades and components under spinning conditions in a vacuum. Two heteropolar radial magnetic bearings and a thrust bearing and the associated control system were integrated into the DSR to provide noncontact magnetic suspension and mechanical excitation of the 35 lb vertical rotor with blades to induce turbomachinery blade vibration. A simple proportional-integral-derivative (PID) controller with a special feature for multidirectional radial excitation worked very well to both support and shake the shaft with blades. However, more advanced controllers were developed and successfully tested to determine the optimal controller in terms of sensor and processing noise reduction, smaller rotor orbits, and energy savings for the system. The test results of a variety of controllers we demonstrated up to the rig's maximum allowable speed of 10,000 rpm are shown.

Choi, Benjamin↗

NASA NTRS2002

Oxidation of a Silica-Containing Material in a Mach 0.3 Burner Rig

A primarily silica-containing material with traces of organic compounds, as well as aluminum and calcium additions, was exposed to a Mach 0.3 burner rig at atmospheric pressure using jet fuel. The sample was exposed for 5 continuous hours at 1370 C. Post exposure x-ray diffraction analyses indicate formation of cristobalite, quartz, NiO and Spinel (Al(Ni)CR2O4). The rig hardware is composed of a nickel-based superalloy with traces of Fe. These elements are indicated in the energy dispersive spectroscopy (EDS) results. This material was studied as a candidate for high temperature applications under an engine technology program.

Nguyen, QuynhGiao N.↗

NASA NTRS2003

Threshold Assessment of Gear Diagnostic Tools on Flight and Test Rig Data

A method for defining thresholds for vibration-based algorithms that provides the minimum number of false alarms while maintaining sensitivity to gear damage was developed. This analysis focused on two vibration based gear damage detection algorithms, FM4 and MSA. This method was developed using vibration data collected during surface fatigue tests performed in a spur gearbox rig. The thresholds were defined based on damage progression during tests with damage. The thresholds false alarm rates were then evaluated on spur gear tests without damage. Next, the same thresholds were applied to flight data from an OH-58 helicopter transmission. Results showed that thresholds defined in test rigs can be used to define thresholds in flight to correctly classify the transmission operation as normal.

Dempsey, Paula J.↗

NASA NTRS2003

Test Rig for Evaluating Active Turbine Blade Tip Clearance Control Concepts

Improved blade tip sealing in the high pressure compressor and high pressure turbine can provide dramatic improvements in specific fuel consumption, time-on-wing, compressor stall margin and engine efficiency as well as increased payload and mission range capabilities of both military and commercial gas turbine engines. The preliminary design of a mechanically actuated active clearance control (ACC) system for turbine blade tip clearance management is presented along with the design of a bench top test rig in which the system is to be evaluated. The ACC system utilizes mechanically actuated seal carrier segments and clearance measurement feedback to provide fast and precise active clearance control throughout engine operation. The purpose of this active clearance control system is to improve upon current case cooling methods. These systems have relatively slow response and do not use clearance measurement, thereby forcing cold build clearances to set the minimum clearances at extreme operating conditions (e.g., takeoff, re-burst) and not allowing cruise clearances to be minimized due to the possibility of throttle transients (e.g., step change in altitude). The active turbine blade tip clearance control system design presented herein will be evaluated to ensure that proper response and positional accuracy is achievable under simulated high-pressure turbine conditions. The test rig will simulate proper seal carrier pressure and temperature loading as well as the magnitudes and rates of blade tip clearance changes of an actual gas turbine engine. The results of these evaluations will be presented in future works.

Lattime, Scott B.↗

NASA NTRS2004

Mechanical Design of a Performance Test Rig for the Turbine Air-Flow Task (TAFT)

To support development of the Boeing-Rocketdyne RS84 rocket engine, a full-flow, reaction turbine geometry was integrated into the NASA-MSFC turbine air-flow test facility. A mechanical design was generated which minimized the amount of new hardware while incorporating all test and instrumentation requirements. This paper provides details of the mechanical design for this Turbine Air-Flow Task (TAFT) test rig. The mechanical design process utilized for this task included the following basic stages: Conceptual Design. Preliminary Design. Detailed Design. Baseline of Design (including Configuration Control and Drawing Revision). Fabrication. Assembly. During the design process, many lessons were learned that should benefit future test rig design projects. Of primary importance are well-defined requirements early in the design process, a thorough detailed design package, and effective communication with both the customer and the fabrication contractors.

Forbes, John C.↗

NASA NTRS1995

Advanced Subsonic Combustion Rig Developed

The Advanced Subsonic Combustion Rig (ASCR), a unique, state-of-the-art facility for conducting combustion research, is located at the NASA Lewis Research Center in Cleveland, Ohio. The ASCR, which was nearing completion at the close of 1995, will be capable of simulating the very high pressure and high temperature conditions that are expected to exist in future, advanced subsonic gas turbine (jet) engines. Future environmental regulations will require much cleaner burning (more environmentally friendly) aircraft engines. The ASCR is critical to the development of these cleaner engines. It will allow NASA and U.S. aircraft engine industry researchers to identify and test promising clean-burning gas turbine engine combustion concepts under the pressure and temperature conditions that are expected for those future engines. Combustion processes will be investigated for a variety of next-generation aircraft engine sizes, including engines for large, long-range aircraft (with typical trip lengths of about 3000 mi) and for regional aircraft (with typical trip lengths of about 400 mi). The ASCR design was conceived and initiated in 1993, and fabrication and construction of the rig, including the buildup of an advanced control room, took place throughout 1994 and 1995. In early 1996, the ASCR will be operational for obtaining research data. The ASCR is an intricate part of the NASA Advanced Subsonic Technology Propulsion Program, which is aimed at developing technologies critical to the next generation of gas turbine engines. This effort is in collaboration with the U.S. aircraft gas turbine engine industry. A goal of the Advanced Subsonic Technology Propulsion Program is to develop combustion concepts and technologies that will result in gas turbine engines that produce 50 percent less nitrous oxide (NO_x) pollutants than current engines do. This facility is unique in its capability to simulate advanced subsonic engine pressure, temperature, and air flow rate conditions. Specifically, it will provide operating temperatures up to 3000 F and pressures up to 60 atm. Under these conditions, researchers will obtain detailed combustion temperatures, pressures, and flow velocities as well as the chemical compositions of the combustion exhaust. Researchers also will be able to obtain data by using nonintrusive laser diagnostic techniques. The ASCR facility will be used to test fundamental combustion configurations (flametubes) for detailed study of combustion processes, to test sectors of gas turbine combustors to study the process in configurations more like those of aircraft engines, and in some cases to test full annular combustors.

Source record↗

NASA NTRS1998

Magnetic Suspension for Dynamic Spin Rig

NASA Lewis Research Center's Dynamic Spin Rig, located in Building 5, Test Cell CW-18, is used to test turbomachinery blades and components by rotating them in a vacuum chamber. A team from Lewis' Machine Dynamics Branch successfully integrated a magnetic bearing and control system into the Dynamic Spin Rig. The magnetic bearing worked very well both to support and shake the shaft. It was demonstrated that the magnetic bearing can transmit more vibrational energy into the shaft and excite some blade modes to larger amplitudes than the existing electromagnetic shakers can.

Johnson, Dexter↗

NASA NTRS2005

Hybrid Bearing Prognostic Test Rig

The NASA Glenn Research Center has developed a new Hybrid Bearing Prognostic Test Rig to evaluate the performance of sensors and algorithms in predicting failures of rolling element bearings for aeronautics and space applications. The failure progression of both conventional and hybrid (ceramic rolling elements, metal races) bearings can be tested from fault initiation to total failure. The effects of different lubricants on bearing life can also be evaluated. Test conditions monitored and recorded during the test include load, oil temperature, vibration, and oil debris. New diagnostic research instrumentation will also be evaluated for hybrid bearing damage detection. This paper summarizes the capabilities of this new test rig.

Dempsey, Paula J.↗

NASA NTRS2003

Optimal Controller Tested for a Magnetically Suspended Five-Axis Dynamic Spin Rig

NASA Glenn Research Center's Structural Mechanics and Dynamics Branch has developed a fully suspended magnetic bearing system for their Dynamic Spin Rig, which performs vibration tests of turbomachinery blades and components under spinning conditions in a vacuum. Two heteropolar radial magnetic bearings and a thrust magnetic bearing and the associated control system were integrated into the Dynamic Spin Rig to provide magnetic excitation as well as noncontact magnetic suspension of the 35-lb vertical rotor with blades to induce turbomachinery blade vibration (ref. 1). The new system can provide longer run times at higher speeds and larger vibration amplitudes for rotating blades. Also, it was proven that bearing mechanical life was substantially extended and flexibility was increased in the excitation orientation (direction and phasing).

Choi, Benjamin B.↗

NASA NTRS2004

New Dynamic Spin Rig Capabilities Used to Determine Rotating Blade Dynamics

The Dynamic Spin Rig Facility at the NASA Glenn Research Center is used to determine the structural response of rotating engine components without the effects of aerodynamic loading. Recently, this rig's capabilities were enhanced through the replacement of grease-lubricated ball bearings with magnetic bearings. Magnetic bearings offer a number of advantages--the most important here being that they not only fully support the rotor system, but excite it as well. Three magnetic bearings support the rotor and provide five axes of controlled motion: an x- and y-axis translation at each of two radial bearings and a z-axis translation in the vertical or axial direction. Sinusoidal excitation (most commonly used) can be imparted on the rotor through the radial magnetic bearings in either a fixed or rotating frame of reference. This excitation is added directly to the magnetic bearing control output. Since the rotor is fully levitated, large translations and rotations of the rotor system can be achieved. Some of the capabilities of this excitation system were determined and reported. The accelerations obtained at the tip of a titanium flat plate test article versus the swept sine excitation sent to both radial bearings in phase and perpendicular to the plane containing the two blades are shown. Recent tests required the excitation of fundamental bending and torsional blade resonances at rotor speeds up to 10,000 rpm. Successful fixed synchronous rotation of the excitation signal provided the best detectable blade resonant vibrations at excitation frequencies up to 1100 Hz for the particular blades of interest. A noncontacting laser measurement system was used to collect blade-tip motions. From these data, the amplitude and frequency of the motion could be determined as well as the blade damping properties. Damping could be determined using two methods: (1) free decay and (2) curve fitting the vibration amplitude as a function of frequency in and around the resonance of interest and using the half-power method. The free decay of a composite blade vibrating at its first bending resonance while rotating at 3000 rp is shown. This new system is currently being used to support the Efficient Low-Noise Fan project at Glenn. The damping properties of prototype hollow composite blades specially designed to reduce fan noise are currently being determined.

Provenza, Andrew J.↗

NASA NTRS2004

"Fan-Tip-Drive" High-Power-Density, Permanent Magnet Electric Motor and Test Rig Designed for a Nonpolluting Aircraft Propulsion Program

A scaled blade-tip-drive test rig was designed at the NASA Glenn Research Center. The rig is a scaled version of a direct-current brushless motor that would be located in the shroud of a thrust fan. This geometry is very attractive since the allowable speed of the armature is approximately the speed of the blade tips (Mach 1 or 1100 ft/s). The magnetic pressure generated in the motor acts over a large area and, thus, produces a large force or torque. This large force multiplied by the large velocity results in a high-power-density motor.

Brown, Gerald V.↗