1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2016 SAE International All rights reserved. No part of this p
3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/ARP6166 AEROSPACE RECOMMENDED PRACTICE ARP6166 Issued 2011-07 Reaffirmed 2016-09
5、Minisimulator Method RATIONALE ARP6166 has been reaffirmed to comply with the SAE five-year review policy. 1. SCOPE This test method is designed to simulate the synergistic combinations of oil flow, temperature cycling, hot spots, and tribology that would typically be found in a gas turbine engine.
6、The method is intended to quantitatively characterize changes in four basic oil properties that are brought about by exposure to the afore mentioned simulated turbine engine environment: the tendency of aviation lubricants to form coke deposits, viscosity changes, total acid number changes (TAN), an
7、d oil consumption. 2. APPLICABLE DOCUMENTS The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event
8、 of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. 2.1 SAE Publications Available from SAE International,
9、400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. ARP5088 Test Method for the Determination of Total Acidity in Polyol Ester and Diester Gas Turbine Lubricants by Automatic Potentiometric Titration 2.2 ASTM Intern
10、ational Publications Available from ASTM International, 100 Barr Harbor Drive, P.O. Box C700, West Conshohocken, PA 19428-2959, Tel: 610-832-9585, www.astm.org. ASTM D445-11 Standard Test Method for Kinematic Viscosity of Transparent and Opaque Liquids (and Calculation of Dynamic Viscosity) 2.3 U. S
11、. Government Publications Available from the Document Automation and Production Service (DAPS), Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094, Tel: 215-697-9495, https:/assist.daps.dla.mil/quicksearch/. FED-STD-791D Method 3410.1 High Temperature Deposit and Oil Degradation Characteri
12、stics of Aviation Turbine Oils SAE INTERNATIONAL ARP6166 Page 2 of 35 3. METHOD SUMMARY 3.1 Test Operation The minisimulator test method utilizes the minisimulator apparatus. The essential components of the minisimulator apparatus consist of a bearing housing, an oil circulation system with pump, va
13、rious heating elements and a motor to drive two test bearings residing in the bearing housing. The test apparatus is brought up to temperature, the oil flow is established, and the bearings are spun at the required speed. Conditions are maintained for 10 hours (1 cycle). The test is then shut down i
14、n reverse order and the apparatus is allowed to cool completely. This procedure is repeated 10 times. 3.2 Quantitative Characterization After each cycle of the test, oil is sampled. The viscosity and total acid number (TAN) are evaluated. After all ten cycles are completed, the apparatus is disassem
15、bled. The coke deposits on a variety of components are visually inspected and given a score. These scores are compiled into an overall score that is assigned to the test. Coupons of sample metals are placed in the oil sump to evaluate possible corrosive behavior. 4. MINISIMULATOR APPARATUS 4.1 Assem
16、bled Test Head The essential part of the minisimulator apparatus is the Assembled Test Head. Figure 1 shows an assembly drawing of the Assembled Test Head. Engineering drawings of all custom made components in the Assembled Test Head are shown in Appendix A. 4.1.1 The test bearings are two 30-mm bor
17、e angular contact ball bearings (Rolls-Royce Corp. part #6889093). 4.1.2 The thirteen (Figure 1 does not account for the four jets or the two additional ports in the middle of the head at 6:00 and 9:00) thermocouples are type J (Omega part #ICSS-18G-6). They are mounted to positions on the Test Hous
18、ing and the Rear End Cap via 1/8-inch male connectors that have been bored through (Swagelok part #SS-200-1-2BT). A spring washer is used to provide axial loading to the Test Bearings (comparable to Nested Spirawave, part number 12492-01 supplied by Smalley Steel Ring Company, Wheeling IL). The Forw
19、ard Test Bearing is secured by size W-04 lock washer and a size N-04 lock nut. The Rear Test Bearing is secured by the Bearing Retainer which attaches to the Drive Shaft by four cap screws (#3-48x3/8) 4.1.3 The oil jets are assembled into upper and lower pairs. All of the jets are connected to male
20、branch tee fittings (Swagelok SS-200-3TTM) that are screwed into female connectors (Swagelok SS-400-7-2). The upper jets are assembled by connecting the shorter jet tubes to a union cross fitting (Swagelok SS-400-4) using two short -inch sections of tubing. Similarly, the lower jets are assembled by
21、 connecting the longer jet tubes to a union tee fitting (Swagelok SS-400-3) again using two short -inch sections of tubing. The jets are connected to the test head via male connectors (Swagelok SS-200-1-2BT). 4.1.4 The air/oil drain line is attached to the Forward End Cap of the assembly by a male c
22、onnector (Swagelok part #SS-600-1-6). 4.1.5 The air/inert gas inlet is attached to the Forward End Cap of the assembly by male elbow (Swagelok part #SS-200-2-2). 4.1.6 The Forward and Rear End Caps are attached to the Test Housing via V-Band Clamps (Clampco part #994AR-0500). 4.1.7 The rod heater pl
23、aced on Rear End Cap of the assembly (hot spot heater) is rated at 240V/200W and should be the equivalent of Watlow part #J1E52KW24. The band heaters attached to the Test Housing are rated 240V/1000W and should be the equivalent of Watlow part #ME5A1JP8. 4.1.8 The O-ring on the Drive Shaft is size 1
24、15 and constructed from Viton A elastomer. SAE INTERNATIONAL ARP6166 Page 3 of 35 4.1.9 A pair of 1/8-inch stainless steel tube air cooling coils are not shown in Figure 1. Each coil makes six revolutions around the Test Housing. The coils were made by winding the 1/8-inch SS tubing around a circumf
25、erence smaller than that of the Test Housing (ensuring a snug contact when placed on the Test Housing). The coils form a single layer on the head (no overlapping). The windings are side by side (six revolutions for 1/8-inch tubing gives 3/4-inch total width for each coil). An air flow is introduced
26、to dissipate heat build-up in the head due to the bearing heaters. The coils are mirror images of one another so that cold air enters at the center of the Test Housing and hot air exits next to each bearing heater (vented to the room). 4.1.10 Four stainless steel alignment pins are used in assembly
27、of the Assembled Test Head (0.90.01 inch diameter, 0.5 inch long). 4.1.11 Air flow (4.60.1 L/min) is directed through the Air/Inert Gas Inlet (see Figure 1). The air flow is first passed through a filter (Norgren part #5350-03) then sent through a bubbler so that moist air is introduced at the Air/I
28、nert Gas Inlet. SAE INTERNATIONAL ARP6166 Page 4 of 35 FIGURE 1 - SECTION DRAWING OF THE ASSEMBLED TEST HEAD SAE INTERNATIONAL ARP6166 Page 5 of 35 4.2 Drive System The Assembled Test Head attaches to an inline torque sensor equivalent to MCRT model 48701V(25-0) via flexible couplings. The torque se
29、nsor in turn attaches to the drive motor. The drive motor should be rated for at least 3 HP and 12 000 RPM (equivalent to Reuland Electric Company model #145-R-0228, rated for 460V, 4A, 3, 200 Hz). A Lancer GPD502 model #L714 inverter is suitable for powering the aforementioned Reuland Electric moto
30、r. The Assembled Test Head, torque sensor and drive motor should all be mounted to a robust test stand that adheres to site safety standards. 4.3 Oil Flow System There is considerable latitude in how the oil flow system is constructed. Figure 2 illustrates a schematic diagram of one such system, des
31、cribing the essentials that are needed. The oil lines should be ” stainless steel tubing with stainless steel compression fitting couplings. Primarily, tubing should be in place to transport oil from an oil sump, to the oil jets on the Assembled Test Head, and then back to the oil sump. Provision mu
32、st be made to sample oil from the system and add makeup oil to the system. Four thermocouples must be incorporated into the system to measure oil temperature as the oil enters each of the oil jets. A heating tape (310-watt, 6 length, ” width) should be used to heat the oil jet assembly and the tubin
33、g leading up to the oil jet assembly. FIGURE 2 - DIAGRAM OF FLOW SYSTEM BASIC CONCEPTS SAE INTERNATIONAL ARP6166 Page 6 of 35 4.4 Oil Sump and Pump 4.4.1 A gear pump (comparable to Zenith Precision Gear Pump model CPB-5719 supplied by Parker Hannifin Corp., Walthram MA) for cycling oil should be use
34、d. To drive the pump, a HP, 1775 RPM motor should be used (equivalent to US Electrical Motors model #F012, 230V/460V, 2.8A/1.4A, 3, 60 Hz). A suitable inverter should be chosen to drive the motor (for the F012 motor, a Lancer GPD402 model #DS703 is appropriate). The pump should be placed within the
35、sump. 4.4.2 As with the flow system, there is considerable latitude in how the oil sump system is designed. Provisions should be made to place a 200-mesh screen inline on the inlet to the pump to act as a filter. The sump capacity should be 4 liters, though the designer should keep in mind that the
36、test is run with approximately 1.5 liter of test oil. Any elastomeric o-ring type seals should be fabricated from Viton A material. Figure 3 shows a drawing of an example pump/sump arrangement. In this arrangement, three heaters are employed to maintain temperature. The upper band heater is a Watlow
37、 part #ME6J1JP6B rated at 480V/1000W. The lower band heater is a Watlow part #ME6J1JP5 rated at 480V/1250W. The bottom ring heater is a Chromalox part#127FP rated at 240V/550W. Provisions should be made to mount coupons of sample metals. FIGURE 3 - DIAGRAM OF POTENTAIL PUMP/SUMP SYSTEM 4.5 Control a
38、nd Data System The detailed design of the system control and data acquisition is left to the user. The control system must allow for temperature based control of the heaters for the sump, the forward and rear Test Bearings, and hot spot. A variable transformer (120 V, 10 A) is typically used to appl
39、y power to the heating tape for the oil supply line. A system for logging process data (all measured temperatures, oil flow rate, motor speed, and torque) versus time should be designed or purchased. SAE INTERNATIONAL ARP6166 Page 7 of 35 5. APPARATUS PREPARATION 5.1 Cleaning The goal of the system
40、cleaning is to regenerate the system after a test such that there is uniformity of surface finish from test to test. The components of the minisimulator test section must be prepared so as to have clean, polished surfaces. The following steps should be followed: 5.1.1 Clean all parts of the minisimu
41、lator with an initial solvent wash to remove any oil residue from the previous test. Any kerosene-like solvent is acceptable (example Premium Gold Solvent from Safety Kleen). 5.1.2 Once the parts have air-dried, they should be placed in a heated sonic bath charged with a water/detergent mixture. 5.1
42、.3 The parts are then scrubbed with cleanser and thoroughly rinsed. While wet, the parts are given a final rinse with purified water and allowed to air-dry in a clean, covered, stainless steel pan. A nonabrasive scrub cloth should be used to clean the test head components, pump components, sump, and
43、 fittings. Nylon-bristle test tube brushes are recommended for use in cleaning the interior of the stainless steel tubing of the minisimulator system. Aggressive deposits within the minisimulator test section often remain even after sonic cleaning. A soft metal (i.e. brass) rod is useful in flaking
44、off persistent carbon deposits. Even a wire brush can be used to remove deposits from test section components, but surfaces should be polished with 600-grit wet-sand paper to remove scratch marks. It should be noted that all oil-wetted parts should be handled with gloves once they have been cleaned.
45、 5.2 Assembly The two primary elements of the minisimulator that require assembly are the sump and test section. 5.2.1 Assemble the gear pump. The elements of the pump should be lubricated with the test oil as they are connected. In particular, the gears should be primed with oil and rotated to ensu
46、re uniform coverage. Once all layers of the pump are together, the assembly should be loosely bolted together. Using either the inlet or outlet fitting as a support, the pump should be secured in a vice so that the bolts can be tightened. By suspending the pump, the various layers of the assembly ca
47、n be adjusted for proper alignment. The four bolts should be tightened gradually in an “X” pattern while the shaft is repeatedly turned by hand to ensure proper alignment. 5.2.2 The assembled pump can then be installed into the sump system consistent with details of the user designed sump system. 5.
48、2.3 Mount the metal sample coupons in the sump. The coupons should be cleaned, polished, and weighed before they are installed. 5.2.4 The remainder of the sump system should be assembled. The detailed procedures for assembling the sump system should be customized to the sump design that has been dev
49、eloped by the user. 5.2.5 Once assembled, the sump canister should then be filled with 1510 5 mL of the fresh test fluid. If O-ring seals are incorporated into the design, new O-rings should be used for each test. 5.2.6 The assembly of the test head begins with an initial solvent wash of the two test Test Bearings. The Test Bearings come vacuum-sealed with a coating of mineral oil. After the initial rinse (using heptane
