In the micro gas turbine sector, the reliability of the backup lubrication system is a critical point. This article examines a specific case of hydrodynamic bearing failure, where seizure originated from the interruption of the emergency lubricating fluid. The forensic analysis process is detailed using a 3D pipeline that integrates PolyWorks for point cloud capture and processing, and Autodesk Fusion for damage reconstruction and simulation.
Scanning and modeling pipeline for failure inspection 🔧
The inspection protocol began with scanning the bearing and shaft surfaces using a structured light scanner, generating a dense point cloud. This was processed in PolyWorks to align the captures and remove noise, obtaining a high-precision mesh. Subsequently, the mesh was exported to Autodesk Fusion. There, geometric deviation analysis was performed, comparing the profile of the seized bearing with its original CAD design. The metal-to-metal contact zones and drag marks were visually identified, quantifying plastic deformation and material loss on the friction surfaces.
The day the backup oil said no, thanks 😅
It turns out that the backup fluid, the one that always promises to be there when everything goes south, decided to take a vacation right at the worst possible moment. The bearing, which had been spinning happily and lubricated until then, suddenly found itself in a pure, hard friction relationship with the shaft. The seizure was so intense that the marks look like a road map of a city without asphalt. Moral of the story: in the world of turbines, blindly trusting Plan B is like asking a cat to watch your fish tank.