Personal Experience Summary of


Detailed Experience Summary at Teledyne CAE

Teledyne CAE is a manufacturer of small gas turbine engines, most of which are used in expendable DOD missile systems. Ted was hired on 28 June 1982 as a Senior Design Engineer in the Bearings and Lubrication Group and promoted to Principal Engineer in 1985.

Ted's first assignment was as a Program Manager for an IR&D project to develop a full ceramic roller bearing for an advanced Harpoon (J402) missile engine. The Ceramic Roller Bearing Development Program was funded by NAPC (Navy). At the time, no one had ever developed a full ceramic roller bearing for a gas turbine engine. A requirement to make the bearing operate for 5+ hours without the benefit of oil or grease lubrication at 500+ °F and at 1 MDN made the project very challenging. Silver or gold plating was used as a solid lubricant. Other challenges were the mounting of the ceramic rings to the metal shafting. Several complex mounting schemes were developed and tested in this program. Several ceramic bearings ran for the required 5 hour test time. Ted acquired and set up both the TRIBO1 and the A.B. Jones Bearing Analysis computer programs at Teledyne to assist in the design of the ceramic bearing. A NASA computer code (developed by Chris Taylor) was used to design the mounting of the ceramic rings onto the metal shaft and housing. Several presentations were made to NASA, NAPC and WPAFB. This project was terminated in 1985. A technical paper titled "The Development of an All Ceramic Mainshaft Roller Bearing for Advanced Expendable Gas Turbine Engine" was written for presentation at an AIAA conference. Distribution of this paper was cancelled by the DOD because the test engine was classified as DOD Confidential on the day before the paper was to be presented.

Another advanced bearing project was the development of a full ceramic ball bearing that used complex dichalcogenides as a solid lubricant. This bearing operated at 1500 °F and 1.5 MDN for several hours. The bearing glowed so brightly that no illumination was needed to take video of the operating bearing.

Ted worked on multiple high speed metal bearing development projects, including an advanced 3 MDN roller bearing for the ATEGG JTDE program and a 3.5 MDN ball bearing for an advanced rig application. Other bearing projects include the design of high speed closed sump (oil or grease) bearing compartments, ultra small bearings for miniature gas turbine engines, bearings for low cost radial turbine engines and failure analyses of bearings used in existing gas turbine engines.

Other project work included:

The design of carbon nose and labyrinth seals using compressible flow analysis and the SINDA thermal analysis computer program.

A thermal (SINDA) and structural (ANSYS) analysis of a gas turbine combustor.

The design of bearings and gears for a counter-rotating gearbox for an advanced cruise missile development program. The gearbox was the size of a 3 pound coffee can and transmitted 1500 HP at peak power.

Ted left Teledyne CAE in April 1989 during a forced reduction of the work staff resulting from Teledyne CAE not being selected to develop a gas turbine engine for the FOG-M missile program. Ted was hired by General Electric Aircraft Engines to design the mainshaft bearings in the GE90.