Signature Analysis of Cracked Cantilever Beam

International Journal of Advanced in Engineering and Technology (IJARET) International Journal of Advanced Research Research in Engineering ISSN 0976
6480(Print), ISSN 0976 6499(Online) Volume 1, Number 1, May - June (2010), IAEME and Technology (IJARET), ISSN 0976 6480(Print) ISSN 0976 6499(Online) Volume 1 Number 1, May - June (2010), pp. 105-117 IAEME IAEME, http://www.iaeme.com/ijaret.html
IJARET
SIGNATURE ANALYSIS OF CRACKED CANTILEVER BEAM

Sharad V. Kshirsagar Asst. Professor, Mechanical Engineering Department Sinhgad College of Engineering Pune, E-mail: [email protected] Dr. Lalit B. Bhuyar Mechanical Engineering Department Prof. Ram Meghe Institute of Technology & Research Badnera, Maharashtra
ABSTRACT
Beams are more widely used in the machine-structures. Fatigue-type of loading of such engineering parts is likely to introduce cracks at the highly stressed regions and lead to damage and deterioration during their service life. Cracks are a main cause of structural failure. Once a crack is initiated, it propagates and the stress required for propagation is smaller than that required for crack initiation. After many cycles operating stresses may be sufficient to propagate the crack. The crack propagation takes place over a certain depth when it is sufficient to create unstable conditions and fracture take place. The sudden failure of components is very costly and may be catastrophic in terms of human life and property damage. Forced vibration analysis of a cracked cantilever beam was carried out and the results are discussed in this paper. An experimental setup was designed in which a cracked cantilever beam excited by an exciter and the signature was obtained using an accelerometer attached to the beam. To avoid non-linearity, it was assumed that the crack remain always open. Keywords: Crack detection, forced vibrations, signature analysis.
1. INTRODUCTION
Literature on Fault detection and condition monitoring was focused on the vibration-based method which can be classified into modal-based and signature-based methods. In modal based techniques data can be condensed from the actual measured 105
International Journal of Advanced Research in Engineering and Technology (IJARET) ISSN 0976 6480(Print), ISSN 0976 6499(Online) Volume 1, Number 1, May - June (2010), IAEME
quantities like resonant frequencies, mode shape vectors and quantities derived from these parameters for the crack detection [1, 3, 4, 6]. In signature based methods the vibration signature of cracked machinery structure can be useful for the fault diagnosis and condition monitoring. Thus, the development of crack detection methods has received increasing attention in recent years. Among these techniques, it is believed that the monitoring of the global dynamics of a structure offers favorable alternative if the on-line (in service) damage detection is necessary. In order to identify structural damage by vibration monitoring, the study of the changes of the structural dynamic behavior due to cracks is required for developing the detection criterion. [2, 5, 7-13].
2. GOVERNING EQUATIONS OF FORCED VIBRATION

The equation of motion for the beam element without crack can be written as follows from [14]:
where [M ]
(e )
-------------------------------- (1) (e ) is the element mass matrix, [K wc ] is the element stiffness matrix,
(e )
{F (t )}(e )
is the element external force vector, {q(t )}
is the element vector of nodal

wc
degree of freedoms and t is the time instant. The subscript
represents without crack,
the superscript e represents element and dot represents the derivative with respect to the time. The crack is assumed to affect only the stiffness. Hence the equation of motion of a cracked beam element can be expressed as
where {qc (t )}
(e )
------------------------------- (2) is the nodal degrees of freedom of the cracked element, the
(e )
subscript c represents the crack and [K c ] and is given as
is the stiffness matrix of the cracked element
[K c ](e ) = [T ][C ](e ) [T ]T ------------------------------------------- (3)

with
[C ](e ) = [C0 ](e ) + [Cc ](e ) ------------------------------------------ (4)
106
(e ) (e )
where [C0 ]
is the flexibility matrix of the uncracked beam element, [Cc ]

(e )
is the
flexibility matrix of the crack, and [C ] beam element.
is the total flexibility matrix of the cracked
Equations of motion of the complete system can be obtained by assembling the contribution of all equations of motion for cracked and uncracked elements in the system. Then the system equation of motion becomes --------------------------------------- (5) where [M ] is the assembled mass matrix, [K ] is the assembled stiffness matrix,
{F (t )} is the assembled external force vector, and {q(t )} is the assembled vector of nodal
dofs of the system. Let the force vector be defined as
{F (t )} = {F }e jwt , ----------------------------------------------- (6)

where w is the forcing frequency, F is the force amplitude vector (elements of which are complex quantities) and
j = 1
{}
. Thus, the response vector can be assumed as
{q(t)} ={q}ejwt, ------------------------------------------------ (7)

where q is the response amplitude vector and their elements are complex quantities. Using Eqs. (6) and (7) for modal frequency, the system governing equation as follows:
{}
( w [M ] + [K ]){q}= {F }. ------------------------------------------ (8)

2
For a given system properties (i.e. [M ] and [K ] the response can be simulated from Eq. (8) corresponding to a given force F .
{}
3. SIMULATION
In the finite element simulation, a cantilever beam with rectangular edge crack is considered. The length and cross-sectional area of the beam are 800 mm, and 50x6 mm2, respectively. As for the material properties the modulus of elasticity (E) is 0.675 1011 N/m2, the density () 27522.9 kg/m3 and the Poissons ratio ( ) is 0.33.
107
3.1. Generation of Cracked Beam Model

A 8-node three-dimensional structural solid element under SOLID 45 was selected to model the beam. The beam was discretized into 11859 elements with 54475 nodes. Cantilever boundary conditions modeled by constraining all degrees of freedoms of the nodes located on the left end of the beam. APDL PROGRAMMING is used to create 135 cracked beam models by varying the crack depth from 5 mm to 45 mm and crack location from 50 mm to 750 mm. Figure 1 show the finite element mesh model of the beam generated in Ansys (12).
Figure 2 Finite element mesh model.
3.2 Harmonic Analysis

Full Solution Method, Reduced Solution Method, Mode superposition Method are the methods to be used to solve the harmonic equation. Mode Superposition Method is used to solve in the current analysis. [M] {} + [C] {} + [K] {u} = {Fa} __________________________(9) where: [M] = structural mass matrix [C] = structural damping matrix [K] = structural stiffness matrix {} = nodal acceleration vector {} = nodal velocity vector {u} = nodal displacement vector
108
{Fa} = applied load vector All points in the structure are moving at the same known frequency, however, not necessarily in phase. Also, it is known that the presence of damping causes phase shifts. Therefore, the displacements may be defined as: {u} = {umax ei }ei where: umax = maximum displacement i = square root of -1 = imposed circular frequency (radians/time) = 2f f = imposed frequency (cycles/time) t = time t --------------------------------------------- (10)
= displacement phase shift (radians)

{ Fa } = {Fmax ei }ei where: Fmax = force amplitude t-------------------------------------------(11)
= force phase shift (radians)

The dependence on time (ei t) is the same on both sides of the equation and may therefore be removed. Figure 2 show the boundary condtions for harmonic analysis.
Figure 2 Boundary conditions for harmonic analysis.
109
4. EXPERIMENTATION
A number of carefully designed experiments were carried out on a Cantilever Beam. Figure 3 shows the components of this experimentation. Vibration signals were collected for both uncracked and several cracked beam conditions. The excitation frequency was set at approximately 40 Hz. With the sensor mounted on the beam at free end, vibration signals were measured for various fault conditions by on-line monitoring when beam was under stationary excitation. Table 1 show the comparison of the experimental results with the simulated results.
Crack case
1 2 3 4 5 6 7
Figure 3 Experimental setup Table 1 Comparison of simulated and experimental results Crack Mode 1 Mode 2 Mode 3
C/L 1/16 3/16 5/16 7/16 8/16 11/16 14/16 a/h 0.1 0.2 0.1 0.4 0.3 0.4 0.2 0.3 0.2 0.5 0.2 0.4 0.5 Simulated 0.9901 0.9614 0.9935 0.8929 0.9636 0.9315 0.9917 0.9805 0.9944 0.9537 0.9990 0.9951 1 Expt. 1 0.97 1 0.9118 0.9708 0.9433 0.9987 0.9898 1 0.9611 1 1 1 Simulated 0.9945 0.9792 0.9999 0.9972 0.9863 0.9747 0.9804 0.9559 0.9767 0.8477 0.9857 0.9363 0.9917 Expt. 1 0.9867 1 1 0.99 0.9780 0.9890 0.9623 0.9901 0.8602 0.9945 0.9456 0.9989 Simulated 0.9973 0.9899 0.9987 0.9769 0.9589 0.9265 0.9962 0.9912 0.9999 0.9986 0.9753 0.9046 0.9514 Expt. 1 0.9904 1 0.9856 0.9604 0.9394 1 1 1 1 0.9790 0.9200 0.9654
110
5. RESULTS AND DISCUSSIONS

Before the experiments were carried out, the first three natural frequencies of the beams were simulated by FEA. From the results obtained, it was decided that using a frequency range upto 1.2 kHz for experimental measurements would be sufficient to include the first three natural frequencies. The frequency response functions obtained were curve-fitted. The simulated data from the curve-fitted results were tabulated and plotted in the form of frequency ratio (ratio of the natural frequency of the cracked beam that of the uncracked beam) versus the crack depth ratio (a/h) [the ratio of the depth of a crack (a) to the thickness of the beam (h)] for various crack location ratios (C/L) (ratio of the location of the crack to the length of the beam). Figure 4 to 6 show the plots of the first three frequency ratios as a function of crack depths for some of the crack positions considered for each set of boundary conditions (fifteen locations for each set of boundary conditions). Figure 7 to 9 shows the frequency ratio variation of three modes in terms of crack position for various crack depth.
1
1 Frequency Ratio 1st Mode 0.9 0.8 0.7 0.6 0.5 0.1 0.3 0.5 0.7 0.9 Crack Depth Ratio
2 3 4 6 5
Figure 4 Fundamental natural frequency ratio in terms of crack depth for various crack positions C / l (115/16; 29/16; 37/16; 45/16; 62/16).
111
1 0.9 Frequency Ratio 2nd Mode 0.8 0.7 0.6 0.5 0.4 0.3 0.1 0.3 0.5 0.7 0.9 Crack Depth Ratio
1 2 3 4 5 6
Figure 5 Second natural frequency ratio in terms of crack depth for various crack Positions C / l (115/16; 22/16; 35/16; 46/16; 57/16; 610/16).
1 Frequency Ratio 3rd Mode 0.9 0.8 0.7 0.6 0.5 0.4 0.1 0.3 0.5 0.7 0.9 Crack Depth Ratio
1 2 3 4
Figure 6 Third natural frequency ratio in terms of crack depth for various crack positions C / l (12/16; 215/16; 39/16; 414/16; 513/16).
Frequency Ratio 1st Mode 1.00 0.80 0.60 0.40 0.20 0.0625
0.3125
0.5625
0.8125
Crack Location Ratio 0.1 0.3 0.5 0.7 0.9
Figure 7 1st Mode frequency ratio in terms of crack position for various crack depths.
112
Frequency Ratio 2nd Mode
0.90 0.70 0.50 0.30 0.0625
0.3125
0.5625
0.8125
Figure 8 2nd Mode frequency ratio in terms of crack position for various crack depths.
Frequency Ratio 3rd Mode
0.90 0.70 0.50 0.30 0.0625
0.3125
0.5625
0.8125
Figure 9 3rd Mode frequency ratio in terms of crack position for various crack depths. From the results and plots the following observations were made for al1 the cases considered: i. Natural frequencies were reduced due to presence of crack. ii. Effects of cracks were high for the small values of crack location ratio iii. The second natural frequency was greatly affected at the C / l = 11/16 for all crack depths. iv. The third natural frequency was almost unaffected for the crack locations ( C / l = 2/16 and 8/16); the reason for this influence was that the location of nodal point was located at that point on the beam. v. Due to shifts in the nodal positions (as a consequence of cracking) of the second and the third modes, the changes in the higher natural frequencies depended on how close the crack location was to the mode shape nodes. Consequently, it was be observed from 113
the results that the trend of changes in the second, and the third frequencies are not monotonic, as we have in the first natural frequency. vi. From the results obtained, it is observed, for example, that when the crack depth ratio is 0.9, the third natural frequency was comparatively much less affected than the first and second frequencies for a crack located at C / l =8/16 but, it is highly affected for other crack locations. This could be explained by the fact that decrease in frequencies is greatest for a crack located where the bending moment is greatest. It appears therefore that the change in frequencies is not only a function of crack depth and crack location, but also of the mode number. vii. For various cases considered, the frequencies decreased rapidly with the increase in the crack depths for all three modes. As stated earlier, the decrease in the fundamental natural frequency was greatest when the crack occurred closer to the fixed point. This could be explained by the fact that the bending moment was the largest at that point (where the amplitude of the first mode shape is greatest) for the first mode, thereby, resulting in a greater loss of bending stiffness due to crack. However, the second and third modes were less affected at this location. The frequencies decreased by about 23.7% & 10.2%, and 49.7% for the first, second and third modes, respectively, as the crack grew to half of the beam depth (for crack at 50 mm from fixed end).
35 30 25 Area Ratio 20 15 10 5 0 0.1 0.2 0.0625 0.3 0.4 0.5 0.6 0.7 0.5000 0.8 0.5625 0.9 Crack Depth 0.2500 0.3125
Figure 10 Area under the frequency response curve as a function of crack position.
114
14 12 10 Area Ratio 8 6 4 2 0 0.0625
0.1875
0.3125
0.4375
0.5625
0.6875
0.8125
0.9375
Crack Location 0.4 0.5 0.7 0.9
Figure 11 Area under the frequency response curve as a function of crack depth.
CONCLUSIONS
Based on the experimental data, and plots, and the observations above, numerous inferences could be made such as follows: a) For of the cases considered, the dopes of frequency ratio versus crack depth curves were very small for small crack depth ratios. This implies that small cracks have little effects on the sensitivities of natural frequencies. Hence, using only results based on frequency changes alone for identifying cracks in most practical problems may be misleading as it is very unlikely to have large cracks. b) For a particular mode, the decrease in frequency and change in mode shape become noticeable as the crack grew bigger. c) For a given crack depth ratio, the location of the crack greatly affects the dynamic response of the cracked beam. d) Investigating the mode of vibration at some crack location may indicate a pure bending mode for small crack depth ratios, but, as the crack grows in size. The ending mode may contain a significant influence of longitudinal vibration mode also (occurrence of coupling). e) Fatigue crack alters the local stiffness which changes dynamic response. From Fig. 10 -11 it is seen that area under the frequency response curve can be used as one of the elements of crack detection.
115
REFERENCES
[1] T.G.Chondros, A.D.Dimarogonas and J.Yao, A Continuous Cracked Beam Vibration Theory, Journal of Sound and Vibration, 215(1), 1998, pp.17-34 [2] George D. Gounaris, Chris A. Papadopoulos, Crack Identification in Rotating Shafts by Coupled Response Measurements, Engineering Fracture Mechanics, 69, 2002, pp.339-352 [3] G.M. Owolabi, A.S.J. Swamidas, R. Seshadri, Crack Detection in Beams using Changes in Frequencies and Amplitudes of Frequency Response Functions, Journal of Sound and Vibration, 265, 2003, pp.1-22 [4] Shuncong Zhong, S. Olutunde Oyadiji, Analytical Predictions of Natural Frequencies of Cracked Simply Supported Beams with a Stationary Roving Mass, Journal of Sound and Vibration, 311 ,2008, pp.328-352 [5] Jiawei Xiang, Yongteng Zhong, Xuefeng Chen, Zhengjia He, Crack Detection in a Shaft by Combination of Wavelet-Based Elements and Genetic Algorithm, International Journal of Solids and Structures, 45, 2008, pp.4782-4795 [6] Marta B. Rosales , Carlos P. Filipich, Fernando S. Buezas, Crack Detection in Beam-Like Structures, Engineering Structures, 31 ,2009, pp.2257-2264 [7] R. K. C. Chan and T. C. Lai, Digital Simulation Transverse Crack, Appl. Math. Modelling, 19, 1995, pp.411-420 [8] Menderes Kalkat, Sahin Yildirim, Ibrahim Uzmay, Design of Artificial Neural Networks for Rotor Dynamics Analysis of Rotating Machine Systems, Mechatronics, 15 ,2005, pp.573-588 [9] Weixiang Sun, Jin Chen, Jiaqing Li, Decision Tree and PCA-Based Fault Diagnosis of Rotating Machinery, Mechanical Systems and Signal Processing, 21 ,2007, 1300-1317 [10] A.K.Darpe, K.Gupta, A.Chawla, Dynamics of a Bowed Rotor with a Transverse Surface Crack, Journal of Sound and Vibration, 296, 2006, pp.888-907 [11] Ashish K. Darpe, A Novel Way to Detect Transverse Surface Crack in a Rotating Shaft, Journal of Sound and Vibration, 305 ,2007, pp.151-171
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[12] K.M.Saridakis, A.C.Chasalevris, C.A. Papadopoulos, A.J. Dentsoras, Applying Neural Networks, Genetic Algorithms and Fuzzy Logic for the Identification of Cracks in Shafts by using Coupled Response Measurements, Computers and Structures, 86 ,2008, pp.1318-1338 [13] Robert Gasch, Dynamic Behaviour of the Laval Rotor with a Transverse Crack, Mechanical Systems and Signal Processing, 22 ,2008, pp.790-804 [14] N. Dharmaraju, R. Tiwari, S. Talukdar,(2004), Identification of an Open Crack Model in a Beam Based on ForceResponse Measurements, Computers and Structures 82, pp.167-179
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Signature Analysis of Cracked Cantilever Beam

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International Journal of Advanced in Engineering and Technology (IJARET) International Journal of Advanced Research Research in Engineering ISSN 0976

SIGNATURE ANALYSIS OF CRACKED CANTILEVER BEAM

2. GOVERNING EQUATIONS OF FORCED VIBRATION

is the element external force vector, {q(t )}

is the element vector of nodal

degree of freedoms and t is the time instant. The subscript

represents without crack,

subscript c represents the crack and [K c ] and is given as

is the stiffness matrix of the cracked element

[K c ](e ) = [T ][C ](e ) [T ]T ------------------------------------------- (3)

[C ](e ) = [C0 ](e ) + [Cc ](e ) ------------------------------------------ (4)

is the flexibility matrix of the uncracked beam element, [Cc ]

flexibility matrix of the crack, and [C ] beam element.

is the total flexibility matrix of the cracked

{F (t )} = {F }e jwt , ----------------------------------------------- (6)

. Thus, the response vector can be assumed as

{q(t)} ={q}ejwt, ------------------------------------------------ (7)

( w [M ] + [K ]){q}= {F }. ------------------------------------------ (8)

3.1. Generation of Cracked Beam Model

Figure 2 Finite element mesh model.

3.2 Harmonic Analysis

= displacement phase shift (radians)

= force phase shift (radians)

Figure 2 Boundary conditions for harmonic analysis.

5. RESULTS AND DISCUSSIONS

Crack Location Ratio 0.1 0.3 0.5 0.7 0.9

Frequency Ratio 2nd Mode

0.90 0.70 0.50 0.30 0.0625

Crack Location Ratio 0.1 0.3 0.5 0.7 0.9

0.90 0.70 0.50 0.30 0.0625

Crack Location Ratio 0.1 0.3 0.5 0.7 0.9

14 12 10 Area Ratio 8 6 4 2 0 0.0625

Crack Location 0.4 0.5 0.7 0.9

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