Diagnostics of Subsynchronous Vibrations in Rotating Machinery - Methodologies To Identify Potential Instability
Diagnostics of Subsynchronous Vibrations in Rotating Machinery - Methodologies To Identify Potential Instability
POTENTIAL INSTABILITY
A Thesis
by
RAHUL KAR
MASTER OF SCIENCE
August 2005
POTENTIAL INSTABILITY
A Thesis
by
RAHUL KAR
MASTER OF SCIENCE
Approved by:
August 2005
ABSTRACT
coupled forces from variable fluid dynamic pressure around a rotor component, acting in
the direction of the forward whirl and causing subsynchronous orbiting of the rotor.
However, all subsynchronous whirling is not unstable and methods to diagnose the
potentially unstable kind are critical to the health of the rotor-bearing system.
subsynchronous vibrations are benign or have the potential to become unstable. Several
methods will be detailed to draw lines of demarcation between the two. Considerable
focus of the research has been on subharmonic vibrations induced from non-linear
bearing stiffness and the study of vibration signals typical to such cases. An analytical
model of a short-rigid rotor with stiffness non-linearity is used for numerical simulations
frequency with known eigenvalues. Several test rigs are utilized to practically
A remarkable finding has been the possibility of diagnosing instability using the
synchronous phase angle. The synchronous phase angle β is the angle by which the
unbalance vector leads the vibration vector. Experiments have proved that β changes
appreciably when there is a de-stabilizing cross coupled force acting on the rotor as
compared to when there is none. A special technique to calculate the change in β with
Subsequently, a correlation between the synchronous phase angle and the phase angle
measured with most industrial balancing instruments is derived so that the actual
‘LVTRC’. The software was developed in tandem with this thesis project. It is a stand-
alone application that can be used for field measurements and analysis by
turbomachinery companies.
v
DEDICATION
- Bill Watterson
vi
ACKNOWLEDGMENTS
Turbomachinery Laboratory. Without his deep insights and guidance this thesis would
not have been possible. Mr. Preston Johnson (National Instruments) has been an
inspiration behind the development of LVTRC – the ‘eyes’ and ‘ears’ of the research.
I am grateful to Dr. Palazzolo and Dr. Chen for consenting to oversee my thesis.
Laboratory, especially to Mohsin Jafri for his analytical inputs, Bugra Ertas for helping
me set up the test rigs and Kiran Toram for assisting with the experiments. Vivek
Choudhury and Ahmed Gamal added definite spice to what has been two stimulating
The Turbomachinery Research Consortium has been kind enough to sponsor the
Last but not the least, my parents have been outstanding in their support in every
TABLE OF CONTENTS
Page
ABSTRACT.................................................................................................................... iii
DEDICATION..................................................................................................................v
ACKNOWLEDGMENTS ...............................................................................................vi
TABLE OF CONTENTS................................................................................................vii
CHAPTER
I INTRODUCTION ................................................................................................1
Objective .......................................................................................................3
Literature Review..........................................................................................4
Research Procedure .......................................................................................6
CLEARANCE ....................................................................................................18
CHAPTER Page
Equations of Motion....................................................................................26
Non-Dimensional Equations of Motion ......................................................29
Euler Integration Scheme ............................................................................33
Numerical Simulation .................................................................................35
REFERENCES ...............................................................................................................76
APPENDIX I ..................................................................................................................78
APPENDIX II .................................................................................................................81
VITA...............................................................................................................................87
ix
LIST OF FIGURES
Page
Fig 4: Three channels of input into the NI 4472 DAQ device ........................................11
Fig 15: Natural vibration waveform of the rotor from intermittent contact.....................21
Fig 16: Plot of the ratio of the 1st and 2nd harmonic amplitude vs. β .............................23
Fig 18: Analog computer simulation showing response to 2ω excitation for β=0.2........24
Fig 19: Rotordynamic model to analyze the effect of non-linear stiffness ......................25
x
Page
Fig 22: Initial values and system settings. A large value of δ ensures a linear
system..................................................................................................................37
clearance. δ = 0.2..................................................................................................38
Fig 26: Higher harmonics on the X –spectrum at a speed lower than the critical............39
Fig 27: Time waveform at a speed lower than the critical ...............................................40
Fig 28: Vibration signatures at twice the critical speed – time trace,
Fig 34: Non-rotating bearing support without and with stiffener ....................................45
Page
Fig 38: X and Y probe signals at 1300 RPM - below the critical speed ..........................47
Fig 39: Probe signals at 3000 RPM – above the first critical...........................................47
Fig 42: Spectrum at 1800 RPM indicate the presence of higher harmonics ....................49
Fig 45: Waterfall plot from the X-probe showing the onset of subsynchronous
vibration at 0.5X..................................................................................................51
Fig 46: Orbits before, at and after the onset of subsynchronous vibration
Fig 47: Frequency spectrum for linear bearing support at different running speeds .......53
Fig 48: Plot of β against ω/ωn for various values of cross coupled
Page
Fig 56: Unstable subsynchronous vibration at 0.5X when the swirl inducer
is turned on ..........................................................................................................63
Fig 59: Rotor model with cross coupled ‘bearing’ at station 17 ......................................65
Fig 61: Instrument phase plots from XLTRC simulations with and without
cross coupling.......................................................................................................66
Fig 64: Change of instrument phase angle with larger direct damping............................68
Fig 65: Cross coupled force and velocity vectors in circular and elliptical orbits ...........70
Fig 69: Almost circular unstable orbit from the Shell rotor rig .......................................73
Fig 70: Benign subsynchronous orbit from the Bently rotor kit. .....................................74
1
CHAPTER I
INTRODUCTION
cause of instability is never unbalance in a rotor bearing system, but de-stabilizing cross
coupled follower forces around the periphery of some rotor component. In mathematical
terms (Lyapunov), “instability” is when the motion tends to increase without limit
because the system parameters (stiffness/damping) do not remain linear with increasing
amplitude. The rotor may then be operated at non-destructive amplitudes for years but
needs rigorous monitoring tools, since any minor perturbation can destabilize the system
amplitudes are not a common occurrence, but are more destructive and difficult to
remedy than imbalance problems when they do occur. Quite often, they are load or
instructive. Vance [1] defines critical speed as the speed at which the response to
This thesis follows the style and format of Journal of Engineering for Gas Turbines and Power.
2
It is possible to pass through the critical speed of the machine without destruction,
damage.
real part. The real part is responsible for the exponential growth (or decay, if negative) of
the solution while the imaginary part gives the damped frequency. From a rotordynamic
viewpoint, the solution is the function which determines the time dependant amplitude of
Fig 1.
The factor in the differential equations that causes the vibration to grow is almost
always cross-coupled stiffness, which models a force (usually from fluid pressure)
transducers from a rotating machine represents the dynamic whirling motion of the rotor.
Several signal analysis techniques can be used to extract pertinent information from
these signatures – the Fast Fourier Transform (FFT) to obtain all the frequencies present
in the signal, Bode plots for the synchronous rotor response, ‘orbits’ or Lissajous figures
at filtered frequencies, accurate phase and magnitude values for all ‘orders’ etc. Analysis
using these methods will make it possible to predict with a degree of certainty whether a
rotor has the possibility of going unstable. The current research is to explore such
methods and evaluate them with actual experiments at the Turbomachinery laboratory.
analysis tools are not sufficient to extract significant information from subsynchronous
Objective
mistaken as instability, forcing the machine to be shut down out of fear of destruction. In
a 1977 ASME paper [2], Ferrara at Nuovo Pignone examined whether subsynchronous
asynchronous vibrations were the result of some “common cause” and was not self-
Literature Review
widely reported and documented. The first instances began to show up in the early
1920’s when the need arose to operate rotors beyond the first critical speed. The
following section is a brief review of research that has been done in this field.
compressors (GE) operating at supercritical speeds. He came to the conclusion that shaft
whipping was because of internal friction from relative motion at the joint interfaces and
not unbalance excitation. Kimball, working with Newkirk, built a test rig that
Newkirk also observed fluid bearing whip caused by the unequal pressure distribution
about the journal. The enclosed fluid in the fluid film bearing clearance circulates with
an average velocity equal to one-half the shaft speed [4]. Alford [5] hypothesized that tip
of the rotor. Den Hartog [6] described dry friction whip as an instability due to a
5
tangential Coulomb friction force acting opposite to the direction of shaft rotation
(backward whirl). The tangential force will be proportional to the radial contact force
between the journal and the bearing. Ehrich [7] has done a comprehensive survey of the
Ehrich [8] reported the occurrence of a large subsynchronous response at twice the
critical speed from the analog computer simulation of a planar rotor model undergoing
intermittent contact with the bearing surface. His 1966 paper has been discussed at
greater length later in this thesis, since it has initiated the premise of research on
“frequency demultiplication” is also presented by Den Hartog [6]. Bently [9] proposed
and experimentally showed that subsynchronous rotor motion can originate from
Childs [10] solved non-linear differential equations describing a Jeffcott rotor to prove
that ½ and 1/3 speed whirling occurs in rotors which are subject to periodic normal-loose
or normal-tight radial stiffness variations. Vance [1] stated that rotordynamic instability
is seldom from one particular cause and reviewed the mathematics for analyzing the
stability of rotor-bearing systems through eigenvalue analysis. He also analyzed the case
field problems with centrifugal compressors and steam turbines involving instability
along with ‘fixes’ used to overcome the problems. A steam turbine was shown to have a
6
subsynchronous instability at 1800 rpm when the unit speed was 4800 rpm. The
logarithmic decrement was found to be 0.04. The bearing length was reduced and the
clearance increased so that the log-dec increased to 0.2. The subsynchronous instability
disappeared. Another steam turbine case showed that changing to tilt-pad bearings was
not sufficient to overcome one-half speed instability. The most difficult problem was
instability in a gas re-injection compressor which suffered high vibration trip outs even
before reaching operating speed. The subsynchronous frequency became higher than the
first critical speed after modifying the oil seals. It was found that different seal designs
greatly affected the non-synchronous frequency but did not make the unit stable. The
stability improved greatly when a damper bearing was installed in series with the
inboard bearing. The problem was mitigated by increasing the shaft diameter to raise the
Research Procedure
Nevada are limited in their applications and will not be useful in the proposed research.
For example, ADRE can only track subsynchronous frequencies in increments of 0.025
orders, which is extremely inflexible for extraction of data for a vibration which occurs
ADRE and help in diagnostics. LabVIEW from National Instruments was chosen as the
software platform with which to develop the software, for its excellent graphical and
7
data acquisition capabilities. Two add-ons - the Order Analysis Toolset 2.0 and the
Sound and Vibration Toolset, helped with advanced order extraction techniques and
signal processing. Two 8-channel NI-4472 PCI boards were used for data acquisition
and A/D conversion. Once the measurement teststand was in place, several test rigs were
vibrations.
special interest. The method of investigation was based upon a paper by F.F Ehrich [8]
claiming through analog computer simulations, that such a rotor would have a large
subharmonic response at its first critical frequency when rotating at twice its critical
The phenomenon was indeed found to occur in actual experiments and explained the
often noted fact that “the onset of most asynchronous whirl phenomenon is at twice the
contact with the bearing housing was developed so that its stiffness varied as a step
function of the displacement along the direction of contact. The simulation results were
compared with empirical data from a rig where non-linearity in bearing stiffness was
artificially introduced.
from a rig where a forward acting de-stabilizing air swirl around the rotor could be
turned on at will (a large subsynchronous vibration was induced at the first eigenvalue
It was also discovered that the synchronous phase angle (the angle by which the
unbalance vector leads the vibration vector) was affected by destabilizing cross coupled
forces. The change in phase angle from cross-coupling can be a remarkable tool for the
CHAPTER II
The Teststand
vibrations that make measurement and diagnostics more difficult for rotordynamics.
synchronous speed, the use of Lissajous patterns (orbits) with tachometer marks, the
accurate magnitude and phase information for different ‘orders’ of the running speed.
The difficulties are also compounded by inflexible and limited data analysis systems
currently available like the Bently Nevada ADRE™. Consequently, a new system has
been developed using LabVIEW from National Instruments along with associated state-
The teststand (Fig 3) is an Intel Pentium 4, 1.7 GHz personal computer with
Windows®NT operating system, 512 MB RAM and 40 GB of hard drive space. The
system is equipped with two NI 4472 PCI 8-channel boards for data acquisition and
analysis. LabVIEW 7.0 Express with the Order Analysis 2.0 and Sound and Vibration
Proximity probes from Bently Nevada, powered by a -24V power supply are used for all
measurements. The probes are connected to the data acquisition boards via NI
attenuation cables to increase the acceptable voltage range from the input and run the
application DC coupled.
11
Parallel Port
Security
Key
NI 4472
DAQ boards
Master
Slave
Test Setup
All measurements for experiments mentioned in this thesis were carried out using
eddy current proximity probes. The probes were calibrated and set at a voltage gap of
negative 8.0 V DC to ensure linear behavior. The ‘leads’ from the proximity probes were
connected using BNC cables to the DAQ boards as shown in Fig 4. A schematic of the
7 6 5 4 3 2 1 0
Probe Y
DAQ Board: Master
7 6 5 4 3 2 1 0
Tachometer
Fig 5: Experimental setup illustrating wire connections from the probes to individual pins of the
DAQ boards
The channels have to be configured using the calibration units, probe orientation and
Functional Blocks
rotordynamic data acquisition system has. The capabilities are briefly discussed below.
Uncompensated
Compensated
Fig 7 shows the time series data captured from two proximity probes and a tachometer.
The first graph is the raw voltage signal converted to engineering units (in this case mils)
while the second plot is resampled data, compensated and with the DC component
subtracted. Resampling changes the data from the time domain to the angular domain.
14
instabilities etc) leave tell-tale stamps on the spectrum and orbit plots, in terms of the
fraction of the running speeds they occur, the tendency to track the synchronous
component, the ellipticity of the orbit (Fig 8) etc. LVTRC has advanced tracking filters
which can extract accurate phase and magnitude information for any ‘order’ of the
running speed.
One of the most useful features of the application is the ability to plot orbits exactly at
frequencies where the user places his/her cursor on the Spectrum plot (Fig 9).
15
The red cursor is placed at the 40 Hz component on the frequency spectrum. The orbit at
that frequency is plotted. This feature will be used in the study of how orbits filtered at a
Bode Plots
Bode plots (Fig 10) illustrate the rotor response (amplitude and phase) to changing rotor
speed. LVTRC maintains buffered Bode plot data from the raw signals; so that any
channel and any order can be selected at any point of the experiment and the full history
Waterfall Plot
Several of the features like the waterfall plot (Fig 11) have been used extensively to
obtain very encouraging results. The detailed development of the code is not discussed
CHAPTER III
CLEARANCE
rotor stiffness and uses analog computer simulation to show that “the excitation at the
that this subharmonic resonance or frequency demultiplication may play a large role in
the often noted fact that the onset of most asynchronous whirl phenomenon is at twice
the induced whirl speed”. The interest of this thesis originates from the idea that any
produce a large subsynchronous response when running at twice the critical speed and
Clearances between the rotor and stator in a high-speed rotating system lead to
non-linear spring stiffness. The static equilibrium position of the rotor may not be at the
bearing center (Fig 12) but may be eccentric and be in contact with one side of the
bearing (Fig 13). Another and perhaps more realistic case is the intermittent contact
between the journal and the bearing due to rotor vibration (Fig 14).
19
K2
δ
F
K1
K2 Slope = K1
K2
F
K1
Slope = K1 +K2
K2
K2
K1
Slope = K1 +K2
K2 Slope = K1
x
δ
K1
Undamped natural frequency = ω1 =
m
K1 + K 2
Undamped natural frequency = ω2 =
m
The rotor “bounces” on the stator periodically leading to a piecewise linear stiffness of
the system.
= K1 + K2 for x ≥ δ
21
Assuming that the rotor contacts just one side of the stator and the resultant
vibration is not enough for it to contact the other side, the vibration waveform should be
A
ω1
π
Amplitu
ω2
A
ω2 Time
π
ω1
Fig 15: Natural vibration waveform of the rotor from intermittent contact
π
x (t ) = A1 sin ω1t for 0≤t<
ω1
(a)
⎡ π ⎤ π 2π
x (t ) = − A2 sin ⎢ω2 {t − }⎥ for ≤t<
⎣ ω1 ⎦ ω1 ω
dx = dx π −
dt t→ π + dt t→
ω ω
1 1
2π π π
= + ;
ω ω1 ω2
(b)
2ω1ω2
ω=
ω1 + ω2
The Fourier coefficient Cn from the Fourier series expansion of equation (a) is given as:
⎡ ⎛ ω ⎞2 ⎛ω ⎞
2
⎤
⎢ ⎜ ⎟
ω2 ⎠ ⎜ ⎟ ⎥
Cn =
A
⎢ ⎝ − ⎝ ω1 ⎠ ⎛ nπω ⎞
⎥ × 2 cos ⎜ ⎟
πω ⎢ 2 ⎛ω
2
⎞ 1 − n2 ⎛ ω ⎞ ⎥
2
⎝ 2ω2 ⎠
⎢⎣ 1 − n ⎜ ω ⎟ ⎜ ω ⎟ ⎥
⎝ 2⎠ ⎝ 1⎠ ⎦
⎛ nπω ⎞
with a phase angle φn = ⎜ ⎟
⎝ 2ω2 ⎠
The plot of the ratio of the second harmonic to the first harmonic amplitude indicates the
presence of a large second harmonic component (Fig 16) in the excitation waveform for
β = 0.2 (where β = K1/K2). A similar result is also obtained by the FFT of the waveform
(Fig 15: Natural vibration waveform of the rotor from intermittent contact). It yields that
the waveform has several higher harmonic components with only the second harmonic
β = K1/K2
Fig 16: Plot of the ratio of the 1st and 2nd harmonic amplitude vs. β
0
0 2 4 6 8 10
vibration induced out of the inherent non-linearity in the system stiffness. The analog
Fig 18: Analog computer simulation showing response to 2ω excitation for β=0.2
The analysis is now extended from considering a plane vibration case to a ‘Short Rigid
Rotor’ model in the following chapter. Numerical methods will replace analog
simulations.
25
CHAPTER IV
Stator
Rotor
Rotor Stiffness
Stiffness
Stiffness M
u
K1 α
C K2
Y
O
∆
X
Im
Stator
K2
stiffness due to intermittent contact of the rotor along the X-axis only. For simplicity, the
bearing stiffness is assumed to be symmetric. The bearing stiffness is much greater than
the rotor stiffness so that there is practically no displacement of the surface during
contact. The frame of reference is fixed and the generalized coordinates are X, Y and α.
Equations of Motion
u u sin α
C(x,y) Sx+Dx
α C u cos α
r Sy+Dy
X X
O
X m = X + u cos α
Ym = Y + u sin α
X m = X − (u sin α )α
∑F x = mX
∑F y = mY
∑M = I mα
where,
Fx = restorative stiffness force (Sx) and ‘damping force’ (Dx) along the x-axis;
Fy = restorative stiffness force (Sy) and ‘damping force’ (Dy) along the y-axis;
mXm = − K x X − CX
Similarly,
For the particular case under consideration where the static stiffness of the rotor-bearing
system changes as a step function of the rotor clearance (∆) and hence the displacement
along X, the system of equations (1) can be divided into two cases.
29
Case 1: X< ∆
Kx = Ky= K1
Case 2: X ≥ ∆
**Note that the stiffness changes only along the X-axis when contact occurs.
30
Case 1: X< ∆
K C
X + 1 X + X = uα sin α + α 2u cos α
m m
X K1
Let, x = and ω1 =
u m
Let τ = ω1t;
dx dx dτ dτ
= × ; = ω1
dt dτ dt dt
dx dx dx
= ω1 ; x = ω1
dt dτ dτ
d 2x
x = ω12
dτ 2
Similarly,
dα d 2α
α = ω1 ; α = ω12 2
dτ dτ
Replacing in (4)
31
Moment equation:
G
Let , g =
u
∴ I m = mu 2 g 2
Replacing in equation(5),
d 2α dx dy
g 2ω12 + ω12 x sin α − ω12 y cos α + 2ξω12 sin α − 2ξω12 cos α = 0
dτ 2
dτ dτ
x y 2ξ 2ξ
or , α + 2
sin α − 2 cos α + 2 x sin α − 2 y cos α = 0
g g g g
x y 2ξ 2ξ
α + 2
sin α − 2 cos α + 2 x sin α − 2 y cos α = 0
g g g g
32
Case 2: X ≥ ∆
(K + K2 ) C
X + 1 X + X = uα sin α + α 2u cos α
m m
X K1 K
Let, x = , ω1 = ,β = 1
u m K2
( K1 + K 2 ) K1 ( K1 + K 2 ) 1
ω2 = = × = ω1 1 +
m m K1 β
⎛ 1⎞
x + ω12 ⎜1 + ⎟ x + 2ξω1 x = α sin α + α 2 cos α
or ,
⎝ β⎠
Let τ = ω1t;
⎛ 1⎞
x + 2ξ x + x ⎜1 + ⎟ = α 2 cos α + α sin α
⎝ β⎠
Moment equation:
x ⎛ 1⎞ y 2ξ 2ξ
α + 2 ⎜
1 + ⎟ sin α − 2 cos α + 2 x sin α − 2 y cos α = 0
g ⎝ β⎠ g g g
⎛ 1⎞
x + 2ξ x + x ⎜1 + ⎟ = α 2 cos α + α sin α
⎝ β⎠
x ⎛ 1⎞ y 2ξ 2ξ
α + 2 ⎜
1 + ⎟ sin α − 2 cos α + 2 x sin α − 2 y cos α = 0
g ⎝ β⎠ g g g
Equations (6) and (9) are integrated using Euler’s method to obtain the response
of the system modeled for unbalance excitation. The following substitutions are made:
x = u1; x = u2 ; y = u3 ; y = u4 ;α = u5 ;α = u6
34
∆
Case 1: For x < δ (where δ = )
u
u1 u 2ξ 2ξ
u6 = − 2
sin u5 + 32 cos u5 − 2 u2 sin u5 + 2 u4 cos u5
g g g g
Case 2: For x ≥ δ
⎛ 1 ⎞
u2 = −2ξ u2 − u1 ⎜1 + ⎟ + u6 cos u5 + u6 sin u5
2
⎝ β ⎠
(11)
u4 = −2ξ u4 − u3 + u6 2 sin u5 − u6 cos u5
u1 ⎛ 1 ⎞ u3 2ξ 2ξ
u6 = − 2 ⎜
1+ ⎟ sin u5 + 2 cos u5 − 2 u2 sin u5 + 2 u4 cos u5
g ⎝ β ⎠ g g g
u1 (t + δ t ) = u1 (t ) + u2 (t )δ t
u2 (t + δ t ) = u2 (t ) + u2 (t )δ t
u3 (t + δ t ) = u3 (t ) + u4 (t )δ t
u4 (t + δ t ) = u4 (t ) + u4 (t )δ t
u5 (t + δ t ) = u5 (t ) + u6 (t )δ t
u6 (t + δ t ) = u6 (t ) + u6 (t )δ t
35
Numerical Simulation
Numerical integration of equations (10) and (11) with different initial conditions
is used to simulate an experimental rotor rig with non-linear bearing stiffness. The
system parameters are set to closely represent the actual rotor. The numerical model is
excited by unbalance. Details of the experimental set up have been provided in the next
chapter.
The stiffness ratio K1/K2 = β for the rotor bearing system is 0.23. It is necessary
to find out the non-dimensional critical frequency of the waveform described by Ehrich.
2ω1ω2
ω=
ω1 + ω2
ω2 K1 + K 2 1
= = 1+
ω1 K1 β
1
2ω1 1 +
β
ω=
1
1+ 1+
β
36
The non-dimensional response waveform for the rotor rotating at the critical speed can
be represented as:
2πω1/ω
X/u
τ =ω1t
1 ω
f = = , where ω is the running speed.
T 2πω1
1
f = = 0.16 *
2π
1 1
2ω1 1 + 1+
β β
f = = (12)
1 1
2πω1 (1 + 1 + ) π (1 + 1 + )
β β
f = 0.222
*This value provides a check to see if the numerical integration has been correctly executed.
37
A likely proof of the verity of the numerical model will be to obtain the response
of the system to a large clearance (no contact) for different rotational speeds. The
the rotor are shown below (Fig 22). Note that ‘alphadot’ is the rotating speed.
Fig 22: Initial values and system settings. A large value of δ ensures a linear system.
Integration with increasing values of ‘alphadot (0)’ or the rotating speed shows a large
Synchronous
Response
Fig 24: Initial and parametric constants to simulate small rotor-stator clearance. δ = 0.2
39
With a non-linear stiffness along the x-axis, the non-dimensional critical frequency is
0.225 (Fig 25). At a speed lower than the critical frequency, the spectrum of X shows
Synchronous Speed
Higher harmonic
Components
Fig 26: Higher harmonics on the X –spectrum at a speed lower than the critical
40
The time waveform (Fig 27) also illustrates that collision occurs along the X – axis
speed
When the rotor speed is twice the critical speed, a large subsynchronous
component (Fig 28) on the X-spectrum at exactly the critical frequency is noted. The Y-
response is largely synchronous. The orbit shows the proverbial inside loop.
41
Synchronous
Fig 28: Vibration signatures at twice the critical speed – time trace, spectra and orbit
On increasing the speed, the subsynchronous vibration disappears indicating that the
Synch Synch
CHAPTER V
Numerical simulations from the rotordynamic model in the previous chapter have
yielded typical response to non-linear stiffness which might be used as diagnostic tools
vibration phenomenon which occurs at twice the critical speed. This chapter shows the
produce non-linear bearing support stiffness and the signals generated from orthogonally
Air turbine
Swirl Inducer
Proximeter Non-rotating
Power 250 psi
Line bearing
supply support
Ram Air
Turbine
Prox Probe
Bracket Ball
Bearing
Balance Hollow
Rotor Nozzle
Plane
Steel Rod
Support Swirl Inducer
(non - Housing
rotating) Ball
Bearing
The rotor (Fig 30 and Fig 31) is mounted on ball bearings constrained at the inner
race by a non-rotating cantilevered steel support rod. Pressurized air drives the air-
turbine upto a maximum speed of 6000 rpm. The swirl inducer housing has nozzles
arranged around the periphery of the rotor to induce air swirl when pressurized. The air
swirl is in the direction of rotor rotation and generates whirl instability from
destabilizing cross coupled stiffness above the first critical speed (2100 rpm). A
Two calibrated orthogonally mounted eddy current proximity probes were used
to capture vibration data from the rotor. Another proximity probe was used to read
tachometer pulses from a raised notch on the rotor surface. LVTRC was used for all data
acquisition and analysis. The rotor was modeled using XLTRC2 (Appendix II) after the
stiffness of the bearings at the inducer end and the air turbine end were measured in
44
horizontal and vertical directions. The values were used as bearing inputs and minimal
damping was assumed. The first mode shape (Fig 33) of the rotor showed that the
balance plane should be as close to the inducer end bearing as possible. Fig 31 shows the
balance plane. The single plane orbit method was used to balance the rotor to acceptable
limits of vibration.
forward
backward
f=2328.3 cpm
d=.1064 zeta
N=3000 rpm
the displacement along the horizontal axis, a stiffener was constructed and mounted as
Stiffener
Non-rotating
bearing support
Stiffener
Force
Transducer (lbs)
A force transducer and a dial gauge was used (Fig 35 and Fig 36) to estimate the
stiffness at the bearing location and ensure that the force against displacement plot (Fig
37) showed the same step function characteristic as in Ehrich’s 1966 paper.
Dial gauge
F in lb X in inches
Stiffness
0 0.00
5 0.00050 120
11 0.00110 100
15 0.00150 y = 43068x - 115.78
80
21 0.00210
Force in lbs
60
26 0.00260
31 0.00310 40
y = 8040.1x - 0.4002
41 0.00410 20
50 0.00500 0
70 0.00700 0.0000
-20
0.0010 0.0020 0.0030 0.0040 0.0050 0.0060
90 0.00900 Disp in inches
100 0.01000
clearances from the non-rotating bearing support till satisfactory results were obtained.
Fig 37 is such a case and all results reported below (unless otherwise mentioned) pertain
to that case.
Uncompensated
waveforms
Runout-
Compensated
waveforms
Fig 38: X and Y probe signals at 1300 RPM - below the critical speed
Fig 39: Probe signals at 3000 RPM – above the first critical
48
Uncompensated
Runout-
Compensated
waveforms
Uncompensated
waveforms
Runout-
Compensated
waveforms
Fig 38 - Fig 41 demonstrate how the rotor behavior changes as the effect of non-
linear stiffness sets in with increasing speed. At low speeds (below the critical, Fig 38)
mainly 1X from unbalance excitation. At higher speeds (above the first critical, Fig 39)
the X-probe signal is clipped (the stiffener is mounted along the X-axis) and also shows
frequency demultiplication as analyzed by Ehrich [5] with his planar model. Note that
the compensated probe signals at twice the critical speed (2 x 2010 RPM) shown on the
‘Resampled’ plot take two revolutions (x-axis scale shows the number of revolutions) to
complete one cycle. The phenomenon disappears as the rotor speed increases (Fig 41)
Fig 42: Spectrum at 1800 RPM indicate the presence of higher harmonics
50
Fig 42 shows the presence of higher harmonics in the frequency spectrum below the
The order spectrum at 4200 RPM (Fig 43) indicates the presence of a large
proved in numerical and empirical results above, non-linear stiffness at the bearings
causes the large subsynchronous vibration at twice the first critical speed. A useful
Subsynchronous vibration
Critical
Fig 45: Waterfall plot from the X-probe showing the onset of subsynchronous vibration at 0.5X
52
Orbit Plots
The orbit plots (Fig 46) exhibit an inside loop at twice the critical speed but is
transitory. With a slight change in speed, the loop disappears. The orbits bear similarities
Fig 46: Orbits before, at and after the onset of subsynchronous vibration at twice the critical speed
From an analog oscilloscope
The results from the previous section are compared to the case where the rotor-
bearing stiffness was linear throughout its operating speed range. Measurements were
made with the nonlinear stiffener removed. The frequency spectrum does not show any
Fig 47: Frequency spectrum for linear bearing support at different running speeds
It can be concluded from the above experiments and analysis that non-linearity in
rotating at twice the critical speed. The vibration disappears on increasing the speed.
54
CHAPTER VI
real part. The vibration amplitude associated with instability becomes unbounded
(infinitely large), if linear stability theory holds. In practice, the vibration with growing
amplitude will cause seals or blades to rub or it will reach a ‘limit cycle’ due to non-
negative direct damping seldom occurs. Instead cross coupled stiffness, modeled as a
follower force driving the forward going whirl orbit is usually the factor responsible for
instability.
The Jeffcott rotor model with cross coupled stiffness is a modal model for any
real machine operating through its first critical speed. It may be represented
mathematically as:
It is found that for the particular case where kxy = - kyx = K ; K > 0; the cross coupled
forces drive the rotor unstable in forward whirl (the common mode in real machines). It
55
represents a type of force induced by fluid forces around a turbine, impeller, or fluid
The particular solution to equation (13) is of interest. The amplitude and phase of
mω 2u
| r |=| x + y |=
2 2
(k − mω 2 ) 2 + (ω c − K ) 2
(14)
⎡ ωc − K ⎤
β = tan −1 ⎢
⎣ k − mω ⎥⎦
2
K
ce = c − , (15)
ω
which is a function of the magnitude of cross coupled stiffness and the speed of rotation.
Noticeably, the synchronous phase angle β is also affected by the cross coupled stiffness.
It therefore can be a useful diagnostic value to determine whether the rotating system
can have negative equivalent damping (instability)! As shown by equation (14), both
backward (K < 0) and forward (K > 0) cross coupled follower forces will change the
damping and the value of β - the former increasing and the latter reducing it. However,
backward driving cross-coupled stiffness is rare, a soft continuous rotor rub being one of
the few examples. It is the case of forward driving cross coupling that is the cause of
most instabilities and the need arises to find how ‘β’ changes in this case. A plot of β
⎡ ⎡ ⎛ 2⋅ shi ⋅ w − k ⎞ ⎤ ⎤
⎢ ⎢⎜ ⎥⎥
beta ( w , k) := ⎢
180
⋅ atan ⎢
⎝ wn K ⎠
⎥⎥
⎢ π ⎢ ⎛ w ⎞
2 ⎥⎥
⎢ ⎢ 1−⎜ ⎥⎥
⎣ ⎣ ⎝ wn ⎠ ⎦⎦
100
87.807
80
60
K= - 60,000
40
beta( w , − 60000)
K= - 60,000
60
80
− 87.788 100
0 0.5 1 1.5 2
0 w 2
wn
Fig 48: Plot of β against ω/ωn for various values of cross coupled stiffness. Direct stiffness = 90000,
A typical chart is plotted in MathCAD, for a rotor with 10% damping. At speeds lower
than the critical speed (for a slightly damped system) a backward driving cross coupled
force increases the value of β whereas a potentially unstable forward driving cross
coupling decreases β. At speeds higher than the first critical, the exact opposite occurs.
Also, the change in β is most sensitive near the critical speed range. This is further
illustrated in Fig 49 where the first derivative of β with respect to the cross coupled
stiffness K is plotted. The maximum change in β occurs near the critical speed range.
.10 5
−5 6
5.29×10
5 ω = 1.1ωn
beta( k , 0.7⋅ wn) 4 .10
d
dk
d 5
beta( k , 0.9wn) 2 .10
dk
d ω = 1.5ωn
beta( k , 1.0wn) 0
dk
d ω = 0.7ωn
beta( k , 1.1wn) 5
dk 2 .10
d
beta( k , 1.5wn) 5
dk 4 .10
ω = 0.9ωn
−5
− 5.847×10 6 .10
5
5 4 4 4 4 4 4 4 4 5
1 .10 8 .10 6 .10 4 .10 2 .10 0 2 .10 4 .10 6 .10 8 .10 1 .10
4 k
− 9×10 9×10
Fig 49 also indicates that there is a definite ratio of the cross coupled stiffness to the
system stiffness for which the cross coupling may have any significant effect on the
system equivalent damping. In this particular case (ξ = 0.1) the ratio is 20-25%. A
58
similar result is presented in [1] is shown (Fig 50), where λ is the real part of the
eigenvalue.
The synchronous phase angle is the angle by which the unbalance vector leads
The synchronous phase angle can be measured (Fig 52) using the influence coefficient
method (actual measurement of the synchronous phase angle is not required for
diagnosis, but can be correlated to the phase angle displayed by most balancing
Step 1:
Run the rotor at a particular speed ‘N rpm’ and save the vibration vector (1X).
V = |V| @ θ1
All phases are measured from a fixed mark ‘P’ on the rotor. The ‘P’ mark is the exact
point below the probe when the tachometer notch is lined up with the tachometer.
Step 2:
Stop the rotor and add a trial known mass at a specified angle.
M = |M| @ γ
60
Step 3:
Rev the rotor up to N rpm again to find the new vibration vector
V* = |V*| @ θ2
Evaluate ‘β’:
Vector A = V* - V
Vector α = + V/A
Unbalance vector U = α. M = |U| @ δ
‘β’, is calculated as the angle by which the unbalance vector leads the vibration vector.
i.e. β = δ – θ1
Direction of Rotation
U
V
A
P
V*
measurement instruments in the industry is however not the synchronous phase angle. A
Fig 53 illustrates an experimental setup for phase measurements for balancing. β is the
synchronous phase angle. All phase measurements in balancing machines are from the P
mark on the rotor which is the exact point below the X-probe, when the tachometer
notch is lined up with the tachometer. θ is the constant angular distance of the
unbalance of the rotor from the ‘P’ mark. All angles are measured positive opposite to
The experiment detailed below is proof of how the synchronous phase angle
experimental rig shown in Fig 30 was used for investigating the variation of β with cross
coupled instability induced from a high pressure air swirl around the rotor. A special
virtual instrument was created with LabVIEWTM (Fig 54) to implement the influence
Two sets of experiments were performed above the first critical speed – one with the
swirl inducer turned on and one without. The frequency spectrum showed the presence
of a strong subsynchronous component at the first eigenvalue in both the cases (Fig 55
and Fig 56). In the first case (Fig 55), subsynchronous vibration was induced from non-
linear bearing stiffness by mounting a stiffener (as explained in Chapter V) and without
air swirl around the rotor. ‘β’ was almost 180 degrees, as is to be expected for a lightly
damped rotor. In the second case (Fig 56) the swirl inducer was pressurized at 200 psi to
63
induce de-stabilizing cross coupled forces (the stiffener was still mounted). The value of
Synch
Synch
Fig 56: Unstable subsynchronous vibration at 0.5X when the swirl inducer is turned on
Note that the instrument phase shows a reverse trend and decreases from 91° to 82°.
The change of phase angle from cross coupling is more pronounced near the
critical speed. The experiments above were carried out at twice the critical speed so that
affect the phase angle. A second reason for the choice of experiment speed is that near
the critical speed, with de-stabilizing cross coupling, damping is minimal. Consequently,
the amplitude of vibration will be beyond safe limits. With greater direct damping (as in
most industrial machines), it will be possible to carry out experiments near the critical
speed. For this thesis, XLTRC simulations are used instead to study phase shifts from
cross coupling in more detail for the rotor described above with higher damping.
Complete details of the XLTRC model are included in Appendix (II). Fig 57 and
Fig 58 show the ‘Geo plot’ and the response of the rotor to unbalance excitation. De-
stabilizing cross coupled forces were added to the model (Fig 59 and Fig 60) to find out
5
Shaft Radius, inches
16 18
6 8 10
Shaft1 Shaft1
2.5 1 2 4 22 24
14
12 20
-2.5
-5
-7.5
-10
0 5 10 15 20 25
35
30
ilspk-pk
25
20
esponse, m
15
10
R
0
0 2000 4000 6000 8000 10000 12000 1400
Rotor Spe e d, r pm
5
Shaft Radius, inches
16 18
6 8 10
Shaft1 Shaft1
2.5 1 2 4 2224
14
12 20
-2.5
-5 Cross coupled
bearing
-7.5
-10
0 5 10 15 20 25 30
400
350
300
250
Degrees
200
99 degrees
150
100
50
92 degrees
0
0 1000 2000 3000 4000 5000 6000 7000
RPM
Fig 61: Instrument phase plots from XLTRC simulations with and without cross coupling
XLTRC outputs the instrument phase (not β) from the simulations and Fig 61
shows how the instrument phase changes when the cross coupling bearing is
included/excluded from the model. Comparison with Fig 55 and Fig 56 show close
Industrial turbomachinery have much higher damping than the rotor modeled
above, to decrease the vibration amplitude near the critical speed. They also require
greater values of cross coupled stiffness to drive the rotor unstable. The swirl inducer
model is modified to include larger direct damping at the bearings. The results follow
7
6
Response, mils pk-pk
5
4 Horz Amp
Vert Amp
3
2 Excitat ion = 1x
1
0
0 2000 4000 6000 8000 10000 12000 14000
350
300
250
200
Degrees
150
100
50
0
0 1000 2000 3000 4000 5000 6000 7000
RPM
Fig 64: Change of instrument phase angle with larger direct damping
69
CHAPTER VII
Ertas, Kar and Vance [12] summarized diagnostic indicators for benign
subsynchronous vibrations. Several amongst them were verified after signal analyzing
vibration data from laboratory test rigs. The diagnostic indicators are discussed below:
Frequency Tracking
rule has been observed in certain pumps where the instability tracks the synchronous at a
system. The frequency can be determined from an accurate rotordynamic model or from
bump tests.
70
The sources of most instability are de-stabilizing follower forces pushing on the
rotor in the direction of subsynchronous whirl. Most follower forces are produced by
cross-coupled stiffness, which models a force that is always normal to the instantaneous
rotor deflection vector (orbit radius). As Fig 65 shows, this force can be purely a
follower force only if the orbit is circular. The force normal to the orbit radius becomes
more oblique to the orbital velocity as the orbit becomes more elliptical. The orbit shape
is not an absolute indicator of potential instability. However, it can be stated that highly
elliptical orbits (almost a straight line) cannot become unstable from cross-coupled
stiffness.
Fcc
V V
r Fcc r
Fig 65: Cross coupled force and velocity vectors in circular and elliptical orbits
The rate of energy input to the orbit from the cross coupled force is given as,
G G
J = Fcc .v
J = Fcc v cos θ
71
A rotor going unstable requires energy to be ‘fed’ into the system from the cross coupled
Orbits from benign subsynchronous vibrations are expected to be highly elliptical. The
orbits have to be filtered at exactly the subsynchronous frequency for them to be used as
caps, or loose foundations are excited by intermittent impact as the separated surfaces
come together repeatedly as the machine runs. These impacts will excite a number of
natural frequencies, not just the one of concern. Spectral analysis of the complex signal
Two test rigs were used to capture subsynchronous orbits and test the hypothesis
regarding orbit shape. The Shell rig (Fig 66) is mounted on two double row self-aligning
ball bearings with a center disk constrained to the shaft. This test rig has the ability to
operate with different interference fits between the center disk and the shaft. At a critical
shrink fit the rotor goes violently unstable from internal friction. The Bently Rotor kit
(Fig 67) was used to capture a benign subsynchronous vibration induced from the
journal clearance within a worn out ‘Oilite’ bushing (Fig 68). LVTRC with its advanced
72
filtering capability was required to extract the orbits at the subsynchronous frequency
desired.
Vertical
Motion Probe
Old Sleeve
Bearing
Horizontal
Motion Probe
Synch
Fig 69: Almost circular unstable orbit from the Shell rotor rig
74
Synch
Fig 70: Benign subsynchronous orbit from the Bently rotor kit.
Fig 69 and Fig 70 show orbits from two different sources. The unstable subsynchronous
orbit from the Shell rig is almost circular whereas the benign orbit is extremely elliptical.
75
CHAPTER VIII
CONCLUSION
vibration from a rotor is potentially unstable. It has detailed vibration signatures typical
to a rotating system with non-linear bearing or support stiffness, especially the large 0.5
X subharmonic response that is present when the rotor is running at twice its critical
speed. The experimental results were substantiated with numerical simulations of a short
rigid rotor with stiffness varying as a step function of the rotor displacement along a
particular axis. The subsynchronous vibration in this case is benign, not a true instability.
synchronous phase angle was developed and verified with experiments. XLTRC
simulations were also used to show that de-stabilizing cross coupling changes the
tools, a state-of-the-art teststand is now available that far exceeds the capability of
current market products. The teststand software – LVTRC is now in use by the
REFERENCES
4. Newkirk, B.L., 1924, “Shaft Whipping”, General Electric Review, 27, pp. 35.
5. Alford, J.S., 1964, “Protecting Turbomachinery from Self Excited Rotor Whirl”,
ASME-64-WA/GTP-4, pp. 333-344.
6. Den Hartog, J.P., 1956, Mechanical Vibrations, 4th Edition, McGraw-Hill, New
York.
7. Ehrich, F.F., 1972, “Identification and Avoidance of Instabilities and Self-
Excited Vibrations in Rotating Machinery”, ASME-72-DE-21.
8. Ehrich, F.F., 1966, “Subharmonic Vibration of Rotors in Bearing Clearance”,
ASME-66-MD-1.
9. Bently, D.E., 1974, “Forced Subrotative Speed Dynamic Action of Rotating
Machinery”, ASME-74-PET-16.
10. Childs, D.W., 1981, “Fractional-Frequency Rotor Motion Due to Non-symmetric
Clearance Effects”, ASME- 81-GT-145.
11. Wachel J.C., 1982, “Rotordynamic Instability Field Problems”, Rotordynamic
Instability Problems in High Performance Turbomachinery -1982, NASA
Conference Publication 2250, Texas A&M University, College Station.
12. Ertas, B., Kar. R, Vance J.M, 2004, “Diagnosing Subsynchronous Vibrations –
Unstable or Benign”, Turbomachinery Consortium Annual Report, pp. 1-55.
77
Ehrich, F.F., 1991, “Some Observations of Chaotic Vibration Phenomena in High Speed
Ehrich, F.F., 1992, “Observations of Sub critical Super Harmonic and Chaotic Response
Eisenmann R.C, Sr., Eisenmann Robert C., Jr., 1997, Machinery Malfunction Diagnosis
in Rotating Machinery”, The Shock and Vibration Digest, 21, pp. 3-11.
National Instruments, 2003, LabVIEW™ Order Analysis Toolset- User Manual, National
Yao-Qun Lin, 1993, “Rotor Instability Induced by Dead Band Clearance in Bearing
APPENDIX I
The NI 4472 is a 8-channel data acquisition device which, when used with the Sound
The test stand uses two such boards, thus possessing the capability of 16 channel
Eight analog inputs with 24 bit resolution analog-to-digital (A/D) converters achieve low
noise and distortion free signals. It is possible to sample at 102.4 kilo samples / second
without distortion.
Antialiasing:
Input signals are passed through fixed analog filters to remove signals with frequency
79
components greater than those of the ADC’s; then digital antialiasing filters adjust their
cut off frequency to remove any frequency components above half the sampling rate.
Multidevice synchronization:
If more than one DAQ board is used, it is necessary to synchronize their operation.
Synchronization between multiboards are carried out by sharing a digital trigger from
one device and synchronizing all devices to the same clock. Minimal phase mismatch is
important for obtaining phase information in cross channel measurements. The NI 4472
has approximately 0.1 degree phase mismatch for a 1 kHz signal between two channels
across devices.
Triggering:
Several trigger modes are available for signal acquisition. Pre-trigger mode digitizes
signals before and after a trigger condition occurs. Post-trigger mode digitizes signals
after a trigger condition occurs. Delay trigger mode begins signal capture after a
programmable delay from the trigger. The source of the trigger can come from an analog
Calibration:
The offset voltage and gain accuracy of the analog input are calibrated by National
The SMB-120 is a specific attenuation cable for the NI-447X Data acquisition boards. It
has a custom attenuation circuit designed to avoid impedance mismatch and distortion.
80
The attenuation cable ‘weakens’ the signal by 10 dB (a gain of –10dB). The cable is
designed specifically for eddy current proximity probes. By using the SMB-120 cable,
APPENDIX II
The following section describes in detail the geometrical characteristics and the
XLTRC2 data sheets used to model the response of the experimental rotor.
XLUseKCM™ User Defined Support Stiffness, Damping, and Mass Rotordynamic Coefficients Press Control-F1 for help.
Version 2.0, Copyright 1996 - 1998 by Texas A&M University. All rights reserved.
Title: Swirl Inducer Bearing stiffness inducer end
Perform a Paste/Special/Link for the Title box within XLTRC to create a link to your rotor model.
Speed Kxx Kxy Kyx Kyy Cxx Cxy Cyx Cyy Mxx Mxy Myx Myy
rpm lb/in lb/in lb/in lb/in lb-s/in lb-s/in lb-s/in lb-s/in lb-s**2/in lb-s**2/in lb-s**2/in lb-s**2/in
0 2739.5 0 0 3359.9 3 0 0 3 0 0 0 0
2000 2739.5 0 0 3359.9 3 0 0 3 0 0 0 0
4000 2739.5 0 0 3359.9 3 0 0 3 0 0 0 0
5000 2739.5 0 0 3359.9 3 0 0 3 0 0 0 0
Speed Kxx Kxy Kyx Kyy Cxx Cxy Cyx Cyy Mxx Mxy Myx Myy
rpm lb/in lb/in lb/in lb/in lb-s/in lb-s/in lb-s/in lb-s/in lb-s**2/in lb-s**2/in lb-s**2/in lb-s**2/in
0 62335 0 0 116042.3 3 0 0 3 0 0 0 0
2000 62335 0 0 116042.3 3 0 0 3 0 0 0 0
4000 62335 0 0 116042.3 3 0 0 3 0 0 0 0
The values were obtained experimentally using a force transducer and a dial gauge.
Rotor Model Data Entry: Multiple Shafts, Elements, Sub-Elements and Layers. Station Numbers
H
Shaft Element Sub- Layer Length Left Right Material Shear Axial Left Right
I
Element OD ID OD ID Interact. Force Station Station
D
# # # # inches inches inches inches inches # ( 0 or 1 ) lbf # #
E
1 1 1 1 0.25 3.75 1.25 3.75 1.25 1 1 0 1 2
1 2 1 1 0.25 4 0 4 0 1 1 0 2 3
1 3 1 1 1.75 4 0 4 0 1 1 0 3 4
1 4 1 1 1.77 1.94 0 1.94 0 1 1 0 4 5
1 5 1 1 0.85 2.97 0 2.97 0 1 1 0 5 6
1 6 1 1 1 1.94 0 1.94 0 1 1 0 6 layer
1 6 1 2 1 6 1.94 6 1.94 2 1 0 layer 7
1 7 1 1 1 1.94 0 1.94 0 1 1 0 7 layer
1 7 1 2 1 6 1.94 6 1.94 2 1 0 layer 8
1 8 1 1 1.07 1.94 0 1.94 0 1 1 0 8 9
1 9 1 1 0.85 2.97 0 2.97 0 1 1 0 9 10
1 10 1 1 0.75 5.93 0 5.93 0 1 1 0 10 11
1 11 1 1 3 1.94 0 1.94 0 1 1 0 11 12
1 12 1 1 3 1.94 0 1.94 0 1 1 0 12 13
1 13 1 1 3.18 1.94 0 1.94 0 1 1 0 13 14
1 14 1 1 0.83 2.97 0 2.97 0 1 1 0 14 15
1 15 1 1 0.534 7.16 6.62 7.16 6.62 2 1 0 15 layer
1 15 1 2 0.534 2.97 0 2.97 0 1 1 0 layer 16
1 16 1 1 1.315 7.16 1.94 7.16 1.94 2 1 0 16 layer
1 16 1 2 1.315 1.94 0 1.94 0 1 1 0 layer 17
1 17 1 1 0.4355 7.16 1.94 7.16 1.94 2 1 0 17 layer
1 17 1 2 0.4355 1.94 0 1.94 0 1 1 0 layer 18
1 18 1 1 0.486 7.16 2.915 7.16 2.915 2 1 0 18 layer
1 18 1 2 0.486 1.94 0 1.94 0 1 1 0 layer 19
1 19 1 1 0.3935 7.16 4.629 7.16 4.629 2 1 0 19 layer
1 19 1 2 0.3935 1.94 0 1.94 0 1 1 0 layer 20
1 20 1 1 2.43 1.94 0 1.94 0 1 1 0 20 21
1 21 1 1 1.75 4 0 4 0 1 1 0 21 22
1 22 1 1 0.25 4 0 4 0 1 1 0 22 23
1 23 1 1 0.25 3.75 1.25 3.75 1.25 1 1 0 23 24
Geo Plot
7.5
5
Shaft Radius, inches
16 18
6 8 10
Shaft1 Shaft1
2.5 1 2 4 22 24
14
12 20
-2.5
-5
-7.5
-10
0 5 10 15 20 25 30
Eigenvalues
Speed zeta1 cpm1 zeta2 cpm2 zeta3 cpm3 zeta4 cpm4 zeta5 cpm5
500. 0.118 2100.7 0.106 2327.3 0.028 9735.5 0.020 11749.6 0.022 22452.9
1000. 0.118 2100.6 0.106 2327.4 0.028 9735.3 0.020 11749.7 0.022 22450.8
1500. 0.118 2100.5 0.106 2327.5 0.028 9734.9 0.020 11750.0 0.022 22447.2
1700. 0.118 2100.4 0.106 2327.6 0.028 9734.8 0.020 11750.1 0.022 22445.4
1900. 0.118 2100.4 0.106 2327.7 0.028 9734.6 0.020 11750.2 0.022 22443.4
2000. 0.118 2100.3 0.106 2327.7 0.028 9734.5 0.020 11750.3 0.022 22442.3
2100. 0.118 2100.3 0.106 2327.8 0.028 9734.3 0.020 11750.4 0.022 22441.1
2200. 0.118 2100.2 0.106 2327.8 0.028 9734.2 0.020 11750.5 0.022 22439.9
2300. 0.118 2100.2 0.106 2327.9 0.028 9734.1 0.020 11750.6 0.022 22438.7
2500. 0.118 2100.1 0.106 2328.0 0.028 9733.8 0.020 11750.7 0.022 22436.0
3000. 0.118 2099.8 0.106 2328.3 0.028 9733.1 0.020 11751.3 0.022 22428.3
3500. 0.118 2099.4 0.106 2328.7 0.028 9732.2 0.020 11751.9 0.022 22419.3
4000. 0.118 2099.0 0.106 2329.1 0.028 9731.2 0.020 11752.6 0.022 22409.0
4500. 0.118 2098.5 0.106 2329.6 0.028 9730.0 0.020 11753.4 0.022 22397.5
6000. 0.118 2096.8 0.107 2331.4 0.028 9725.7 0.020 11756.4 0.022 22355.6
7000. 0.118 2095.4 0.107 2332.9 0.028 9722.2 0.020 11758.9 0.022 22322.2
8000. 0.118 2093.8 0.107 2334.6 0.028 9718.1 0.020 11761.7 0.022 22284.8
9000. 0.118 2092.0 0.107 2336.5 0.028 9713.5 0.020 11764.9 0.022 22243.7
10000. 0.118 2090.1 0.107 2338.5 0.028 9708.4 0.020 11768.4 0.022 22199.4
Mode shapes
Damped Eigenvalue Mode Shape Plot Damped Eigenvalue Mode Shape Plot
forward forward
backward backward
f=2328.3 cpm f=11761.7 cpm
d=.1064 zeta d=.0203 zeta
N=3000 rpm N=8000 rpm
Response
35
30
Response, mils pk-pk
25
20
Horz A mp
15 V ert A mp
10 Excit at ion = 1x
0
0 2000 4000 6000 8000 10000 12000 14000
Rotor Spe e d, rpm
De-stabilizing cross coupled forces were added to the XLTRC model to find out
7.5
5
Shaft Radius, inches
16 18
6 8 10
Shaft1 Shaft1
2.5 1 2 4 2224
14
12 20
-2.5
-5
-7.5
-10
0 5 10 15 20 25 30
Figure II. 11: Eigenvalue Table showing that the first forward mode is unstable
86
Speed Horz Amp Horz Phs Vert Amp Vert Phs Speed Horz Amp Horz Phs Vert Amp Vert Phs
rpm mils pk-pk degrees mils pk-pk degrees rpm mils pk-pk degrees mils pk-pk degrees
200 0.038941 89.12254 0.031744 359.2864 200 0.036677 15.42908 0.03049 289.0259
300 0.088593 88.6693 0.07207 358.9201 300 0.083548 14.96375 0.069438 288.7151
400 0.159992 88.1979 0.12977 358.5419 400 0.151005 14.53617 0.125406 288.4732
500 0.255181 87.70101 0.206167 358.1474 500 0.240927 14.1429 0.199832 288.3012
600 0.377029 87.16996 0.303091 357.7311 600 0.355911 13.78094 0.294685 288.2018
700 0.529463 86.59429 0.422993 357.287 700 0.499445 13.44776 0.412611 288.1794
800 0.717802 85.96088 0.569105 356.8077 800 0.676188 13.14124 0.557142 288.241
900 0.949275 85.25283 0.745677 356.2841 900 0.892354 12.85973 0.733008 288.3959
1000 1.233794 84.44778 0.958317 355.7047 1000 1.15629 12.60219 0.946616 288.6573
1100 1.585177 83.51519 1.214487 355.055 1100 1.479345 12.36852 1.206786 289.0424
1200 2.023106 82.41207 1.52425 354.3156 1200 1.877202 12.1602 1.525939 289.5741
1300 2.576398 81.07569 1.901412 353.4607 1300 2.372 11.98162 1.922067 290.2824
1400 3.288695 79.41075 2.365322 352.4548 1400 2.995814 11.84281 2.422147 291.2065
1500 4.228803 77.26532 2.94381 351.2481 1500 3.796689 11.76489 3.068333 292.3976
1600 5.510398 74.38287 3.678176 349.7687 1600 4.849624 11.79186 3.929785 293.9241
1700 7.331096 70.29928 4.632076 347.9114 1700 6.278337 12.01579 5.126706 295.8825
1800 10.04868 64.10498 5.908813 345.5211 1800 8.30269 12.63431 6.883299 298.4292
1900 14.28696 53.87962 7.691393 342.3664 1900 11.35646 14.09199 9.657573 301.886
2000 20.61637 35.69407 10.37023 337.974 2000 16.42958 17.48213 14.5113 307.1082
2100 26.21211 5.933501 14.88441 330.184 2100 26.23477 26.01073 24.36677 316.9573
2200 24.50698 335.4161 22.13681 313.7107 2200 47.84711 51.85514 47.13383 343.2533
2300 19.99079 316.9228 29.988 285.2 2300 54.77171 112.132 57.28316 42.913
2400 16.76416 305.3876 30.24526 251.2452 2400 32.29723 145.7341 35.59097 74.91663
2500 14.23562 297.1955 24.37293 227.521 2500 21.46615 158.0882 24.59095 85.03119
2600 12.32936 291.8968 19.27838 214.2325 2600 16.19907 164.4869 19.00596 88.96626
2700 10.94585 288.3693 15.85801 206.4886 2700 13.22715 168.6188 15.69316 90.73617
2800 9.922806 285.8687 13.55771 201.5702 2800 11.36396 171.577 13.50932 91.61043
2900 9.143443 284.0011 11.94416 198.2071 2900 10.10418 173.7948 11.96598 92.07722
3000 8.533004 282.5497 10.76332 195.7728 3000 9.202317 175.4961 10.82128 92.34586
3100 8.04341 281.3867 9.867462 193.9318 3100 8.527245 176.8202 9.941543 92.51224
3110 7.99977 281.2829 9.789773 193.7721 3110 8.469003 176.9358 9.86475 92.52529
3120 7.956987 281.1811 9.71395 193.6162 3120 8.4122 177.0487 9.789724 92.53781
3130 7.915037 281.0812 9.639927 193.464 3130 8.35678 177.1589 9.716402 92.54985
3140 7.873895 280.9832 9.567645 193.3153 3140 8.302697 177.2666 9.644734 92.56142
3150 7.833542 280.887 9.497045 193.1701 3150 8.249902 177.3717 9.574666 92.57256
3160 7.793953 280.7926 9.42807 193.0281 3160 8.198351 177.4744 9.506144 92.58328
3170 7.755109 280.7 9.360668 192.8893 3170 8.147998 177.5748 9.439123 92.59361
3180 7.716989 280.609 9.294787 192.7536 3180 8.098805 177.6729 9.373556 92.60356
3190 7.679573 280.5196 9.23038 192.6209 3190 8.05073 177.7687 9.309397 92.61316
3200 7.642845 280.4319 9.167398 192.491 3200 8.003738 177.8623 9.246602 92.62242
3210 7.606782 280.3456 9.105794 192.364 3210 7.957788 177.9538 9.185133 92.63135
3220 7.571372 280.2609 9.045529 192.2396 3220 7.912852 178.0432 9.124947 92.63997
3500 6.787941 278.3647 7.768417 189.5803 3500 6.961244 179.8918 7.838603 92.79678
4100 5.860889 276.0136 6.392496 186.5947 4100 5.921533 181.5954 6.43443 92.88024
4400 5.582558 275.2634 6.008859 185.7106 4400 5.623178 181.947 6.041319 92.86048
4500 5.505434 275.05 5.905271 185.4651 4500 5.541418 182.0264 5.935178 92.84815
4600 5.434475 274.8513 5.811113 185.2389 4600 5.46652 182.0917 5.838716 92.83345
4700 5.368912 274.6655 5.725162 185.0295 4700 5.397589 182.1447 5.750685 92.81665
4800 5.308092 274.4913 5.64639 184.835 4800 5.333865 182.1874 5.670037 92.79798
4900 5.251444 274.3273 5.573933 184.6536 4900 5.274705 182.2212 5.59588 92.77763
5000 5.198482 274.1725 5.507051 184.4838 5000 5.219554 182.2472 5.527456 92.75579
5100 5.148777 274.0259 5.44511 184.3245 5100 5.167935 182.2665 5.464117 92.73261
5200 5.101954 273.8867 5.387565 184.1745 5200 5.119429 182.28 5.405299 92.70823
5300 5.057681 273.7541 5.333945 184.0328 5300 5.073672 182.2883 5.35052 92.68278
5400 5.015662 273.6276 5.283836 183.8987 5400 5.030341 182.2922 5.299356 92.65638
5500 4.975633 273.5066 5.236881 183.7714 5500 4.989146 182.2922 5.251434 92.62911
5600 4.937354 273.3905 5.192759 183.6503 5600 4.949829 182.2887 5.206428 92.60106
5700 4.900608 273.2788 5.151194 183.5348 5700 4.912156 182.2823 5.164053 92.57232
5800 4.865195 273.1713 5.111936 183.4245 5800 4.875915 182.2732 5.124052 92.54296
5900 4.830928 273.0675 5.074763 183.3188 5900 4.840907 182.2618 5.086197 92.51302
6000 4.797633 272.967 5.039479 183.2174 6000 4.806951 182.2484 5.050288 92.48257
Figure II. 12: Response without cross coupling Figure II. 13: Response with cross coupling
87
VITA
Email: [email protected]
India, 2002
USA, 2005