https://ntrs.nasa.gov/search.jsp?

R=19860020728 2020-04-12T07:43:48+00:00Z

M86-3
CRACKED ROTOR DEMONSTRATION
R.F. Bosmans
Bently Rotor Dynamics Research Corporation
Minden, Nevada 89423

Rotating elements in turbomachinery are exposed t o a number of concurrent

forcing functions. These forces may result in l a r g e displacements and
vibrations of the rotor. If the forces are periodic and very high, the
r o t o r w i l l experience high induced stress l e v e l s with a l a r g e number of
cycles. Any combination of high stress/low number of cycles o r low stress/
high number cycles may cause a f a t i g u e f a i l u r e within t h e r o t o r , i n i t i a t e d
by a crack i n the r o t o r a t a s i t e of t h e highest stress l e v e l . Typically,
this occurs i n areas such as coupling keyways o r other shaft lateral
locations experiencing stress concentrations.

The onset of a crack i n t h e r o t o r system introduces an immediate asymmetry

in the r o t o r geometry. TMS asymmetry modifiss the s t i f f n e s s properties of
t h e r o t o r . The s t i f f n e s s in t h e plane of t h e crack is much s o f t e r than t h e
axis perpendicular t o t h e crack. If the r o t o r operates in t h e horizontal
plane, a unique forcing function occurs. The force of gravity acts
perpendicular downward on t h e r o t o r . Each time the crack ( s o f t a x i s ) is
exposed t o t h i s force of gravity, t h e r o t o r ' w i l l d e f l e c t some a d d i t i o n a l
amount. For a singular crack site on t h e r o t o r , t h e s o f t axis w i l l be
exposed t o gravity forces twice f o r each revolution of the r o t o r . This
introduces a vibration component which has a frequency value of twice ( 2 X )
r o t o r speed i n t h e r o t o r response. It can be measured with t h e use of
proximity transducers and quantified with t h e help of an oscilloscope
observing s h a f t c e n t e r l i n e motion and/or a spectrum analyzer.

If t h i s malfunction is observed over some RF'M range of operation, a

secondary e f f e c t can manifest. Since t h e r o t o r i s experiencing a strong 2X
vibration component, when the r o t o r speed is exactly one half t h e frequency
of a system resonance, that resonance w i l l be excited. Amplitudes of t h e
2X component will increase, inducing f u r t h e r stresses and u l t i m a t e l y crack
propagation. Repeated operation in these areas w i l l cause t h e r o t o r t o
u l t i m a t e l y fracture. This t r a n s i e n t behavior can b e s t be observed with
oscilloscope, spectrum cascade, and 2X POLAR PIA7l'S. For t h e r o t o r
operation speed exceeding 1/2 first balance resonance, each start-up and
shutdown, t h e machine will cuase a t r a n s i e n t high vibration l e v e l .

OBJECTIVE
The purpose of t h i s demonstration is t o observe t h e behavior of a r o t o r
with a s i n g l e crack. This w i l l b e presented i n oscilloscope o r b i t s , 2.X
POLAR PLOTS, and spectrum cascade diagrams. Crack detection must be
observed in a l l three formats and monitored over a period of t i m e o r
start-ups. The change i n the 2X behavior patkern provides an early warning
443
 a& a l l y exists and that it is l i k e l y propagating toward
or
ROTOR SYSTEM
The demonstration r o t o r system (FIG. 1) contains t h e following:

A) Variable speed d r i v e motor with speed c o n t r o l l e r

B) Flexible Coupling
C) Three bronze o i l i t e bearings
D) Two mass d i s k s located between bearings
1 & 2 and 2 & 3
The r o t o r system is operated over a speed range from 0 - 5000 RPM. This
range permits e x c i t a t i o n of two balance resonances and t w o resonances of
t h e from the 2X vibration component. The r o t o r contains a r a d i a l crack of
approximately 25% shaft penetration. The crack is located between bearings
2 & 3. Speed is controlled with a s p e c i a l speed control module which
determines maximum speed and rate of acceleration. During t h e start-up,
t h e oscilloscope and spectrum analyzer are t h e primary instruments used f o r
v i s u a l observation. The oscilloscope presentation will i n d i c a t e a large
i n t e r n a l loop on t h e o r b i t when t h e 2X vibration e x c i t e s t h e balance
resonance. The spectrum display w i l l show t h e '1x and 2X components over
t h e e n t i r e operating range. The dynamic motion data will be processed
through t h e H? computer with ADRE software f o r 2X POLAR p l o t s and spectrum
cascade diagrams (FIG.'s 2 , 3, & 4).

Mrrfng 2
DISK WITH
CONTROLLED UNBALANCE

DIGITAL
VECTOR __z COMPUTER
FILTER

Figure 1 . - Rotor system w i t h "cracked" s h a f t simulated by saw c u t .

444
 INSTRUMENTATION
The system behavior is captured with proximity t r a n s d u c e r s l o c a t e d between
bearing 1 & 2 and 2 & 3. The output of t h e s e t r a n s d u c e r s can be observed
on t h e o s c i l l o s c o p e f o r s h a f t c e n t e r l i n e motion s t u d i e s . In a d d i t i o n , a
DVF2 and spectrum analyzer are connected d i r e c t l y t o an HP9836 computer
o p e r a t i n g on ADRE software. The DVF2 is configured w i t h its i n t e r n a l
t r a c k i n g f i l t e r locked i n t o t h e 2X v i b r a t i o n component. This permits
p r e s e n t a t i o n of 2X POLAR PLOTS with t h e use of ADRE software. The spectrum
analyzer and ADRE software permits p r e s e n t a t i o n of spectrum cascade p l o t s
over the o p e r a t i n g speed range. The 2X p o l a r p l o t s (FIG. 3) i n d i c a t e s t h e
resonance response of the system due t o t h e f o r c i n g f u n c t i o n of 2X dynamic
motion behavior. The spectrum cascade p l o t (FIG. 4) i n d i c a t e s t h e response
of t h e 1X and ZX v i b r a t i o n over the e n t i r e o p e r a t i n g speed range,

Figure 2.- 1 X polar p l o t o f cracked r o t o r response.

SUMMARY
Observing c r a c k e d ' r o t o r behavior in these three p l o t formats provides e a r l y
warning of cracked r o t o r c o n d i t i o n , Monitoring this behavior over a period
of time provides i n s i g h t toward rate of propagation of a crack and w i l l
prevent c a t a s t r o p h i c r o t o r fracture. The lX and 2X components must be
monitored as v e c t o r s i.e. AMPLITUDE & PHASE have t o be acquired a t each
r o t a t i v e speed, b y change in behavior must be q u a n t i f i e d as v e c t o r s .
These v e c t o r s can be p l o t t e d within a POLAR diagram and a range of "normal"
behavior e s t a b l i s h e d . S i g n i f i c a n t v e c t o r a l d e v i a t i o n from t h e acceptable
range of values provides warning of cracked r o t o r a c t i v i t y .
445
 E

OF POOR QUAcl7Y

PLRNT ID: CRFCKED SHRFT xno

TRRIN ID: 1
270 98 MACHINE ID: 2x
SOLID DATA: VERT OUTB 2 X

DATE: 1 M a r 1900 TIMEr 00147: 05

FULL 5CRLE
B flV PK-PK
18Gs
BRLRNCE P L R M 3

Figure 3 . - 2X polar p l o t o f cracked rotor response.

$ 100% -
O.SX
26%

"r
I

SHAfTCUT
: II

2x

.3x

-0 1.2 2.4 3.6 4.8 6

FFIEaUENCY INPCTS/MIN x IOOOI

Figure 4.- Spectrum cascade diagram o f cracked rotor response.

446