Mechanical and Electrical Run-

G. A. Horattas Out Removal on a Precision

M. L. Adams
Department of Mechanical
and Aerospace Engineering,
Case Western Reserve University,
Cleveiand, Otiio 44106
F. Dimofte
NASA Lewis Researcti Center,
Cieveland, Ohio 44135
Rotor-Vibration Research
Spindle
Experimental determination of both steady-state and dynamic performance of a jour-
nal bearing requires the use of a high precision spindle with a vanishingly small
range of run-out. This was achieved by first eliminating the mechanical run-out of
the spindle by grinding the journal specimen while rotating in place. Once the
mechanical run-out was removed, the electrical run-out sensed by the displacement
proximity-probe-transducers was also removed. Using this procedure the mechanical
and electrical run-outs of a research spindle were reduced to less than 0.2 micron
(10 fj,in.), which is better than the resolution of the data acquisition system, 1 micron
(50 pin.).

Introduction
The rotordynamic test facility at Case Western Reserve Uni-
versity covers a floor space of 300 square feet, encompassing
the test spindle and chamber, two 25-horsepower variable speed
drive motors, oil and water pumps, oil mist air system, sump
tanks and computerized data acquisition system. The heart of
the facility, (test chamber and double spool shaft), are shown
schematically in Fig. 1. As described in [1], the test rig is
equipped with two independent load measuring systems con-
nected in series. A piezoelectric system captures the dynamic
loads on the test bearing, while a newer strain gage system
captures static and dynamic loads. The outer spindle of the
double spool shaft, which produces the orbit frequency, is
equipped with a timing disk at its drive end. This disk contains
360 equally spaced slots which interrupt a light beam, triggering
the A to D converter as an external clock. Eight channels of
data are taken, which include four force signals {x and y from
the two load measuring systems) and four displacement signals
(x and y at each end of the test bearing) using inductance type,
noncontacting proximity probes by Bently Nevada [ 2 ] . A ninth
channel has been added as a part of this work and is used to
capture a key phasor on the inside shaft using a reflective optical
sensor on the drive end of the inside shaft. Thus 40 digitized
data points are taken from each channel per cycle of orbit.
Typically, data are taken for 50 consecutive cycles and time
averaged. Previously, data was taken at sufficiently incommen-
surate-with-spin frequencies so that extraneous signals not co-
herent with the orbit frequency would be essentially filtered-out
through time averaging. Such non-coherent signal components
include any synchronous-coherent run-out (mechanical and
electrical) as well as ball bearing noise, and electrical line fre-
quency interference. As is well known, the electrical run-out
comes from impurities and imperfections in the journal material
and also any residual magnetism in the targeted journal surface.
Experimental determination of both steady-state and dynamic
performance of a fluid-film journal bearing requires the use of
a high precision spindle with a very small range of run-out. The
maximum run-out accepted is typically less than ten percent of
the bearing clearance. When a bearing with a 0.25 mm (0.010
in.) clearance is tested a maximum run-out in the journal of
Contributed by the Technical Committee on Vibration and Sound for publica-
tion in the Journal of Vibration and Acoustics, Manuscript received Jan. 1995.
Associate Technical Editor: D. T. Noah.
0.025 mm (0.001 in.) can be accepted, and this is not a problem
for a test specimen journal turned on a lathe. When the clearance
of the test bearing is reduced to 0.05 mm (0.002 in.), special
measures need to be taken to ensure that the journal mechanical
run-out is reduced below ten percent of this clearance. This can
only be achieved by grinding the spindle and journal assembly
while turning in it's own bearings. Optimally, the journal me-
chanical run-out can be reduced to the residual run-out in the
spindle bearings.
The need for this enhancement to the Rotordynamic Test Rig
at Case Western Reserve University was recently recognized
when a NASA grant to study the properties of an air-lubricated
hydrodynamic bearing was awarded to CWRU. The 150 mm
(6 in.) test bearings were to have a 0.05 mm (0.002 in.) radial
clearance, and dynamic displacement measurements ap-
proaching 0.25 pm (0.01 mil) accuracy were desirable. To
minimize synchronous, (once-per-rev) run-out of the test jour-
nal, final machining had to be performed using a jig-grinder,
with the test journal rotating in it's own spindle bearings. The
system described herein was therefore designed and built as a
special accessory to the existing test rig.
The Grinder Assembly
The main component of the journal grinding system shown
in Fig. 2 is the THEMAC J45 half horsepower, motorized
grinder, Ref. [3]. This grinder is equipped with a Circumferen-
tial Swing spindle that can be locked and operated in any posi-
tion, allowing fine adjustment of the grinding wheel to take
smaller cuts, down to 2.5 pm (0.1 mil) per pass. The THEMAC
spindle is a 6-in., 3-Bearing Spindle Assembly for deep internal
grinding. It was preferred over an extension spindle for internal
grinding as it provides greater stiffness and stability and elimi-
nates spindle run-out.
Special precision dovetail slides, Ref. [4], are used for the
radial adjustment of the grinding wheel, and for a smooth con-
stant traverse feed. Hand-scraped way slides were preferred as
they have a lower coefficient of friction, operate smoother, and
are more precise than milled slides. The slide gibs were origi-
nally adjusted at the factory, but had to be re-adjusted on site
at a tighter setting to provide for the required accuracy. The
grinder is attached on top the saddle of the smaller slide (Oilman
L3), and a gib lock is used to lock the saddle in place. This
slide is mounted perpendicular to the feed line of a Oilman
DC4 slide, that is used to advance and position the grinder in

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 Journal Run-Out
Mechanical Run-out

Fig. 1 Conceptual drawing of double-spool shaft spindle

the axial direction. The DC4 has a 178 mm (7 in.) travel, as

much as the depth of the test-rig test chamber. Its actuator is a
Schrader Bellows air cylinder, Ref. [5], mounted in-line with 20 40 60 80100120140160180
the rest of the slide, and controlled by a 4-Way 4-Port 3-Position Number of Cuts
hand operated valve. To provide the required smooth feed, this
slide is equipped with hydraulic checks, that control the traverse
feed in both directions, and needle valves that permit the adjust-
ment of the feed rate. The DC4 is attached on the top of the
supporting platform that bolts on the front face of the test cham-
ber. More details about the design and operation of the system Fig. 3 Total peak-to-peak run-out measured using a high precision dial
can be found in Ref. [6]. indicator graduated in 2.5 jum (0.1 mil) Increments

The Workpiece (Test Journal)

The test journal was made of carbon steel, and its outer ing down to the final dimension. This was done to minimize
diameter surface was plated with hard chromium before grind- electrical run-out from the proximity probes targeting the jour-
nal, harden the journal surface, and prevent the journal bearing
from seizing in case of metal-to-metal contact. According to
Parthasaradhy [7], hard chromium plating gives the surface
high hardness (800 to 1000 Vickers), abrasion resistance, low
GRINDER coefficient of friction, good corrosion resistance, high heat resis-
tance (up to 400 C), and also non-sticking and anti-seizing
properties.
GRINDER The journal which has a tapered bore for proper positioning
on the test-rig's inside spindle, was made with a 150 mm (5.93
THEMACI
J45 in.) outside diameter concentric with the taper bore and was
IM .^PRECISION plated with a thick layer of hard chromium. To ensure that the
proximity probes do not read the steel surface under the plating,

PLATFORM Journal Run-Out

from Proximity Probes
SIDE VIEW FRONT VIEW
0.18- 2 1

0.16- *^\
0.14 Vs. FRONT

0.12-
3 0.1-
O
C 0.08
3
0.06'
0.04-
0.02-
0- 1 r 1 1—1 1 1 1—1 1 1 1

0 20 40 60 80 100120140160180
Number of Cuts

Probe # 1 « Probe # 2

Fig. 2 Conceptual drawing and picture of the precision journal grinding

system Fig. 4 Total peak-to-peak run-out measured by the proximity probes

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 ELECTRICAL RUNOUT ORBIT IMPOSED
FILTERED SIGNAL ON THE JOURNAL

4.0

2.0

0.0 . 1 J
\
-2.0 ^
-4.0

0.0 400.0 800.0 1200.0 1600.0 2000.0

200.0 600.0 1000,0 1400.0 1800.0
Points for one rev. of j o u r n a l '

-12.0 -6,0 -4,0 0,0 4.0 8.0 12.0

Probe X micron
- » - Probe X Probe Y

Fig. 7 Plot of the orbit imposed on non-rotating journal

Fig. 5 R e m o v e d filtered electrical run-out signal from t w o proximity
probes

journal. This occurs because the grinding wheel spends more

at least 0.76 mm (0.030 in.) of chromium plating is required.
The journal was plated with 2.30 mm (0.090 in.) of hard chro-
mium before grinding it to its final diameter.
The Grinding Process
For cylindrical grinding of hard chromium plating, Hey wood
[8] recommends using an Aluminum Oxide, vitrified wheel of
medium grade and 60 to 80 abrasive grain. This wheel type was
used throughout the grinding process, that employed peripheral
speeds of 6000 to 7000 sfpm (surface feet per minute) for the
wheel, and 30 to 90 sfpm for the workpiece, as recommended
by Parthasaradhy [7] for hard chromium. These speeds ensure
cutting with no overheating.
As this grinding system is intended to be used for light cuts
only, (the in-feed cut was typically less than 0.0125 mm (0.0005
in.) per traverse), there is no cutting fluid used in the process.
The heat developed during the grinding operation did not cause
any problems to the process, and "loading" of the grinding
wheel was not observed.
While grinding the test journal, run-out measurements were
taken at seven equally spaced points along its length using a
dial indicator. In addition, proximity probe measurements were
taken at two journal locations. The journal mechanical run-out
time at these two locations. In addition, any deflections in the
assembly relax faster as the grinder is more rigid at the ends.
Figure 4 reveals that the journal run-out, as measured by the
proximity probes, does not seem to be eliminated. This is be-
cause the proximity probe outputs include not only mechanical,
but also electrical run-out. The results in this figure indicate
that the electrical run-out is 0.018 mm (0.72 mil) for Probe #1
and 0.012 mm (0.48 mil) for Probe #2.
To check whether the run-out of the journal changes if the
journal is removed from the spindle and then remounted, the
journal-spindle angular position was marked, and the journal
was removed. When the journal was remounted back onto the
spindle, and the run-out measured, it was found that the maxi-
mum run-out introduced during this procedure was 0.01 mm
(0.4 mil). Thus for the precision required in this research, the
journal should not be removed until testing is completed. Re-
AVERAGED ORBIT
50 CYCLES CORRECTED
^-c::.-^

became practically unmeasurable after 200 cuts.

Mechanical Run-Out Removal Results

The mechanical run-out measurements from the dial indicator
were recorded and are plotted in Fig. 3, while the run-out mea- \ ^fJ

surements from the two proximity probes, which include both

mechanical, and electrical run-out, are plotted in Fig. 4. Figure
3, shows that the run-out at the edges of the journal, and espe- -12.0 -8.0 -4,0 0.0 4.0 S.O 12.0
cially the front edge, is eliminated faster than the rest of the Probe X micron

AVERAGED ORBIT
50 CYCLES NOT CORRECTED
ELECTRICAL RUNOUT
VIRTUAL ORBIT REMOVED
j,p«.>^
6.0'
...SS^ > » a _
4.0'
K
2,0
....<C3
i
ajk^
J / \
/J
i -2.0
/ h
L.-^ '\ii 4
\i "V fln-
-12.0 -8.0 -4.0 0.0 4.0 8.0 12.0
-6.0 Probe X micron
-10.0 -6.0 -2.0 2.0 6.0 10,0
-8.0 -4.0 0.0 4,0 8.0
Fig. 8 Plot of t h e electrical run-out corrected and un-corrected orbit
Probe X micron
after time averaging over 50 orbit cycles (21.2 spin cycles, n = 1668
R P M , M = 707 R P M ) . Legend: . . . from Fig. 7.
Fig. 6 Filtered electrical run-out plotted as journal orbit

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 AVERAGED ORBIT phasor on the inside shaft, relative to the data acquisition clock
10 CYCLES CORRECTED which is synchronized by the outer shaft. As the frequency and
spin speeds are completely independent, the number of data
points acquired for each revolution of the journal depends on
^ the orbit frequency and spin speed as follows:
\ 0*360
No. of Points =
u!* Channels
\
where,
J'' J
n = Orbit frequency
u! = Spin Speed
-12.0 -8.0 -4.0 0.0 4.0 8.0 12,0 Channels = Number of Channels
Probe X micron 360 = Number of clock points per orbit
AVERAGED ORBIT After achieving "zero" mechanical run-out, the electrical
10 CYCLES NOT CORRECTED run-out from every test journal displacement proximity probe
was recorded for ten revolutions of the journal, and after averag-
ing and filtering out the high frequencies, it was stored (Figs.
5 and 6). Note that Fig. 6 is also the picture shown on the
oscilloscope when the journal spins without orbiting.
A data post-processing program was coded to remove the
electrical run-out from each of the proximity probe test signals.
Using the optical sensor once-per-rev signal as the reference
point (key phasor), and the speeds of the two shafts, the pro-
gram finds the corresponding electrical run-out point and sub-
tracts it from the measured digitized signal. Time averaging
-4.0 0.0 4.0 over the number of cycles desired can then also be applied.
Probe X micron

Fig. 9 Plot of the electrical run-out corrected and un-corrected orbit Electrical Run-Out Correction Results
after time averaging over 10 orbit cycles only (4.2 spin cycles, O = 1668
RPIVI, ft. = 707 RPM) A plot of the "actual" orbit of the journal center can be
found in Fig. 7. It was obtained by whirling the journal (rotating
the outside spindle), while at the same time keeping the inside
grinding is also an option if a journal must be removed and spindle from spinning. The same figure is overlaid on Figs. 8 -
subsequently re-installed. 11 for comparison. Figure 8 shows the orbit from an actual
The grinding system developed, when used with the proper
measuring equipment, can provide very precise sizing for the
diameter of the journal. This precision is estimated to be as
small as 0.25 /xm (0.01 mil). At present, the achieved precision
AVERAGED ORBIT
5 CYCLES CORRECTED
exceeds our inspection measurement accuracy.

Electrical Run-Out Removal

The CWRU Rotordynamic Testing Facility spindle was made
by the Schumman Bros. Co., Warrington PA, with nearly perfect
\X
zero run-out, (ground while turning in its own bearings). This
gives the potential of removing the measurable mechanical run-
out from the journal, and therefore provides the ability to re- -^g^ —,•<
move the electrical run-out'' from the proximity probe signals,
as well.
Commercially available proximity-probe signal processing -12.0 -8.0 -4.0 0.0 4.0 6.0 12.0
equipment (e.g. Bently Nevada DVF3) remove the once-per- Probe X micron
rev portion of the perceived electrical run-out based on slow-roll
measurements. This is a vast improvement over earlier systems
AVERAGED ORBIT
5 CYCLES NOT CORRECTED
without the option. Such an improvement was first conceived
about twenty-five years ago as a result of some widely publi-
cized "false-trips," where plant machinery was tripped off line
based upon monitored vibration levels that were contaminated ^' ••'"•xv
with large electrical run-out. The method described in this paper
removes "all" of the electrical run-out, not just the once-per- \\ -"^
rev portion, and the resulting orbit measurement precision is at
least an order of magnitude better than is commercially avail-
able. Keep in mind that the method described herein is for \.\^. ,f..
precision laboratory research, whereas the commercially avail-
able electrical run-out methods are for vibration monitoring
of plant machines and are more than adequate for such non- -4.0 0.0 4.0
laboratory applications. Probe X micron

At CWRU, the electrical run-out is removed by using a ninth Fig. 10 Plot of the electrical run-out corrected and un-corrected orbit
input channel on the Data Acquisition system to capture a key over 5 orbit cycles only (2.1 spin cycles, ft = 1668 RPM, M = 707 RPM)

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 SYNCHRONOUS OPERATION Conclusion
CORRECTED - AVERAGED (50 CYCLES) The work reported in this paper demonstrates the ultimate
precision that can be achieved in run-out removal and dynamic
rotor orbit measurement. This is of particular importance to
rotor based research test rigs. This work also demonstrates that
even small amounts of residual electrical run-out can be essen-
tially removed, subsequent to the virtual elimination of mechan-
u. ical run-out.
The major conclusions are thus summarized:
\\ y_ ^>
1. It is proven that time averaging over several clock cycle
periods (e.g., 50) incommensurate with spin speed effectively
eliminates run-out components from the proximity probe dis-
-4.0 0.0 4,0 placement signals (See Fig. 8).
Probe X micron
2. Using the approach taken in this work, (i.e., elimination
SYNCHRONOUS OPERATION of mechanical run-out followed by post-test removal of electri-
NOT CORRECTED - AVERAGED (50 CYCLES) cal run-out) accurate orbits were obtained even with only a few
12.0 time-averaging cycles (See Figs. 9 and 10).
3. The approach taken in this work provides the new capa-
e.o bility of obtaining very accurate orbit data at clock speed periods
which are commensurate with the spin speed, something that
e
•i ^o
\zi the time-averaging technique can not accomplish (See Fig. 11).
v/ "••.
This simplifies laboratory testing considerably since it elimi-
\ V
t 0.0 I
nates the need to avoid orbit-frequency/spin-speed ratios which
O 1
are commensurate, i.e., where the time-averaging filter breaks
//
1 \ J

-4.0 down.
4. Most importantly, when measuring transient rotor orbits,
-4.0 0.0 4.0
the possibility of time-averaging does not exist. Thus the preci-
Probe X micron sion mechanical and electrical run-out removal demonstrated
here could also greatly improve measurement accuracy for tran-
Fig. 11 Plot of the electrical run-out corrected and un-corrected orbit
after time averaging over 50 cycles for synchronous orbit and spinning
sient rotor orbital motion (e.g., rub impacts and instability
speeds ( n = 1000 RPIM, « = 1000 RPIVI) growth).

test, both corrected and un-corrected for the electrical run-out,
and after time averaging over fifty cycles. The two plots are
almost identical and they closely resemble the actual orbit of
Fig. 7 shown in dotted lines. This indicates that the process of
time averaging over an adequate number of cycles effectively
removes signals not coherent with the orbit frequency, such as
electrical run-out. When the time averaging is performed over
fewer cycles, the electrical run-out removal process corrects the
results noticeably, as shown on Figs. 9 and 10. The main advan-
tage is that it can correct data that are taken even at synchronous
frequencies. Fig. 11, something that time averaging can not do
as shown.
References
1 Adams, M. L., Sawicki, J. T., and Capaldi, R. J., ' 'Experimental Determina-
tion of Hydrostatic Bearing Rotordynamic Coefficients," Proceedings, Interna-
tional Conference on Vibrations in Rotating Machinery, C432/145, pp. 365-374,
IMechE, 1992.
2 Bently Nevada, Minden, Nevada.
3 Themac Inc., Catalog No. 104, East Rutherford, N.J.
4 Oilman Russell T. Company, "Oilman Dovetail Slide AssembUes," Cata-
log 3000, 1985.
5 Schrader Bellows, Akron, Ohio.
6 Horattas, G. A., "Design and Implementation of a Precision Journal Grind-
ing System as an Attachment on a Journal Bearing Test Rig," MS Thesis, Case
Western Reserve University, 1994.
7 Parthasaradhy, N. V., Practical Electroplating Handbook, Prentice Hall,
Englewood Cliffs, 1989.
8 Heywood, J., Grinding Wheels and Their Uses, 2nd ed., Penton Publishing
Company, Cleveland, 1942.

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