The Effect of Misalignment on

Rotor Vibrations
Rotors with three or more fluid-film bearings (or fluid seals) have "redundant"
supports, and, therefore, interdependent bearing loads that are generally unknown
both in magnitude and direction. The steady-state bearing eccentricities and the
dynamic stiffness and damping coefficients of the bearings are, therefore, also un-
known since both are functions of the bearing loads. Thus, the dynamic behavior of
J. L. Nikolajsen multibearing rotors generally cannot be predicted with good accuracy without access
Staffordshire University, to a procedure for calculating the steady-state bearing loads and eccentricities. This
School of Engineering, paper outlines such a procedure in terms of both the influence coefficient method,
Stafford, ST18 OAD, the transfer matrix method, and the finite element method. Radial bearing misalign-
England
ment and flexibility of the bearing back-up structures are accounted for. Once the
eccentricities are available, the bearing stiffness and damping coefficients can be
calculated in the usual way and used to predict critical speeds, instability threshold
speed, and rotor response to imbalance. A numerical example is presented that
illustrates some of the nonlinear effects of bearing support redundancy, notably the
large variations in instability threshold speed with radial bearing misalignment.
The example shows how the method can be used to determine the level of bearing
misalignment that leads to optimum rotor stability. It is concluded that no simple
guide lines exist by which optimum stability can be achieved. Neither perfect bearing
alignment nor equal load sharing between bearings necessarily lead to optimum
stability.

Introduction implementation of the method will be outlined in terms of both

Some types of turbomachinery, such as pumps and turbo-
generators, have rotors with several journal bearings and/or
fluid seals. The resulting support redundancy makes the
steady-state bearing loads interdependent and difficult to cal-
culate. The bearing eccentricities and the dynamic bearing
coefficients are equally difficult to obtain since both are non-
linear functions of the bearing loads. Bearing misalignment
and flexibility of the back-up structure further complicates
the calculations. Thus, poor accuracy can be expected in the
predicted rotordynamic characteristics for machines with
multibearing rotors unless specially designed software is used
to calculate the bearing loads or eccentricities. As an exam-
ple, it is well-known that if a plain journal bearing is misa-
ligned so that it does not carry its full load, it becomes a
potential source of rotor instability. However, since bearing
alignment is usually adjustable, it could potentially be used
as a means of improving rotor stability. The problem is that
the adjustments leading to optimum stability are generally
unknown and difficult to determine because of the interde-
pendence between the bearing loads.
This paper provides a method for calculating the coupled
bearing loads and eccentricities for multibearing rotor systems,
thus allowing the dynamic characteristics of such rotors to be
determined with the same accuracy as for simple rotors without
support redundancy. Any rotor system can be analyzed as long
as the usual bearing and seal data are available relating the
steady-state load (Sommerfeld number) to eccentricity and atti-
tude angle. For unsymmetric bearings, this data is required for
all load directions. The analysis procedure, briefly stated, is
to calculate the steady-state bearing eccentricities and attitude
angles from a nonlinear simultaneous equation system derived
from force and moment equilibrium equations for the rotor. The
the IC (influence coefficient) method, the FE (finite element)
method, and the TM (transfer matrix) method because of the
fundamental differences between the three. Once the eccentricit-
ies have been determined, the hydrodynamic stiffness and
damping coefficients for all the bearings can be calculated in
the usual manner, and the natural frequencies, mode shapes,
unbalance response, and instability threshold speed can be pre-
dicted with standard rotor programs (e.g., Lund (1974); Nelson
(1976)) with the same accuracy as for rotors without support
redundancy.
This work builds in part on theory developed in Nikolaj-
sen (1978), Nikolajsen and Gajan (1988), and Kelly
(1989). The only other published works in this area, known
to the author, are those of Rieger (1970) and Takagi (1980).
Rieger (1970) appears to be the first to analyze misalign-
ment effects, but his method is too rudimentary for practical
use. Takagi (1980) mentions a practical method in exis-
tence, but gives no details. Other publications on multibear-
ing rotors, including Tondl (1965) and Morton (1972), ig-
nore the effect entirely.
Bearing Eccentricity Calculation
The steady-state bearing eccentricities are calculated here
with the assumption that no moment reactions occur either at the
bearings or at the seals. This is still the conventional assumption,
although theoretical moment coefficients are available for seals,
see, for example, Childs (1981). The following derivations can
be extended to include such moment reactions. Implementation
in terms of both the IC, FE, or TM method is described for use
in rotor programs based on these methods. The IC method is
considered to be conceptually the simplest and will be presented
first.

Contributed by the International Gas Turbine Institute and presented at the 41ST
International Gas Turbine and Aeroengine Congress and Exhibition, Birmingham,
United Kingdom, June 10-13, 1996. Manuscript received by the ASME Head-
quarters January 31, 1996. Paper No. 96-GT-373. Associate Technical Editor:
J. N. Shinn.
The Influence Coefficient Method. Figure 1 shows the
steady-state equilibrium position J of the journal within the
flexibly supported bearing. Three forces, acting on the jour-
nal, are in static equilibrium: P (the bearing's share of the

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 _B earing fx Shaft 2 _ 3

y z
Fig. 2 Shaft displacement components

da = -(Exi + hx,)(z„ - Zi)/(zn - z,) + Exi + hxi + exi

- (Exn + hx„)(z, - Zi)l(Zn ~ zi)
B=Bearing Ctr.
J=Journal Ctr. 2 < ( < « - 1 (2)

dyi = - ( £ , / + hyl)(z„ - Zi)/(z„ - z,) + Eyl + hyi + eyi

Fig. 1 Steady-state equilibrium in journal bearing - (Ey„ + hyn)(zi - Zt)/(zn - Zi).

The bearing housing displacements h can be expressed in

terms of the hydrodynamic bearing forces F and the housing
rotor weight), F (the hydrodynamic fluid-film force), and Q flexibilities a by
(the elastic restoring force from the shaft). Thus, for bearing
no.;' hxi = axiFi cos (#, ,)
1 (3)
h^ = ayiFi sin (6>, - </>,•).
Qxj = Fj cos (6j - fa) - Px
Alternative expressions for d can be written in terms of the
shaft elastic restoring forces Q and the shaft flexibility influence
Qyj = Fj sin (6j - fa) - Pyj (1) coefficients atl as follows:
n-1 /i-i
P is, by definition, set equal and opposite to the support reac-
tions that would exist if all the bearings and seals were replaced dxi = - X aijQxj = - X a,j[Fj cos (0, - fa) - Pxj]
by perfectly aligned pinned supports. P can, therefore, be found J=2 j-2

by the standard flexibility influence coefficient method for stati- 2 < ( < « - 1 (4)
cally indeterminate beams, see, for example, Argyris (1958).
The influence coefficients for a shaft with variable cross section «-i n-i
can be derived as outlined in Vernon (1967). They are listed dyi = ~ X ayQyj = - X aij[Fj sin (0, - fa) - PyJ],
inNikolajsen(1978). j=2 ;=2

Figure 2 shows the total static shaft displacements at the

where Q has been substituted from Eqs. (1).
bearing locations, zi through z4, for a four-bearing rotor. The
Equations ( 2 ) , ( 3 ) , and (4) combine to give
shaft displacements consist of (1) the elastic shaft deflections
d, relative to the end bearings, (2) the bearing eccentricities E,
- [ c ^ , cos Qx + axXFx cos (6, - fa_)](z„ - Zi)/(z„ - zt)
(3) the elastic displacements h of the flexible bearing housings,
and (4) the bearing misalignments e relative to the end bearings, + Citi cos Bi + axiFi cos (9j — </>,•)
as measured before the rotor is installed. By means of Fig. 2, n-l
the following generalized expressions can be deduced for the + X aiAFj cos (6j - fa) - Pxj]
elastic shaft deflections d: 1=2

Nomenclature
av = flexibility influence coefficient
for simply supported shaft = ra-
dial deflection of station i due
to unit force at station j
ayi = back-up structure flexibilities at
bearing (or seal) no. i
c = radial bearing (or seal) clear-
ance
d = elastic shaft deflection
e = radial bearing (or seal) mis-
alignment
E = bearing (or seal) eccentricity or
elastic modulus of shaft mate-
rial
F = hydrodynamic fluid-film force
h = bearing (or seal) housing radial
displacement
/ = second moment of area of shaft
cross section
K, k = seal stiffness (direct and cross-
coupled)
/ = length of shaft element
n = number of bearings and seals
N = total number of shaft stations
P = external force on journal
Q = internal shaft elastic restoring
force
x, y = radial displacements
z = axial bearing (or seal) loca-
tion
e = Elc = bearing (or seal) eccentricity
ratio
6, 4> = angular displacements
0 = direction angle of E
4> = bearing attitude angle
H = oil viscosity
fi = shaft rotational speed

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 — [c„e„ cos 0„ + ax„Fn cos (0„ — <£„)] Lumped A*i .
Mass L/A6i
X (Zl. - z,)l{zn ~ z,) + exi = 0 (5)
M, M'yy M,
and

-[<:,£, sin 9X + ay[F{ sin (9, - ft.)](z„ - Zi)l(z„ ~ z,) u H--HE

VJ V,!U
ShaftElement

I
™V*'

Jvji+,
+ CiCj sin Oi + ayiFi sin (0,- — # , ) v; vt
n-l

+ X a f f [F ; sin (0j - ft) - Pyj] Fig. 3 Discrete shaft model for transfer matrix analysis

-[c„e„ sin 0„ + aynF„ sin (8„ - 0,,)]

X (z, - z,)/(z„ - zi) + eyi = 0. (6) Also, the hydrodynamic bearing forces FX(E) and Fy(E) can
be expressed in terms of the housing flexibilities ax and ay, and
Moment equilibrium of the external forces for the entire shaft the bearing misalignments ex and ey as
about the end bearing positions results in
Fx = (ex - x')lax
I [Fj cos (0j - ft) - Pxj](zn -z,) =0 (7)
;=i Fy = (.ey ~ y')lay
from which
I [Fj sin (0y - <£,) - Pyj](z„ - zj) = 0 (8)
j=i
axFx
I [Fy cos (6j - </>,) - Pxj](zj -z,) =0 (9) y' = ey- ayFy. (13)
J =2

H Substitution of Eqs. (12) and (13) into Eqs. (11) leads to

X [Fy sin (fl, - ft) - Pyj](.zj - z.) = 0. (10)
J =2 [K0]{{X'} + {E)} = [K0][{e} - {aF} + {E}}

Equations ( 5 ) through (10) constitute a set of 2« nonlinear = {F} ~ IP)

simultaneous equations from which the magnitudes e and direc-
tions 9 of the n eccentricity ratios can be found. The equations
are nonlinear because the bearing forces F,- are nonlinear func-
tions of Cj and Oj, as given in the literature, e.g., Lund ( 1 9 6 5 ) .
For seals, however, F is usually assumed to be a linear function
of e, see Childs (1981).
Equations ( 5 ) through (10) were solved by a combined
steepest-descend/Newton-Raphson iteration algorithm due to
Powell (1970). The method was found to be efficient and stable
with almost global convergence.
The Finite Element Method. Using a standard finite ele-
ment rotor model, e.g., Nelson ( 1 9 7 6 ) , the steady-state equi-
librium equations for a flexible rotor can be written as fol-
lows:
[K0]{X] = { F } - [P] (11)
where [K0] is the unsupported shaft FE stiffness matrix (a
known matrix of order four times the number of shaft stations).
Vector {X } contains the x and y -components of the radial and
angular shaft displacements at all the FE nodes, including the
bearing and seal-eccentricity components Ex and Ey, which are
being sought. { F } is an unknown vector containing the x and
y-components of the hydrodynamic bearing and seal forces,
which are known functions of the bearing and seal eccentricity
components Ex and Ey. {P} is a known vector containing x and
y -components of all the external forces acting on the journal,
including the rotor weight.
By reference to Fig. 1, the x and y-components of the bearing
eccentricity £ , can be expressed as the difference between the
location of the journal center and the location of the bearing
center, i.e.,
Ey = y -y'. (12)
[K0]{E] = [[I] + [Kl]]{F) - {P^, (14)
where [Pt} = {P} + [^ 0 ]{e} is a known vector of constant
forces. [Ki] is equal to [K0], except for the columns associated
with bearing and seal locations that have been multiplied by
the support flexibilities ax and ay. [I] is the identity matrix.
{E} contains the desired x and y-components of the bearing
eccentricities at the bearing locations and it contains the absolute
shaft displacements at all other stations.
Seal forces are usually assumed to be known linear functions
of the seal eccentricities, but nonlinear functions of rotational
speed. Thus, if seals are present, the seal forces can be expressed
as
K k
(15)
-k K
which can be substituted into Eq. (14) at the seal locations to
simplify the calculations.
Equation (14) is a nonlinear equation system from which the
bearing eccentricities E = (Ex, Ey) can be found. If a Newton-
Raphson iteration procedure is used, and if derivatives rather
than finite differences are used in the Jacobian matrix, then it
is advantageous to note that some of the derivatives turn out to
be the bearing stiffness coefficients that are known functions
of the bearing eccentricity, see, for example, Lund (1965).
The Transfer Matrix Method. Figure 3 shows the usual
lumped mass and massless flexible shaft elements used in rotor-
dynamic analysis based on the TM method, see, for example,
Lund (1974). The rotor is assumed here to be in steady-state
equilibrium. Using the standard TM procedure, it can be verified
that transfer across a mass and beam-element combined is given
by

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 Cx 1 " 1 0 / 0 j l3/(6EI) 0 l2/(2EI) 0 (Px - Fx),Pl(6EI) n
X
2
y 0 1 0 / 1 0 P/(6EI) 0 l /(2EI) (Py - Fy),P/(6EI) y
0 0 0 1 0 ! l2l(2El) 0 11 {El) 0 (Px - Fx)ll2/(2EI) 9
4> 0 0 0 1 | 0 l2/(2EI) 0 ll(EI) (Py - Fy)il2l(2El)
yx • = 0 0 0 0 | 1 0 0 0 n
(P* ~ Fx), • yx (16)
Vy 0 0 0 0 | 0 1 0 0 (Py ~ Fy), Vy
My 0 0 0 0 1 I 0 1 0 KPX - Fx), My
Mx 0 0 0 0 ] 0 / 0 1 KP, ~ Fy), Mx
. 1 . >+i Lo o o o o 0 0 0 1 J . 1 .

where the eight top elements of the last column of the matrix
are nonzero at the bearing and seal locations only. Shear flexi-
bility has been omitted in Eq. (16) for clarity, but can easily
be included in the usual manner. If seals are present and the
seal forces are considered linear, then further simplification can
be achieved by substitution of Eq. (15).
The effect of bearing and seal support flexibility and radial
misalignment is included, as before, by substitution of Eqs. (12)
and (13), giving
resulting transfer matrix will look similar to Eq. (18), with
nonzero elements in the last column resulting only from the last
transfer as the bearing is reached. Thus, the two first lines of the
matrix equation represent two nonlinear equations from which
improved values of the eccentricity components at bearing no.
1 can be derived, for example by Newton-Raphson iteration.
This procedure in repeated between bearings no. 1 and 2, etc.
to calculate improved values of all the bearing eccentricities;
(vi) go back to (ii) until convergence.

Ex] - Fx),l3/(6EI) - (axFx - ex)i + (axFx -- e*)i+i

!{p*
Ey An I An \(Py - Fy)iP/(6El) - (ayFy - ey), + (OyFy -- ey)i+\
0 (Px - Fx)il2l(2EI)
* (Py - Fy)il2l(2EI)
V* > r (Px - Fx)i
Vy A21 A22 (Py ~ Fy)t
My KPx - Fx),
Mx KPy - Fy),
1J i+l 0 0 0 0 |o 0 0 0 1

where An through A22 are the four 4 x 4 submatrices outlined Numerical Example
inEq. (16). The three methods described above have been programmed
The basic solution procedure goes as follows: and included in rotordynamic programs based on the IC, FE,
and TM methods, respectively. They have been thoroughly
(i) choose initial values of eccentricity components Ex and tested and found to produce consistent results. One of the test
Ey at all the bearing locations; cases is presented here, for the rotor-system shown in Fig. 4,
(ii) make a transfer across the entire shaft, using Eq. (17), to illustrate the analysis procedure and to provide some insight
to get into the static and dynamic behavior of multibearing rotors.
[EA The rotor system shown in Fig. 4 consists of two lumped
Ey fill By. masses carried by a massless shaft supported by four identical
6 plain journal bearings. The shaft and the bearing stiffnesses are
of the same order of magnitude. The bearings were realistically
<^ 0 dimensioned with regard to mean bearing pressure, minimum
> = Vx (18) oil-film thickness, oil flow, friction loss, and temperature rise.
V"
y. A damped free vibration analysis was carried out using the
Vy
My My IC method, extended for eccentricity calculation, as described
Mx Mx
I 1J N . 0 0 0 0 0 0 0 0 1 1 J
(iii) Substitute the boundary conditions (usually zero forces E
and moments at the ends) to get Y § 001657 m
d 01
Ex E=2.05-l01'N/m-
-X
&x- g--G=CWE-
10
(19)
<P C=7.5«r?n
u=3.92-1(J2Ns/m
(iv) calculate {Ex, Ey, 9, $} 1 from the linear equation system
(19); 0.8 m
(v) use the corresponding full state vector {Ex, Ey, 9, <f), 0,
0, 0, 0}i in a transfer from station no. 1 to bearing no. 1. The Fig. 4 Sample multibearing rotor

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 o location of middle journals for this rotor. The minimum threshold speed occurs as expected
x location of end journals
at a misalignment that unloads either the middle bearings or
the end bearings. The steep drop from maximum to minimum
threshold speed indicates that the bearings must be aligned
within relatively close tolerances to avoid a serious drop in
stability.
Figure 6 also shows that with a vertical misalignment of
( - 0 . 5 ± 0.5) X 10~4 m, the threshold speed would be in the
range 8800 rpm to 8500 rpm, which is close to optimum. By
inspection of Fig. 4 and without access to Fig. 6, it would seem
reasonable to position the bearings for zero misalignment to
make them all carry approximately the same load. If this were
done to within the same tolerance of ±0.5 X 10 4 m (\ of the
bearing clearance), then the threshold speed could be anywhere
(a) (b)
between 8800 rpm and 7500 rpm, i.e., it may be 1000 rpm
lower than could be achieved with access to Fig. 6.
Bearing support flexibilities of 1.2 X 10 ~7 m/N were intro-
duced in the x and y -directions for the misalignment configura-
tion shown in Fig. 5(b). This reduced the operating misalign-
ment from -3.69 X 10" 4 m to -2.45 X 10 " 4 at 6000 rpm so
the middle bearings were no longer completely unloaded. As a
result, the threshold speed increased from 5307 rpm to 6342
rpm. Thus, bearing support flexibility may stabilize a multibear-
ing rotor, whereas in general it is considered destabilizing be-
cause it lowers the first critical speeds and the instability thresh-
old speed is often close to twice the first critical speed. Finally,
according to Fig. 6, superior stability can be achieved by severe
(c) (d)
bearing misalignment but this is generally unacceptable due to
Fig. 5 Steady-state bearing loci the adverse effect on other parameters, such as the minimum
film thickness.

above. The Sommerfeld Number, the attitude angle, and the Conclusions
usual eight bearing stiffness and damping coefficients for the
bearings were determined from graphs given in Woodcock A complex relationship has been shown to exist between
(1971). The bearing loads are generally not vertical for a radial bearing misalignment and stability of a multibearing ro-
multibearing rotor so it becomes necessary to perform a coordi- tor. Neither perfect alignment nor equal load sharing between
nate transformation of the bearing coefficients as outlined for bearings can be relied upon to give optimum stability. Numeri-
example in Nikolajsen (1973). cal analysis is necessary to predict the "misalignments" and
the tolerances on alignment that will ensure an adequate stability
The calculated steady-state journal positions as functions of
margin. Bearing support flexibility can improve the stability of
speed are shown in Fig. 5 for selected misalignments e of the
badly aligned rotors. However, it could reduce the stability of
middle double-bearing relative to the two end bearings. The
a well-aligned rotor by lowering the natural frequency in which
instability threshold speed QT is also indicated. The arrows
the rotor goes unstable. The complex relationship between mis-
indicate the direction of motion of the journal centers for in-
alignment and threshold speed, illustrated here, suggests that
creasing speed. The points on the loci correspond to speeds that
improper alignment could be responsible for some of the unex-
are continually doubled from a low of 500 rpm through 1000
plained cases of turbomachinery instability which occur from
rpm, 2000 rpm, etc. up to 128,000 rpm to get traces of the
time to time. It is recommended that misalignment effects be
entire loci, although in practice fiT sets an upper limit for the
investigated in such cases using one of the methods outlined
speed.
above. These methods are useful for all types of fluid-film bear-
In Fig. 5 ( a ) , the vertical misalignment has been chosen such ings and seals whose dynamic characteristics vary with eccen-
that the total static bearing loads on all four bearings are equal tricity ratio.
at all speeds. In Fig. 5(b), the misalignment is such that the
middle journals are concentric in the bearings at zero speed.
This leads to the unusual situation of increasing eccentricity for
increasing speed (below 1000 rpm). The loci of Figs. 5(c) and
(d) result when horizontal misalignment equal to the bearing
clearance is also added.
Figure 5 shows that both the bearing loci and the instability
threshold speed depend in a complex manner on the magnitude
and direction of misalignment. For example, Figs. 5(c) and
5(d) suggest that, for this rotor, misalignment in the negative
^-direction results in better stability than the same misalignment
in the positive x-direction. However, if the x-misalignments are
increased to ±4.28 X 10~4 m, then the threshold speeds become
10,795 rpm and 10,141 rpm respectively, thus reversing the
trend.
In Fig. 6, the instability threshold speed has been plotted as
a function of vertical misalignment of the middle bearing pair.
Optimum stability occurs at a misalignment of about -0.25 X
10~4 m (vertically down). This corresponds to neither equal
load sharing nor perfect alignment, although it is close to both Fig. 6 Rotor stability chart

Journal of Engineering for Gas Turbines and Power JULY 1998, Vol. 120 / 639

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 For rotors with many bearings and seals, the required para-
metric studies become very time consuming unless they are
automated. This can be done for example by linking the rotor
program with a standard nonlinear optimization program that
considers the threshold speed to be a nonlinear function of the
misalignments and seeks to maximize this function.
Acknowledgments
This work was supported by the Engineering and Physical
Sciences Research Council, UK and by the Turbomachinery
Research Consortium at Texas A&M University. The paper was
prepared at Staffordshire University.
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Transactions of the ASME