crack diagnosis

diagnosis in rotating shafts during acceleration

acceleration
Vibration-based crack
resonance
through resonance
t , Andrew
Jerzy T. Sawicki*l,
Sawicki*1, Xi Wu*,
Wu*, George
George Y.
Y. Baaklini
Baaklinit,
Andrew L.
L. Gyekenyesi
Gyekenyesi **
*Cleveland State University, Dept. of
Mechanical Engineering,
Engineering, Cleveland,
Cleveland, OH
OH 441
44115;
ofMechanical
15;
tNASAGlenn
GlennResearch
ResearchCenter,
Center,2 21000
BrookparkRoad,
Road,MS
MS66-1,
NASA
1 000 Brookpark
1 , Cleveland, OH 44135;
**OAI/NASAGlenn
GlennResearch
ResearchCenter,
Center, 21000
21000 Brookpark
Brookpark Road, MS 6-1, Cleveland, OR
**OAJ/ASA
OH 44135
44135

ABSTRACT
The dynamic
dynamic response
cracked Jeffcott
Jeffcott rotor
rotor passing
passing through
through the
the critical
critical speed
speed with
with constant
constant acceleration
acceleration isis
The
response of a cracked
investigated analytically
investigated
analytically and
and numerically.
numerically. The
The nonlinear
nonlinear equations
equationsof
of motion
motion are
are derived
derived and
and include
include aa simple
simple hinge
hinge
model for small cracks
cracks and Mayes' modified
modified function
function for
deep cracks.
model
for deep
cracks. The
The equations
equations of
of motion
motion are
are integrated
integratedininthe
the
rotating coordinate
rotating
coordinate system.
system. The
The angle
angle between
between the
the crack
crack centerline
centerlineand
andthe
the shaft
shaft vibration
vibration(whirl)
(whirl)vector
vectorisisused
usedtoto
determine the closing and opening of the crack, allowing
allowing one
determine
one to
to study the
the dynamic
dynamic response
response with
with and
and without
withoutthe
therotor
rotor
of possible tools for detecting
detecting the existence of cracks.
cracks. The
dominance. Vibration phase response
response is used as one of
weight dominance.
of parametric studies of
of the effect
effect of
of crack
crack depth, unbalance eccentricity orientation with respect to
results of
to crack,
crack, and
and the
the
rotor acceleration on the
the rotor's response are presented.
presented.
Keywords:
crack, rotor,
rotor, diagnosis,
diagnosis, acceleration,
acceleration, resonance,
resonance, unbalance,
unbalance, nonsynchronous
nonsynchronous response.
Keywords: crack,
response.

1. INTRODUCTION
been an
an increasing
increasing interest
interest for the
the development
development of rotating
rotating machinery
machinery shaft
In recent years, there has been
shaft crack
crack detection
detection
methodologies and
1-9. Shaft
methodologies
and on-line
on-line techniques
techniques'9.
Shaft crack
crack problems
problems present
present aa significant
significant safety
safety and
and loss
loss hazard
hazard in
in nearly
nearly
turbomachinery, particularly
particularly in
only. Recently,
Recently, the
every application of modem turbomachinery,
in the
the power
power generation industry,
industry, but
but not
not only.
the
10
Federal Aviation
Aviation Administration
for additional
additional NDE
NDE
Federal
Administration(FAA),
(FAA),following
followingseveral
severalreports
reportsofof shaft
shaft cracks,
cracks, called
called' for

of certain main rotor

rotor shafts
shafts in
in helicopters.
helicopters. Conventional
Conventional NDE
NDE methods,
methods, however,
however, have
have unacceptable
unacceptable limits.
inspections of
Some
Some of these
these techniques
techniques are
are time-consuming
time-consuming and
and inconvenient
inconvenient for
for turbomachinery
turbomachineryservice
servicetesting.
testing.Almost
Almostall
allofofthese
these
techniques require that the vicinity of the damage is known in advance,
advance, and
and they
they can
can provide
provide only
only local
local information
informationand
and
of the structural strength at a component and/or
no indication of
and/or system
system level.
level. Also,
Also, the
the effectiveness
effectivenessof
ofthese
theseexperimental
experimental
measurement noise levels existing in complex turbomachine structures. Therefore,
techniques
techniques is affected by the high measurement
Therefore, the
the
of vibration monitoring along with vibration analysis have
use of
have recently
recently received
received increasing
increasing attention.
attention.
3
the
An extensive
extensive review of the
the early literature
literature on
on cracked
cracked shafts
shafts was
waspublished
publishedby
byWauer 11 . Dimentberg
Dimentberg3 was apparently the
of the
the rotating
rotating asymmetry
asymmetry on
on the
the shaft
shaft lateral
lateral vibration.
vibration. Henry and
and Okah-Avae4
Okah-Avae4 presented
first to report the effect
effect of
first
presentedthe
the
results
results of analog computer study and reported the
the subcritical
subcritical resonance
resonancedue
duetoto an
an interaction
interactionbetween
betweenthe
thecrack
crackand
andthe
the
weight. Mayes
Mayes and
and Davies5
Davies s studied the
rotor's weight.
the behavior
behavior of a cracked shaft model
model which
which took into
into account
account opening
opening and
and
function. Later,
closing of the crack as a stiffness step function.
Later, they
they extended
extended their
their work
work and
and suggested
suggestedaamethod
methodfor
forcalculation
calculation
change in stiffness
stiffness due
due to
to aadeep
deepcrack6.
crack6 Gasch78
Gasch7-8 modeled
modeled the breathing
breathing crack
crack by aa spring-loaded
spring-loaded hinge,
hinge, and
of change
and
numerically demonstrated a subharmonic resonance. Grabowski9
Grabowski9 used
used modal
modal approach
approach to
to the
the problem
problem and
and demonstrated
demonstrated
numerically strong dependence of the rotor vibrational
vibrational behavior
behavior on
on the
the crack
crackposition.
position.

The previously published research results focused

focused primarily
primarily on
on the
the study
study of
of cracked
cracked shafts
shafts subjected
subjected to
to constant
constantangular
angular
lO
speed.
speed. However,
However, it has
has been well recognized
recognized'
that vibration monitoring
monitoring during
during startup
startup or shutdown can
can reveal
reveal important
important
IJerzy.T.Sawicki@grc.nasa.gov;phone
phone1.216.433.2467;
1.216.433.2467;fax
fax 1.216.977.7150
1.216.977.7150
1Jerzy.T.Sawickigrc.nasa.gov;

NDE and Health Monitoring of Aerospace Materials and Composites II, Andrew L. Gykenyesi,
Peter J. Shull, Editors, Proceedings of SPIE Vol. 5046 (2003) 2003 SPIE 0277-786X/$15.00

machines such as aircraft

aircraft engines,
engines, which are subjected to frequent
frequent starts and stops
machine malfunctions, especially for machines
high speeds
speeds and
and acceleration
acceleration rates.
rates. The topic
topic of
of transient
transient cracked rotor response
response has been treated by only a
as well as high
a1. 13 analyzed
few authors. Plaut et al.13
analyzed the
the transient
transient response
response of
of a simply supported,
supported, rotating,
rotating, Euler-Bernoulli
Euler-Bernoulli shaft
shaft with
with aa
breathing transverse crack, during its passage through a critical speed at constant acceleration
acceleration or
or deceleration.
deceleration. Recently
Recently
investigated the transient
transient vibration
vibration response
response of
of aa cracked
cracked rotor
rotor passing
passing through
through its
its critical
critical speed,
speed, utilizing
utilizing a
Sekhar 14- 15 investigated
Sekhar'4'5
simple hinge
assumption that
hinge model for small cracks. He made an assumption
that the
the vibrations
vibrations remain
remain small
small in
in comparison
comparisontotothe
thesag
sag
of
the
rotor
under
its
own
weight.
If
a
cracked
shaft
rotates
slowly
under
the
load
of
its
own
weight,
then
the
crack
of
If a cracked
under the load its own weight, then the crack will
will
open and close once per revolution. He noted oscillations which are
are developed
developed near
near critical
critical speed.
speed.
shaft. The
paper, the Jeffcott
Jeffcott rotor model
model is analyzed
analyzed and a transverse
transverse crack
assumed at
middle of the
In this paper,
crack is
is assumed
at the
the middle
the shaft.
The

characteristic changes in the accelerating rotor phase response due to the crack and are presented as a possible
possible diagnostic
diagnostic
crack has been
been
for crack
crack detection
detection in the
the accelerated
accelerated rotors.
rotors. The
The criterion
criterion for
the opening
opening and
closing of the crack
tool for
for the
and closing
centerline and
developed based on the angle between the crack centerline
and the
the shaft
shaft vibration
vibration vector
vector which
which makes
makes possible
possibleone
onetoto
ignore
weight-dominance assumption.
ignore the
the rotor weight-dominance
assumption.Stiffness
Stiffnessweakening
weakeningeffects
effectsofofcracked
crackedrotor
rotorininboth
bothstrong
strongand
andweak
weak
axes
axes are
are taken into
into consideration for deep cracks.
cracks.

2. ROTOR AND CRACK MODEL

The theoretical model, called the Jeffcott rotor, employs a flexible rotor composed of a centrally located unbalanced
unbalanced disk
disk
mounted symmetrically on rigid bearings
l(a). The
attached to a massless elastic shaft which is, in turn, mounted
bearings (see
(see Fig.
Fig. 1(a).
The shaft
shaft
across its
does have a transverse crack running across
its section and
and located
located close
close to
to the
the disk.
disk. The
The stiffness
stiffhess of
ofthe
theuncracked
uncrackedrotor
rotor
system is symmetric (isotropic) and the damping due
due to
to the
the air resistance
resistance effect
effect isis assumed
assumed to
tobe
be viscous.
viscous.
1]
77

61

z
(a)
(a)

(b)
(b)

Figure 11:: (a) Model ofJeffcott

of Jeffcottrotor
rotorwith
withcrack,
crack,(b)
(b)shaft
shaftand
andcrack
crackposition
positiondescribed
describedinininertial
inertialand
androtating
rotatingcoordinate
coordinatesystems.
systems.

coordinate frames
frames coincide
coincide with
with each
each other
other and
and are
The
are
The origins
origins of
of the
the inertial
inertial (x,y,z)
(x,y,z)and
andbody-fixed
body-fixedrotating
rotating(S:17,q)
(,
"attached" to
to the
the center
center line
line of the
the bearing
bearing supports.
supports. At
At any
any instant
instantof
oftime,
time,the
the ~-axis
i-axis remains
remains perpendicular
perpendiculartotothe
theface
face
"attached"
frame rotates with the
the same velocity as
as the
the rotor.
rotor. The crack position with respect
respect to
to the
the
of the crack, causing
causing that
that (cc,
(, 1], q) frame
changes continuously
continuouslywith
withthe
therotor's
rotor's speed.
speed. Finally,
Finally, the
the rotor's
rotor's
vibration vector
vectorisis determined
determinedby
byangle
angle If/,
t', which changes
vibration
oriented at
at constant
constant angle
anglef3,6with
withrespect
respecttotothe
thecrack
crackoror~-axis.
i-axis. For
For aa rotor
rotor subjected
subjectedtoto
unbalance eccentricity
eccentricity eC is oriented
unbalance

i)

Proc. of SPIE Vol. 5046

constant
theinitial
initial speed
speed (assumed
(assumed to
w isisthe
to
, where (1)0
w0t++at ,where
constant acceleration
accelerationa,a,the
thespin
spinangle
anglechanges,
changes,i. e.,
i.e., <1>(t)
ct(t) =
=<1>(0)
t(O) + (1)ot
2
be zero)
zero)and
and <1>(0)
t(O) == -p
fi..
The
opening and
The opening
and closing
closing or
or "breathing"
"breathing" of
of the
the crack,
crack, as
as the
the rotor
rotor rotates,
rotates, results
results in
in aa periodic
periodic change
change in
in the
the rotor
rotor
stiffness.
the weight
weight dominance
dominance assumption,
assumption, where
stiffness. In order to not be restricted to the
where the
the dynamic
dynamic displacement
displacement isis smaller
smaller
than
If/ (see
(seeFig.
Fig.1(b))
l(b))isisused
usedto
to judge
judge the
the opening
opening and
and closing of
of the crack.
crack. This
than the
the rotor's sag, the angle yt
This angle
angle more
more
practically describes
of the crack by taking into
describes the
the "breath" of
into consideration
consideration the
the influence
influence of
of the
the whirl
whirl speed
speedon
onthe
theclosing
closing
and opening of
of crack. The rotor stiffness
stiffness in
in the crack
crack and
and cross directions can be written as8:
ass:

(K O"l (K '\

1AK O'

0 KqJ0 KJ( o J

(1)
(1)

For linearly
linearly elastic
may
For
elastic crack
crack and
and rotor
rotor deflections,
deflections,the
thechanges
changesininthe
thestiffness
stiffness1iK~
L\Kand
and1iK
isK
maybe
be assumed
assumedtotobe
be
11
small and
and often assumed to
constant. For
constant.
For all
all but
but very
very large
large cracks,
cracks, the
the stiffness
stiffnesschange
change1iK"
AK isis small
to be zero.
zero. However,
However,in
inthis
this
MC
M<.

study,
for the
the case
case of
ofthe
its effect
effect isis included,assuming
includedassumingthat
that6 AKq
= --~ .. The steering
study, for
the deep crack,
crack, its
1iK11 =
steering function
function !(If/)
f(i') is a
6
-L
periodic function depending on both, the rotor spin and whirl speed,
speed, and
and isis shown
shown on
on Fig.
Fig. 22 for
for small
smalland
anddeep
deepcracks.
cracks.

f(ljI)
f(v')
Open
Open

Closed
Closed
0

90

180

H
270

ljI (degree
(degree)
VI

(a)

(b)
(b)

(a) the
the closing
closing behavior
behavior of(I)
of (I)the
thehinge
hingemodel
modelfor
forsmall
smallcracks
cracksand
and(II)
(II)Mayes'
Mayes'modified
modifiedfunction
functionfor
fordeep
deep
Figure 2: Crack model; (a)
of the crack
crack as
as aa function
function ofthe
of theshaft
shaftposition
positionalong
alongits
itsorbit.
orbit.
cracks, (b) opening and closing ofthe

small cracks,
cracks, the
the rectangular
rectangular function
function for
for the hinge
hinge model8
models is
Fig. 2(a)), which describes
describes the
For small
is used
used (see
(see Fig.
the crack's
crack's
sudden opening and closing,
closing, by
by switching
switching from
from 11 (open)
(open) to
to 00 (closed).
(closed). This
This function
function can be approximated
approximated by the Fourier
sudden
expansion
expansion as follows:
1 2
2
2
--cos3lf/
f()
cos
!(If/)=
=- ++cos
-coslf/
+ -cos
3
+
cos 5lf/5 - ...
2 1rr
3'r
31r
51r
5ir

(2)
(2)

Proc. of SPIE Vol. 5046

In the case of deep cracks, there is a smooth transition

transition between
between the
the opening
opening and
andclosing
closingof
ofthe
thecrack
crackand
andthis
thisisisreflected
reflected
modified function6,
function6 , Le.,
by the Mayes' modified
i.e.,
(If/) = 1+ cos If/
f()l+cos
2

(3)
(3)

3. EQUATIONS OF MOTION
motion for
Jeffcott rotor,
rotor, with
with aa cracked
cracked shaft,
shaft, in aa presence
presence of
of gravity
gravity forces
forces and
and unbalance
unbalance
The equations
equations of motion
The
for a Jeffcott

excitation, and subjected to constant acceleration, can be

be expressed
expressed in
in inertial
inertial coordinate
coordinate frame
frameas
asfollows:
follows:

IM
+1c OIKii
0J{~}+(C
0J{~}+(Kll K12J{Z}={Mg}+M8{~:C~SB+~SinB}
OoM)IjJ O C)$'J LK21 K22)yj
(M

K12

K 21

K 22

() sm()-()cos()
Le2sinGecosGJ

(4)
(4)

and yare
the displacements
displacements of the
t) (where
(where qq =(z
(z )T)
y)T)isisnonlinear,
nonlinear, depending
depending
where zz andy
are the
the disk.
disk. The
The stiffness
stiffhessmatrix
matrixK(q,
K(q,t)
not only on time,
time, but also on the position of the
the shaft center
center along
along the
the orbit.
orbit.

The above equations of motion in the rotating coordinate

coordinate can
can be
be written
written as
as

IM
1K_f(yJ)AK Md
M 0J{~}+( C
C_2Ma')J
-2M(OJ{~}+(K-f(lJI)M(~-M(02
(
wC+Mct
M LJ
'l
2M(0
C ) 'lJ
(OC+Ma
oo M)
(2Ma'
C
I cos 1
I sinfl
Icos/31
=Mg { COS <P } +M8(o 2 {cos fJ}+Mea
+Mea { sin fJ } ;
=Mg
- sin <I>
sin fJ
- cos fJ
sinJ
[sin/3J
cosfl

-aC-Ma
K-f(yi)tK _Mw2)l?7

(5)
(5)

where the transformation between the inertial and rotating

rotating coordinate
coordinate frames
frames takes
takes the
the form:
form:

(z')(cos
_sinct)(
-SincI>J(~J
(yzJ = (c~ScI>
sIn <P cos
<I> 'l
y[(\sin
cos)

(6)
(6)

Incorporating the
the hinge
hinge model
model for
for small
small cracks
cracks into
into Eq.
Eq. (5)
(5) (M(11
(AKq==0),
0), normalizing displacements with respect to static
deflection,
deflection, and using
using nondimensional time
time yields:
yields:

-2.!!!.(On

[1 og"
[o lji7'

2'
8 (02

I cos
cos<I> 1}
{ - sin <I> +
I sin cJJ

--2

'l st (On
8

{~}+
ea.

cosfJ+--2 slnfJ

(02.

'l st (On

e a

- - 2 slnfJ--2

'lSI (On

(02
(0
a
1- f(lJI)M(-(02 -2'---2
(On (On
n
(02
(0
a
1 -(022'-+-2
(On (On
cD2
n

'lSI (On

cosfJ

where here
rectangularsteering
steering function
function (see
(see Fig.
where
here f(lJI)
f(ii) isisaarectangular
Fig. 2(a.
2(a)).

Proc. of SPIE Vol. 5046

l-

{~}=
(7a)
(7a)

AK
M<.
Similarly,
of motion (Eq. (5)) the
the model
model for
= 1-,
--~ ,
for deep
deep crack,
crack,assuming
assumingM<."
AK =
Similarly, one can incorporate into the equations of
6

= 1+ cos(cif)
cos(lf/) (see Fig. 2(a,
and
Meyes 6 modified
and Meyes6
2(a)), and write
write that
that
modifiedsteering
steeringfunction
functionf(lf/)
f(u) =
2

-2~

[1 1f

ijlj

[o

2~

OJ2

--2

cos <I> }
{ -sin <I> +

{~}+

OJn

1]st OJn

l-f()AK-

OJ2

1- f(lJI)M<.-OJ2
co
n
OJ

OJn

OJn

2~-+-2
2--+--ai
w2
n

-2- a
OJ

-2~---2
OJn
O),

f(lJI)M<.
1- f(w)AK
6

OJ
(0,,n

OJ2

{~}=-

OJ2
w2
nn

(7b)
(7b)

ea.

cosfJ+--2 slnfJ
1]st OJn

e a

OJ2.

- - 2smfJ---2 cosfJ
1]st OJn

1]st OJn

the above
above equations
equations the
the following
following definitions
definitions and nondimensional
nondimensional variables
employed (see Nomenclature
Nomenclature
variables were
were employed
In the
section):
section):

K
aa
M(~
22 =
= C , 7y=
co
= AK
= i, (;=
(j)n = M
M', AK
I1K=T'
2M(j)n'
OJ2
K
2Mco
co,n

Mg g -_
- t, --', , 1 , i---a)
=K=-2'
___i,
K w
ii
i!
g

Mg

1]st
list

~ =-,

OJn

1]

1]

=-,

1]st

Ti.

1]st

(On

= OJo +at = at, forw0=O

for OJo = 0
co=co0+at=at,
2
at
yr 2
at2
yi.2

OJ

<I> = <1>0 + OJot + =- , for

<1>0 = 0
for0=O
l0+co0t+,
2
2

_g _g2'_g' '
7

cO

co

gfj'

1]=-

OJn
cO

=gff, ij=gir
where

"
1 d()
1 d2()
0', -= d(.)
dO =_1
dO, 0" = d2(.)
d (.)

,() d 0 =_1
0
2

di.
dr

() =cf> + /3;
9=cl+fi;

OJn dt
O)dt

di.
dr 22

2
2
OJ; dt
O)dt
2

If/ = cf> - arctan ( ~) (see Fig. 1(b.

=_arctan2) (seeFig. 1(b)).

4. RESULTS AND DISCUSSION

The
The presence
presence of a crack
crack on
on the
the shaft
shaft results
results in
in the
the stiffhess
stiffness variation
variation as aa function
function of
of time.
time. In
In most
most rotor
rotor dynamic
dynamic
analysis, the system response is obtained in the form of steady state amplitude
amplitude data at each operational
operational speed.
speed. In
In the
the case
case
analysis, the dynamic response
response can be obtained using
of transient analysis,
using time
time marching
marching techniques.
techniques. In
In this
this study
study Runge-Kutta
Runge-Kutta
(7b)). The
nonlinear responses
was employed
employed to numerically solve
solve equations
method was
equations of motion
motion (Eq.
(Eq. (7a)
(7a) and (7b)).
The nonlinear
responses of
of rotor
rotor
passing through
ratios
(y(= -)
a2 ) and different
passing
through the
the critical
critical speed
speed with
with several
severalvalues
valuesofofconstant
constantangular
angularacceleration
acceleration
ratios
OJn
(On

Proc. of SPIE Vol. 5046

crack depths
depths (( AK
IV<. )) were
were evaluated.
evaluated. For
ratio
~ =0.05 and normalized unbalance
For all
all cases
casesititwas
wasassumed
assumedthat
thatdamping
damping
ratio
crack
. . IS
. -8 =
005 .
0.05.
eccentrIcIty
eccentricity
is -f-- =.

1'Jst
list

The change
change in the rotor phase response due to the acceleration
acceleration and
and crack
crack isis presented
presented in
in Fig.
Fig. 4.
4. In
In general,
general, due
due to
to the
the
crack the amplitude
amplitude of the phase angle decreases
decreases for
crack
for the
the given
given speed
speed ratio
ratio and
and acceleration
accelerationrate.
rate.In
Inaddition,
addition,ititcan
canbe
be
seen that
that the
the crack
crack induces
induces significant
significant oscillations
oscillations in the rotor
rotor phase
phase response
response (see Fig. (4b)),
(4b)), especially
especially for
for higher
higher
seen
acceleration rates.
characteristic "saw-cut" pattern of
of the phase waveform can find potential
potential application
application in the
acceleration
rates. Such a characteristic
crack on-line detection monitoring systems.
350
300

I /

~ 1~

y = 0.8x10-3

200:

!Y

~loo
50

IV

~ 2~

I/

,..

y= 10"

!~

250

y = 10"

t t!

I~~ I y=0.8xl~

y=0.01

III"

I !
i

100

0.3

0.35

0.4

r---"'/

I )

50

0.15
0.2
0.25
SPEEDRA11O
RAllO
SPEED

300

/'~

O~~
o
0.05
0.1

350

y= 0.01

.....

crack depth 0.4

_.
0.05

0.1

(a) no crack

0.15
0.2
0.25
SPEED RAllO

0.3

0.35

0.4

(b) M(= 0.4

(b)MC=
3

theaccelerated
accelerated rotor
rotor passing
passing through
through the
the critical
critical speed for y=O.O1,
y=O.OI, 0.8xl0, and
O.
ofthe
O.8x103,
and10iO,, and {3=
,8= 0.
Figure 4: Phase angle of

8
I .4

0 1.2

.2 4
0

N
C
a,

E -2

0.8

II

rml lJ1

i?f4

1ii

-4
0.6

-6
-8L..----------L-----....l..----I......--.L..---------L_-----..L-._....J.......-_..i.---------.L_--l.---------..J

0.2
0.2

0.4
0.4

0.6
0.8
0.8
)
Speed Ratio
Ratio (ro!ro
n
(wfo))

(a) no crack

1.2
1.2

0.1
0.1

0.2

0.3

0.4
0.4

0.6 0.7
0.5
0.8
0.6
0.8
)
Speed Ratio
Ratio (ro!ro
(o)/co)
n

0.9
0.9

1.1
1.1

(b)
M(= 0.32
(b)AK=

Figure 5: Vibration amplitude

the accelerated
accelerated rotor
amplitude in
in Z-direction
Z-direction of
ofthe
rotor passing
passingthrough
throughthe
thecritical
criticalspeed
speedfor
fory=
y=0.8xl00.8xl033 and
and{3=
fi= O.
0.

Proc. of SPIE Vol. 5046

1.6r---------.-~--.----------,------------.----------,-----,-----------,

8
I .4

:7

0,1.2

< 1

24

.2

:o.8

>3

0.6

0.4

0.4

0.2

0.6
0.8
Speed Ratio (o)I(o)
(o:,/())n)

:a0.1

'---------'----'-------'---~"'_________'_~______'____~___L....____'_______"___________'_......._C_______'_________...l

1.2

0.2
0.2

0.3

0.4
0.4 0.5
0.5

0.6

0.7

0.8
0.8

0.9

1.1

(ro/IDn)
Speed Ratio (&o))

(a) no crack

(b) t:J( =0.32

0.32
(b)K=

Figure 6: Vibration amplitude ofthe

of theaccelerated
accelerated rotor
rotor passing
passing through
through the
the critical
critical speed for y=
y= 0.8x103,
0.8x 10-3 , fi=
{3 = 0 and
and t:J(
K == 0.32.

Z-direction and
and the
the overall
overall amplitude,
amplitude, respectively,
respectively,for
forthe
the
show nondimensional vibration amplitude
amplitude in Z-direction
Figures 5 and 6 show
ofAK
t:J( =
= 0.32.
0.32. It is apparent that the shaft crack reduces the stiffness of
of the system, shifting the resonance to
depth of
crack depth
to a
lower speed.
speed. It can
can be
be noticed
noticed the
the presence
presence of
ofsub-critical
sub-critical (1/3,
(1/3, 1/2)
1/2) response
response peaks
peaks and large increase
increase of vibration
vibration
lower
response at the fundamental resonance peak when the crack exists.
exists.
3,....--------,....----------.------,....--------,-----,-----.------,-----,....-------~

VJl.fJ~\OJWv~~~"lI'IV(NjlIllwll'M',JmJII,'I!I~IWi~\11

1 [-;,)...A.AJ\.J.,J\',A\1:4:i~,~,MtM~~fiWi[~i~wt~~Wr1rM~ylf)'yorN\1WN~-WIWt~J:j~(f{j~

a
c:::

g
.2

crack depth ==0.O.1155

-1I L....-----.-.-------.-J'---------------l_ _'--------------lL....-----.-.-_l..-_l..-_'------_l..-------.-JL....-----.-.----l

0.7
0.2
0.4
0.5
0.6
0.8
0.9
1.1
0.3
1.2

.;~05
a
I. :
. 0.2

wwiim

:0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2
-e
crack depth = 0.28
:~6..---,......--------r-------.------r--.----------.------------,----------.--------,--.-------,
~
O'------'---------"--------'--------'----"---------'-----L-.-------'-'-'~~----l.-_____l

:0

~4

...,

.5

52

(l)

"'0

1
c.. -5 '----'-------'--'-----'-----"'--------"'--------'-----'-------'--------'

0.3
0.4
0.5
0.6
0.8
0.9
0.7
0.8
1
1.1
1.2
~ 0.2
40 ,....---.--------,----,....---.-----.-----,....--------,-----,....-------........--.-,
20

0a

.."-.-

I> 0.2
:
~

:90'----------'-.------.-----'----.-.---L..--------'----'--.-----.-.----'----------"'------'----~----'----'-'------------'--_________I

0.2
0.3
0.4 0.5 0.6 0.7 0.8 0.9
1
1.1
1.2
40,....--~--.---------,----. . . . . . . .---r~--.----~---,--------,--~------.-~-------.,.--------,
4C
crack depth
depth =
= 0.37
0.37

I1

20

-20
r

0.2
0.2

0.3

0.4

0.5
0.5

0.6

0.7

0.8
SpeedRatio
Ratio(cWo))
(co!w n)
Speed

(a)
(a)

0.9

1.1

1.2

o """""""'--"'--"'-"\
0.2

..

~~ ""~

0.3

""~{'M'I~

0.4

~\~~

0.5

~...'f'\f ...................

0.6
0.7
0.6
0.8
Ratio(co/con)
(WIDn >
Speed
Speed Ratio

0.9

1.1

1.2

(b)
(b)

of accelerated
accelerated rotor
rotor passing
passing through
through the
the critical
critical speed
speed with
with crack
crack and
and gravity
gravity for
for y=
y=0.8x103,
O.8x 10-3 ,,8=
{3= 0 and MC
t:J( =
Figure 7: Response of
=
and 0.37;
0.37; (a)
(a) vibration
vibration amplitude
amplitude in
in Z-direction, (b) vibration amplitude.
0.15, 0.28, and

in Z-direction
Z-directionand
andthe
theoverall
overallvibration
vibrationamplitude
amplitudetransient
transientresponses
responses
differentcrack
crackdepths
depths and
and
The
The vibration
vibration amplitude in
forfordifferent
can be
be noticed
noticed (see
(see Fig.
Fig. 7(b))
7(b that
that the
thewhirl
whirlvector
vectordevelops
develops significant
significant
constant acceleration
constant
accelerationrate
rateare
are illustrated
illustratedinin Fig.
Fig. 7.
7. It can
of critical
critical speed
speed becomes
becomes wider
wider and
and the
the vibrations
vibrations level
level increases
increases with
with
oscillations near the fundamental resonance speed. The zone of
oscillations
of the crack. As a result, for
for the
the deeply
deeply cracked
cracked rotors there
there is
is no exact
exact critical
critical speed.
speed.
the depth of

Proc. of SPIE Vol. 5046

Presentation
coordinates also
Presentation of
of the
the rotor transient response in rotating coordinates
also provides
provides useful
useful information.
information. Thus,
Thus, Fig.
Fig. 99 shows
shows
theaccelerated
acceleratedrotor
rotor passing
passing through
through the critical speed for
vibration
vibration amplitude
amplitudein
in ~-direction
-dfrection ofofthe
for crack depths
depths IV(
EsK=0.32
0.32
and 0.36.
0.36. In the
the absence
absence of the crack the
the resonant
resonant vibration
vibration amplitude
amplitudealmost
almostdoes
doesnot
notshow-up.
show-up.However,
However,ififthere
thereisisa a
and
crack then the fundamental
fundamental resonance is apparent and additionally
additionally the
the second
second and
and third
third harmonics
harmonics are
arepresent,
present,which
whichisisaa
crack-characteristic
crack-characteristicphenomenon.
phenomenon.It Itcan
canbebeseen
seenthat
thateven
evensmall
smallchange
changeininthe
thecrack
crackdepth
depthcauses
causesthat
thatthe
therise
riseof
of
amplitude.
amplitude.
12
12

12
12

12

10
10

10

10

-2

-2

0.2
0.2

0.4
0.4

0.6

0.8
1
Speed Ratio (o!o)

1.2

1.6

1.4

0.2

0.4

0.6

0.8

1.2

1.4

1.6

0.2

0.4
0.4

Speed
Ratio (ooIoo
)
SpeedRatio
(oho,)
n

0.8
0.8

1.2

1.4

1.6

Speed
Ratio (ooIoo
)
Speed Ratio
(o/o,)
n

(C)
(c)

(b)
(b)

(a)
(a)

0.6
0.6

Figure 9:
Vibration amplitude
amplitude in f-direction
,-directionofthe
of theaccelerated
acceleratedrotor
rotorpassing
passingthrough
through the
the critical
critical speed
speed for y=
y= O.8x103
0.8xlO-3 and fl=
fJ= 0;
0; (a)
9: Vibration
(a)
= 0.32,
0.36.
no crack,
crack,(b)
(b)IV(
iK=
0.32,(c)
(c)IV(
K== 0.36.

The
effect of
of unbalance
unbalance eccentricity
eccentricity orientation
Fig. 10.
10.
The effect
orientationon
on vibration
vibrationamplitude
amplitudeofofaa cracked
crackedrotor
rotor isis shown
shown in
in Fig.
Orientation of unbalance
unbalance affects
affects the
the amplitude
amplitude of the
the fundamental
fundamental resonance,
resonance,but
butdoes
doeshave
haveaalittle
littleinfluence
influenceon
onthe
thesub
subharmonics. The maximum resonant vibration amplitude
amplitude exists
harmonics.
exists when the
the eccentricity
eccentricity vector
vector is
is along
along the
the crack centerline
centerline
p=
unbalance is on the
the opposite
opposite side
sideof
ofthe
crack (P
( fi = 180
= 0).
the crack
the crack
crack is significantly
significantly
0 ). When the unbalance
ofthe
180 ), then the effect of
((f3
the corresponding
diminished. In this
this situation,
situation, the
the resonance
resonance amplitude
amplitude isis only
onlyabout
about1/6
1/6of
ofthe
correspondingamplitude
amplitudefor
forthe
thecase
casewhen
when
f3 =0.
/3=0.
0

),

0.2
0.2

0.4
0.4

0.6
0.6

0.8
0.8

1.2
1.2

20r-----.....-.-,-------------r--------,--------.-----------.---.--,
g~ 2C
90
:E
13
0.
c.
EE
<
c: 10
10
0
.Q

5~ O'-------.-.-...-.l-_ _
-oc
>
0.2
0.4
0.2
0.4
\ ----.

-----L...~=

_._.__l.__~~=.!.:..!..:..:.._

___'_~~_

____l

0.8
1.2
0.8
1
1.2
4r---------r----------r--------,-------.-------------....-----.
0.6

=18O

0.2

0.4

0.6

0.8

Speed Ratio
Ratio (o)I(o)
(rolron)
Speed

Figure 10:
10: The
The effect
effect of
ofeccentricity
eccentricityorientation
orientationon
onvibration
vibrationamplitude
amplitude of
ofaacracked
cracked rotor
rotorfor
for j3
fJ =
and 180
Figure
=0,
0, 90
90 and
l80,,
Me == 0.35
0.35 ,, and
and =y=0.8xl03.
0.8xI0-3

Proc. of SPIE Vol. 5046

5. CONCLUSIONS
presence of a crack
crack in
in the
the shaft
shaftof
ofthe
therotor
rotorsystem
systemaffects
affects the
the dynamic
dynamic response
response significantly.
significantly. The
The presence
The changes
changes of
of
to predict
predict and/or
and/or detect the crack in the shaft. The following conclusions
conclusions can be drawn
vibrational behavior can be used to
drawn
based on the results presented in this
this paper:
paper:
The developed model enables to study the cracked rotor dynamic response
response with and without weight dominance.
dominance. The
The
cracks, as well as cross stiffness effect
model includes small and deep cracks,
effect (for
(for deep
deep cracks).
cracks).
Characteristics "saw-cut" pattern in the phase response waveform
2. Characteristics
waveform can
can fmd
fmd potential
potential application
application in
in the
the on-line
on-linecrack
crack
detection
monitoring
systems.
detection monitoring systems.
Thecrack
crackreduces
reducesstiffness
stiffnessofofthe
thesystem,
system,shifting
shiftingthe
theresonance
resonance to
to lower
lower speeds.
speeds. This
This effect
effect is
is magnified
magnified by the
3. The
the
depth
crack. ItIt can
can be
benoticed
noticedthe
thepresence
presence of
ofsubcritical
subcritical (1/3,
(1/3, '/z)
~) response
response peaks
peaks and large
large increase
increase of
depth of the crack.
of
fundamental vibration response when the crack exists.
exists.
Forthe
theaccelerating
acceleratingrotor
rotorthe
thezone
zoneofofcritical
criticalspeed
speedbecomes
becomes wider
wider and
and the vibration
vibration level
4. For
level increases
increaseswith
withthe
thedepth
depth
of the crack.
crack. The
The whirl
whirl vector
vector develops
develops oscillation
oscillation near the
ofthe
the critical
critical speed.
speed.
Theorientation
orientationofofunbalance
unbalanceeccentricity
eccentricitywith
withrespect
respect to
tothe
thecrack
crackcenterline
centerline affects
affects fundamental
fundamental resonance
5. The
resonance and
and
does have much less effect on subharmonics.
1.
I.

NOMENCLATURE
C
c

gg

K
K
K;
K
K
K"

M
M
b

external damping coefficient

gravitational acceleration
acceleration
uncracked shaft stiffness
stiffness
crackedshaft
shaftstiffness
stiffnessinin~-direction
-direction
cracked
cracked
cracked shaft
shaftstiffness
stiffnessinin1]i-direction
the disk
mass of
ofthe
of bearing centers
centers line
position ofbearing
position

AK
11K

shaft center
inertial coordinate
coordinate system;
system; Z =
= z/ii5
z/1]st , Y =y / 1]st
constant angular acceleration
acceleration
angle between
angle
between 4~ and unbalance
acceleration ratio;
=
(1);
acceleration
ratio; rr =
=
K )
stiffness change ratio ( = 11K;
LK /1K)

11K;
AK

variation of
-directioncaused
caused by crack
variation
of stiffness
stiffhessinin~-direction
crack

Os
Os
z,Y,Z,Y
z,
y , Z, Y

a
a
/3
f3

Ir
AK,1
11K"

c6

=v/

a/

variation of stiffness in r,1] -direction caused

caused by
by crack
crack
unbalance eccentricity of the
the disk
disk
external damping ratio
static deflection
deflection of
of uncracked
uncrackedrotor;
rotor;1]st
i5 =
= g / (1);

g/a

w
co

of unbalance
unbalance eccentricity
eccentricity with
with respect
respect to
to and
and z-axis
orientation of
whirling angle
angle corresponding
corresponding to
to whirling
whirling speed
whirling
speed
rotating
coordinate
system;
~
is
in
the
crack
direction
direction
rotating coordinate system;
~
and
the
line
connecting
bearing
and shaft center
angle
between
and
the
line
connecting
bearing
and
center
angle
anglebetween
between~ and
angle
and zz axes
of
angular
velocity
of
rotation
angular
critical speed of uncracked
uncracked rotor
rotor

Proc. of SPIE Vol. 5046

REFERENCES
1.
1.

Bently Nevada,
Nevada, "Early
Detection
on Rotating
Machinery
UsingUsing
Vibration
Monitoring
and Diagnostics,"
"EarlyShaft
ShaftCrack
Crack
Detection
on Rotating
Machinery
Vibration
Monitoring
and Diagnostics,"
Technical Bulletin
No. 1, 1986.
1986.
Bulletin No.
No. L1036-OO,
L1036-00, No.1,
2. I.I. Imam,
Imam, et al.,
aI., "Development
"Development of an
an On-Line
On-Line Crack
Crack Detection
Detection and
Monitoring System,"
and Monitoring
System,"ASME
ASMEJournal
Journalofof
Vibration,
Vibration, Acoustics,
Acoustics, Stress,
Stress, and
and Reliability
Reliability in
in Design,
Design, 111,
111, pp.
pp. 241-250,
241-250, 1989.
1989.
3.
F.M.Dimentberg,
Dimentberg,"Flexural
"FlexuralVibration
VibrationofRotating
ofRotatingShafts,"
Shafts," Butterworth,
Butterworth, London,
3. F.M.
London, 1961.
1961.
4.
T.A.Henry
Henryand
andB.E.
B.E.Okah-Avae,
Okah-Avae,"Vibrations
"VibrationsininCracked
CrackedShafts,"
Shafts," Paper
Paper C162/76,
C162/76, Proc. ofl.Mech.E.
ofI.Mech.E. Conference
Conference on
4. T.A.
on
Vibrations
in
Rotating
Machinery,
pp.
15-19,
1976.
Vibrations in Rotating Machinery,
5. I.W.
LW.Mayes
Mayesand
andW.G.R.
W.G.R.Davies,
Davies,"The
"TheVibrational
VibrationalBehaviour
Behaviourof
ofaaRotating
Rotating Shaft
Shaft System
System Containing
Containing a Transverse
Transverse
Crack," Paper C168/76, Proc. ofl.Mech.E.
ofI.Mech.E. Conference
Conference on
on Vibrations
Vibrations in
in Rotating
Rotating Machinery, pp. 53-64, 1976.
6. I.W.
LW.Mayes
Mayesand
andW.G.R.
W.G.R.Davies,
Davies,"Analysis
"Analysis ofofthe
theResponse
Responseofofa aMulti-Rotor-bearing
Multi-Rotor-bearing System
System Containing
Containing aa
6.
Transverse
ASME Journal
Journal of
ofVibration,
Vibration, Acoustics,
Acoustics, Stress,
Reliability in
Transverse Crack
Crack in a Rotor," ASME
Stress, and Reliability
in Design,
Design, 106,
106, pp
pp
139-145, 1984.
Gasch,"Dynamic
"DynamicBehavior
Behaviorofofa aSimple
SimpleRotor
Rotorwith
witha aCross-sectional
Cross-sectionalCrack",
Crack", Paper
Paper C178/76,
C178/76, Proc
Proc of
ofI.Mech.E.
7. R.R.Gasch,
I.Mech.E.
Conference on Vibrations in Rotating Machinery, pp. 123-128, 1976.
Gasch,"A
"ASurvey
Surveyofofthe
theDynamic
DynamicBehavior
BehaviorofofaaSimple
SimpleRotating
Rotating Shaft
Shaft with
with aa Transverse
Transverse Crack,"
Crack," Journal
8. R.R.Gasch,
Journal of
Sound and Vibration,
Vibration, 160(2), pp. 313-332,
313-332,1993.
1993.
9. B.B.Grabowski,
Crack," ASME
ASME Journal
Journal of
of
Grabowski,"The
"TheVibrational
VibrationalBehavior
Behaviorof
ofaaTurbine
Turbine Rotor
Rotor Containing
Containing a Transverse
Transverse Crack,"
Mechanical Design, Vol.
Vol. 102,
102, pp. 140-146,
140-146,1980.
MechanicalDesign,
1980.
10. Sawicki,
Sawicki, J.T.,
J.T., "Some
"Some Advances
Advances in Diagnostics
Diagnostics of Rotating
Rotating Machinery
Machinery Malfunctions,"
10.
Malfunctions,"Invited
InvitedPaper,
Paper,Proc.
Proc.of
of
Symposium on
Society of Mechanical
Mechanical
International Symposium
on Machine
Machine Condition
Condition Monitoring
Monitoringand
and Diagnosis,
Diagnosis, The
The Japan
Japan Society
Engineers, pp. 138-144,
138-144, 2002.
111.
1 . Federal Aviation Administration, "Rules Docket No.
2,2001.
No. 2001-SW-01-AD,"
200l-SW-01-AD," Federal Register, March 2,
2001.
Wauer, "On
"Onthe
the Dynamics
Dynamicsof
ofCracked
CrackedRotors:
Rotors: AALiterature
Literature Survey,"
Survey," Applied
Applied Mechanics Review,
12. J.J. Wauer,
Review, 43(1),
43(1),pp.
pp. 13-17,
13-17,
1990.
13. R.H.
R.H. Plaut,
Plaut, R.H.
R.H. Andruet,
Andruet, and
and S.
S. Suherman,
Suherman, "Behavior
"Behavior of a Cracked
Cracked Rotating
13.
Rotating Shaft
Shaft During
During Passage
PassageThrough
Throughaa
ofSound
and Vibration,
Vibration, 173(5), pp. 577-589,
577-589, 1994.
1994.
Critical Speed," Journal
Journal of
Sound and
14. A.S.
Cracked Rotor
Rotor Passing
Passing Through
ThroughCritical
CriticalSpeed,"
Speed,"Journal
Journalof
of
14.
A.S. Sekhar
Sekhar and B.S. Prabhu,
Prabhu, "Transient
"Transient Analysis
Analysis of Cracked
Sound and
and Vibration,
Vibration, 173(3),
173(3), pp.
pp. 415-42
415-421,1994.
Sound
1, 1994.
15.
A.S. Sekhar
Sekhar and
and B.S.
B.S. Prabhu,
Prabhu, "Condition
"Condition Monitoring
Monitoring of
ofCracked
Cracked Rotors Through Transient Response,"
15. A.S.
Response," Mechanism
Mechanism
and Machine Theoiy,
Theory, 33(8), pp. 1167-1175,
1167-1175, 1998.
and

10

Proc. of SPIE Vol. 5046