Coupled horizontal and vertical bending vibrations of a stationary shaft with two cracks

This paper investigates the coupled bending vibrations of a stationary shaft with two cracks. It is known from the literature that, when a crack exists in a shaft, the bending, torsional, and longitudinal vibrations are coupled. This study focuses on the horizontal and vertical planes of a cracked shaft, whose bending vibrations are caused by a vertical excitation, in the clamped end of the model. When the crack orientations are not symmetrical to the vertical plane, a response in the horizontal plane is observed due to the presence of the cracks. The crack orientation is defined by the rotational angle of the crack, a parameter which affects the horizontal response. When more cracks appear in a shaft, then the coupling becomes stronger or weaker depending on the relative crack orientations. It is shown that a double peak appears in the vibration spectrum of a cracked or multi-cracked shaft.Modeling the crack in the traditional manner, as a spring, yields analytical results for the horizontal response as a function of the rotational angle and the depths of the two cracks. A 2×2 compliance matrix, containing two non-diagonal terms (those responsible for the coupling) serves to model the crack. Using the Euler–Bernoulli beam theory, the equations for the natural frequencies and the coupled response of the shaft are defined. The experimental coupled response and eigenfrequency measurements for the corresponding planes are presented. The double peak was also experimentally observed.     

Coupled longitudinal and bending vibrations of a rotating shaft with an open crack

The coupling of longitudinal and bending vibrations of a rotating shaft, due to an open transverse surface crack is investigated. The assumption of the open crack leads to a system with behaviour similar to that of a rotor with dissimilar moments of inertia along two perpendicular directions. The local flexibility due to the presence of the crack can be represented by way of a 6×6 matrix for six degrees of freedom in a short shaft element which includes the crack. This matrix has off-diagonal terms which cause coupling along the directions which are indicated by these terms. Here shear is not considered and three degrees of freedom are used: bending in the two main directions and extension. This leads to a 3×3 stiffness matrix with coupling terms. The undamped free and forced coupled vibration are first considered. The coupling is investigated and the effects of unbalance and gravity are examined. Then damped coupled vibration is considered for free and forced vibration. The existence of coupling between longitudinal and bending vibration due to the crack is a very useful property which, together with the sub-critical resonance due to crack, can form a basis for crack identification in rotating shafts. New and interesting phenomena of coupled transverse and longitudinal motion are presented and discussed.     

FUNDAMENTAL FREQUENCY OF CRACKED BEAMS IN BENDING VIBRATIONS: AN ANALYTICAL APPROACH

This paper presents an analytical approach to the fundamental frequency of cracked Euler-Bernoulli beams in bending vibrations. The flexibility influence function method used to solve the problem leads to an eigenvalue problem formulated in integral form. The influence of the crack was represented by an elastic rotational spring connecting the two segments of the beam at the cracked section. In solving the problem, closed-form expressions for the approximated values of the fundamental frequency of cracked Euler-Bernoulli beams in bending vibrations are reached. The results obtained agree with those numerically obtained by the finite element method.     

Variation in the stability of a rotating blade disk with a local crack defect

The effect of a near root local blade crack on the stability of a grouped blade disk is investigated in this paper. A bladed disk comprised of periodically shrouded blades is used to simulate the coupled periodic structure. The blade crack is modeled using the local flexibility with coupling terms. The mode localization phenomenon introduced by the blade crack on the longitudinal and bending vibrations in the rotating blades has also been considered. Using the Galerkin's method, the imperturbation equations of a bladed disk in which one of the blades is cracked, subject to fluctuations in the rotation speed, can be derived. Employing the multiple scales method, the boundaries of the instability zones in the mistuned turbo blade system are approximated. Numerical results indicate that an additional unstable zone is introduced near the localization frequency and the regions of unstable zones are varied with the crack size and fluctuations in disk speed.     

Rigid finite element model of a cracked rotor

The article introduces a new mathematical model for the cracked rotating shaft. The model is based on the rigid finite element (RFE) method, which has previously been successfully applied for the dynamic analysis of many complicated, mechanical structures. In this article, the RFE method is extended and adopted for the modeling of rotating machines. An original concept of crack modeling utilizing the RFE method is developed. The crack is presented as a set of spring–damping elements of variable stiffness connecting two sections of the shaft. An alternative approach for approximating the breathing mechanism of the crack is introduced. The approach is simple and allows one to intuitively and systematically prepare and analyze the model of a cracked rotor.The proposed method is illustrated with numerical and experimental results. The experiments conducted for the uncracked free–free rotor as well as the numerical results obtained with other software confirm the accuracy of the RFE model. The numerical analysis conducted for a set of cracked rotors has shown that, depending on the eccentricity and its angular location, the breathing behavior of the crack may take different forms. In spite of this, the frequency spectra for different cracks are almost identical.Due to its simplicity and numerous advantages, the proposed approach may be useful for rotor crack detection, especially if methods utilizing the mathematical model of the rotor are applied.     

Mode shapes analysis of a cracked beam and its application for crack detection

In this paper, mode shapes of a cracked beam with a rectangular cross section beam are analysed using finite element method. The 3D beam element is applied for this finite element analysis. The influence of the coupling mechanism between horizontal bending and vertical bending vibrations due to the crack on the mode shapes is investigated. Due to the coupling mechanism the mode shapes of a beam change from plane curves to space curves. Thus, the existence of the crack can be detected based on the mode shapes: when the mode shapes are space curves there is a crack in the beam. Also, when there is a crack, the mode shapes have distortions or sharp changes at the crack position. Thus, the position of the crack can be determined as a position at which the mode shapes exhibit such distortions or sharp changes. While in previous studies using 2D beam element, distortions in the mode shapes caused by a small crack could not be detected, these distortions in the case using the 3D beam element can be amplified and inspected clearly by using the projections of the mode shapes on appropriate planes. The quantitative analysis is also implemented to relate the size and position of the crack with the observed coupled modes. These results can be applied for crack detection of a beam. In this paper, the stiffness matrix of a cracked element obtained from fracture mechanics is presented and numerical simulations of three case studies are provided.     

Vibration of cracked shafts in bending

Cracked rotating shafts exhibit a certain particular dynamic response due to the local flexibility of the cracked section. In this response, most of the features of the response of a shaft with dissimilar moments of inertia can be identified. Moreover, the non-linear behavior of the closing crack introduces the characteristics of non-linear systems. For many practical applications, the system can be considered bi-linear and analytical methods can be applied. A de Laval rotor with an open crack is investigated by way of application of the theory of shafts with dissimilar moments of inertia. Furthermore, analytical solutions are obtained for the closing crack under the assumption of large static deflections, a situation common in turbomachinery. Finally, a solution is developed for the case in which the local flexibility function is found experimentally.     

Experimental investigations of the response of a cracked rotor to periodic axial excitation

In this paper, the coupling of lateral and longitudinal vibrations due to the presence of transverse surface crack in a rotor is explored. A crack in a rotor is known to introduce coupling between lateral and longitudinal vibrations. Steady state unbalance response of a cracked rotor with a single centrally situated crack subjected to periodic axial impulses is investigated experimentally. The cracked rotor is excited axially using an electrodynamic exciter at a frequency equal to its bending natural frequency in both non-rotating and rotating conditions. The resulting time domain and frequency domain signals of the cracked rotor are studied. Spectral response of the cracked rotor with and without axial excitation is found to be distinctively different. When excited axially, it shows prominent presence of rotor bending natural frequency. However for an uncracked rotor, the response is similar with or without axial excitation. It is thus proposed that the response of the rotor to axial impulse excitation could be used for more reliable diagnosis of rotor cracks.     

The vibration signature of chordal cracks in a rotor system including uncertainties

The aim of this paper is to investigate the effects of the presence of a transverse crack in a rotating shaft under uncertain physical parameters in order to obtain some indications that might be useful in detecting the presence of a crack in rotating system. The random dynamic response of the cracked rotor is evaluated by expanding the changing stiffness of the crack (i.e. the breathing mechanism) as a random truncated Fourier series. To avoid the use of the Monte Carlo simulations (MCS), an alternative procedure that is based on a combination of the Harmonic Balance Method and the Stochastic Finite Element Method (SFEM) using the Polynomial Chaos Expansion (PCE) is proposed. So the response of the Fourier components of the cracked rotor is expanded in the polynomial chaoses. The random dynamic response obtained by applying this procedure is compared with that evaluated through numerical integration based on the Harmonic Balance Method and the Monte Carlo simulations.     

Crack effects on the in-plane static and dynamic stabilities of a curved beam with an edge crack

The effects of a single-edge crack and its locations on the buckling loads, natural frequencies and dynamic stability of circular curved beams are investigated numerically using the finite element method, based on energy approach. This study consists of three stages, namely static stability (buckling) analysis, vibration analysis and dynamic stability analysis. The governing matrix equations are derived from the standard and cracked curved beam elements combined with the local flexibility concept. Approximation for the displacements using coupled interpolations based on the constant-strain, linear-curvature element (SC) has yielded results with reasonable accuracy. The numerical results obtained from the present finite element model are found to be in good agreement with those, both experimental and analytic, of other researchers in the existing literature. Results show that the reductions in buckling load and natural frequency depend not only on the crack depth and crack position, but also on the related mode shape. Analyses also show that the crack effect on the dynamic stability of the considered curved beam is quite limited.     

CRACK IDENTIFICATION IN VIBRATING BEAMS USING THE ENERGY METHOD

An energy-based numerical model is developed to investigate the influence of cracks on structural dynamic characteristics during the vibration of a beam with open crack(s). Upon the determination of strain energy in the cracked beam, the equivalent bending stiffness over the beam length is computed. The cracked beam is then taken as a continuous system with varying moment of intertia, and equations of transverse vibration are obtained for a rectangular beam containing one or two cracks. Galerkin's method is applied to solve for the frequencies and vibration modes. To identify the crack, the frequency contours with respect to crack depth and location are defined and plotted. The intersection of contours from different modes could be used to identify the crack location and depth.     

Flexural vibration of non-uniform beams having double-edge breathing cracks

Flexural vibration of non-uniform Rayleigh beams having single-edge and double-edge cracks is presented in this paper. Asymmetric double-edge cracks are formed as thin transverse slots with different depths at the same location of opposite surfaces. The cracks are modelled as breathing since the bending of the beam makes the cracks open and close in accordance with the direction of external moments. The presented crack model is used for single-edge cracks and double-edge cracks having different depth combinations. The energy method is used in the vibration analysis of the cracked beams. The consumed energy caused by the cracks opening and closing is obtained along the beam's length together with the contribution of tensile and compressive stress fields that come into existence during the bending. The total energy is evaluated for the Rayleigh-Ritz approximation method in analysing the vibration of the beam. Examples are presented on simply supported beams having uniform width and cantilever beams which are tapered. Good agreements are obtained when the results from the present method are compared with the results of Chondros et al. and the results of the commercial finite element program, Ansys^©. The effects of breathing in addition to crack depth's asymmetry and crack positions on the natural frequency ratios are presented in graphics.     

New breathing functions for the transverse breathing crack of the cracked rotor system: Approach for critical and subcritical harmonic analysis

The actual breathing mechanism of the transverse breathing crack in the cracked rotor system that appears due to the shaft weight is addressed here. As a result, the correct time-varying area moments of inertia for the cracked element cross-section during shaft rotation are also determined. Hence, two new breathing functions are identified to represent the actual breathing effect on the cracked element stiffness matrix. The new breathing functions are used in formulating the time-varying finite element stiffness matrix of the cracked element. The finite element equations of motion are then formulated for the cracked rotor system and solved via harmonic balance method for response, whirl orbits and the shift in the critical and subcritical speeds. The analytical results of this approach are compared with some previously published results obtained using approximate formulas for the breathing mechanism. The comparison shows that the previously used breathing function is a weak model for the breathing mechanism in the cracked rotor even for small crack depths. The new breathing functions give more accurate results for the dynamic behavior of the cracked rotor system for a wide range of the crack depths. The current approach is found to be efficient for crack detection since the critical and subcritical shaft speeds, the unique vibration signature in the neighborhood of the subcritical speeds and the sensitivity to the unbalance force direction all together can be utilized to detect the breathing crack before further damage occurs.     

IDENTIFICATION OF CRACK LOCATION IN VIBRATING BEAMS FROM CHANGES IN NODE POSITIONS

It is known that the effect of a single crack in an axially vibrating thin rod is to cause the nodes of the mode shapes move toward the crack. This paper is an analytical/experimental investigation of the analogous problem for a thin beam in bending vibration. The monotonicity property linking changes in node position and crack location does not hold in the bending case. The analysis of the direct problem, however, shows that the direction by which nodal points move may be useful for predicting damage location. Analytical results agree well with experimental tests performed on cracked steel beams.     

Dynamic analysis of a geared rotor system considering a slant crack on the shaft

The vibration problems associated with geared systems have been the focus of research in recent years. As the torque is mainly transmitted by the geared system, a slant crack is more likely to appear on the gear shaft. Due to the slant crack and its breathing mechanism, the dynamic behavior of cracked geared system would differ distinctly with that of uncracked system. Relatively less work is reported on slant crack in the geared rotor system during the past research. Thus, the dynamic analysis of a geared rotor-bearing system with a breathing slant crack is performed in the paper. The finite element model of a geared rotor with slant crack is presented. Based on fracture mechanics, the flexibility matrix for the slant crack is derived that accounts for the additional stress intensity factors. Three methods for whirling analysis, parametric instability analysis and steady-state response analysis are introduced. Then, by taking a widely used one-stage geared rotor-bearing system as an example, the whirling frequencies of the equivalent time-invariant system, two types of instability regions and steady-state response under the excitations of unbalance forces and tooth transmission errors, are computed numerically. The effects of crack depth, position and type (transverse or slant) on the system dynamic behaviors are considered in the discussion. The comparative study with slant cracked geared rotor is carried out to explore distinctive features in their modal, parametric instability and frequency response behaviors.     

Free vibration analysis of a cracked beam by finite element method

In this paper, the natural frequencies and mode shapes of a cracked beam are obtained using the finite element method. An ‘overall additional flexibility matrix’, instead of the ‘local additional flexibility matrix’, is added to the flexibility matrix of the corresponding intact beam element to obtain the total flexibility matrix, and therefore the stiffness matrix. Compared with analytical results, the new stiffness matrix obtained using the overall additional flexibility matrix can give more accurate natural frequencies than those resulted from using the local additional flexibility matrix. All the elements in the overall additional flexibility matrix are computed by 128-point (1D) or (128×128)-point (2D) Gauss quadrature, and then further best fitted using the least-squares method. The explicit form best-fitted formulas agree very well with the numerical integration results, and are very convenient for use and valuable for further reference. In addition, the authors constructed a shape function that can perfectly satisfy the local flexibility conditions at the crack locations, which can give more accurate vibration modes.     

Meshless formulation using NURBS basis functions for eigenfrequency changes of beam having multiple open-cracks

This paper presents a meshless formulation using non-uniform rational B-spline (NURBS) basis functions, and its applications to evaluate natural frequencies of a beam having multiple open-cracks. Node-based NURBS basis functions are used to construct the approximation function. The characteristic differentiability of the NURBS basis functions allows it to represent a function having specific degrees of smoothness and/or discontinuity. The discontinuity can be incorporated simply by assigning multiple knots at those locations. Hence, it can yield exact solutions having interior discontinuous derivatives. These advantages of NURBS are well known, and have been used extensively in graphical approximation of geometrical surfaces. However, it is seldom used in other engineering applications. To model the multiple open-cracks in a beam, quartic NURBS basis functions are employed and quadruplicate knots are assigned at the crack locations. Hence, it is capable to model the abrupt changes of slope (the first derivative of displacement) across a crack. In the present applications, additional equivalent massless rotational springs are inserted at the crack locations to represent the local flexibility caused by the cracks. As such, the cracked beam can be treated in the usual manner as a continuous beam. By adopting the meshless Petrov–Galerkin formulation, a generalized stiffness matrix for the cracked beam can be derived. Compared to the conventional finite element method, the present method does not require a finite element mesh for the purposes of interpolation and numerical integration. The advantages and effectiveness of the present method is illustrated in solving the eigenfrequencies of a beam having multiple open-cracks of different depths.     

Vibration and stability of cracked hollow-sectional beams

This paper presents simple tools for the vibration and stability analysis of cracked hollow-sectional beams. It comprises two parts. In the first, the influences of sectional cracks are expressed in terms of flexibility induced. Each crack is assigned with a local flexibility coefficient, which is derived by virtue of theories of fracture mechanics. The flexibility coefficient is a function of the depth of a crack. The general formulae are derived and expressed in integral form. It is then transformed to explicit form through 128-point Gauss quadrature. According to the depth of the crack, the formulae are derived under two scenarios. The first is for shallow cracks, of which the penetration depth is contained within the top solid-sectional region. The second is for deeper penetration, in which the crack goes into the middle hollow-sectional region. The explicit formulae are best-fitted equations generated by the least-squares method. The best-fitted curves are presented. From the curves, the flexibility coefficients can be read out easily, while the explicit expressions facilitate easy implementation in computer analysis. In the second part, the flexibility coefficients are employed in the vibration and stability analysis of hollow-sectional beams. The cracked beam is treated as an assembly of sub-segments linked up by rotational springs. Division of segments are made coincident with the location of cracks or any abrupt change of sectional property. The crack's flexibility coefficient then serves as that of the rotational spring. Application of the Hamilton's principle leads to the governing equations, which are subsequently solved through employment of a simple technique. It is a kind of modified Fourier series, which is able to represent any order of continuity of the vibration/buckling modes. Illustrative numerical examples are included.     

Damage detection of cracked thick rotating blades by a spatial wavelet based approach

This paper presents a technique for blade damage detection based on spatial wavelet analysis. The wavelet transform is used to analyze spatially distributed signals (e.g. mode shape) of cracked thick rotating blades. First, a finite element model is applied to the vibration of a thick rotating blade with a single edge crack. The effects of transverse shear deformation and rotatory inertia are taken into account. Then the mode shapes of the cracked rotating blade are analyzed by wavelet transformation. The effects of crack locations and sizes on the wavelet coefficients are studied. It is found that the distributions of the wavelet coefficients can identify the crack position of the rotating blades by showing a peak at the position of the crack. Then the signals are analyzed by wavelet transform. It is found that the distributions of the wavelet coefficients can identify the crack position. Assumed measurement errors are added to nth mode shape for evaluating the effect of measurement errors on the capability of detecting crack position. The moving average method is used to process the data with assumed measurement errors. The crack positions can also be identified when there exist assumed measurement errors.     

A method for determining the location and depth of cracks in double-cracked beams

The influence of two transverse open cracks on the antiresonances of a double cracked cantilever beam is investigated both analytically and experimentally. It is shown that there is a shift in the antiresonances of the cracked beam depending on the location and size of the cracks. These antiresonance changes, complementary with natural frequency changes, can be used as additional information carrier for crack identification in double cracked beams. Experimental results from tests on plexiglas beams damaged at different locations and different magnitudes are found to be in good agreement with theoretical predictions. Based on the results of the present work, an efficient prediction scheme for crack localization and characterization in double cracked beams is proposed.