Rotor-dynamic stability is a very important subject impacting the design, control, maintenance, and operating safety and reliability of rotary mechanical systems. As rotor-dynamic nonlinearities are significantly more prominent at higher rotary speeds, the demand for better and improved performance achievable through higher speeds has rendered the use of a linear approach for rotor-dynamic analysis both inadequate and ineffective. To establish the fundamental knowledge base necessary for addressing the need, it is essential that nonlinear rotor-dynamic responses indicative of the causes of nonlinearity, along with the bifurcated dynamic states of instability, be fully characterized. The objectives of the research are to study the various rotor-dynamic instabilities induced by crack breathing and bearing fluid film forces using a model rotor-bearing system and to investigate the applicability of the fundamental concept of instantaneous frequency for characterizing rotor-dynamic nonlinear responses. A comprehensive finite element model incorporating translational and rotational inertia, bending stiffness and gyroscopic moment is developed. The intrinsic modes extracted using the Empirical Mode Decomposition along with their instantaneous frequencies resolved using the Hilbert transform are applied to characterize the inception and progression of bifurcations suggestive of the changing rotor-dynamic state and impending instability. The dissertation presents and demonstrates an effective approach that integrates nonlinear rotor-dynamics, instantaneous time-frequency analysis, advanced notions of dynamic system diagnostics and numerical modeling applied to the detection and identification of sensitive variations indicative of a bifurcated dynamic state. All presented studies on rotor response subjected to various system configurations and ranges of parameters show good agreements with published results. Under the influence of crack opening, the rotor-bearing model system displays transitional behaviors typical of a nonlinear dynamic system, going from periodic to period-doubling, chaotic to eventual failure. When film forces are also considered, the model system demonstrates very different behaviors and failures from different settings and ranges of control parameters. As a result, a dynamic failure curve differentiating zones of stability and bifurcated instability from zones of dynamic failure is constructed and proposed as an alternative to the traditional stability chart. Observations and results such as these have important practical implications on the design and safe operation of high performance rotary machinery.

Internal friction has been known to be a cause of whirl instability in built-up rotors since the early 1900's. This internal damping tends to make the rotor whirl at shaft speeds greater than a critical speed, the whirl speed usually being equal to the critical speed. Over the years of research, though models have been developed to explain instabilities due to internal friction, its complex and unpredictable nature has made it extremely difficult to come up with a set of equations or rules that can be used to predict instabilities accurate enough for design. This thesis deals with suggesting improved methods for predicting the effects of shrink fits on threshold speeds of instability. A supporting objective is to quantify the internal friction in the system by measurements. Experimental methods of determining the internal damping with non-rotating tests are investigated, and the results are correlated with appropriate mathematical models for the system. Rotating experiments were carried out and suggest that subsynchronous vibration in rotating machinery can have numerous sources or causes. Also, subsynchronous whirl due to internal friction is not a highly repeatable phenomenon.

Orientadores: Katia Lucchesi Cavalca Dedini, Gregory Bregion Daniel / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-25T08:34:31Z (GMT). No. of bitstreams: 1 Carneiro_AntonioCarlosSanchesGrijotaPiragibe_M.pdf: 5320137 bytes, checksum: 6c4d8edd95179d0d202cdd190a3b7792 (MD5) Previous issue date: 2014 / Resumo: O presente trabalho tem como objetivo a análise dinâmica de sistemas rotativos sujeitos a diferentes tipos de elementos instabilizadores. Os elementos abordados neste estudo são os mancais lubrificados, os selos de fluxo mecânicos e o amortecimento interno do eixo, cujas interações dinâmicas, em condições operacionais pode conduzir o sistema à instabilidade. Os mancais segmentados foram também incluídos no estudo, cujo comportamento é considerado inerentemente estável. O eixo foi modelado por meio do método dos elementos finitos, pela sua robustez, facilidade de implementação e resolução das equações envolvidas. Desse modo, os elementos instabilizadores analisados foram modelados de forma a permitirem sua adição no modelo do eixo, por meio de coeficientes dinâmicos equivalentes. Os mancais segmentados permitem duas modelagens para os seus coeficientes: a reduzida e a completa, com a última exibindo explicitamente os graus de liberdade do segmento, sendo necessárias modificações no modelo de elementos finitos para adiciona-los. A avaliação do limiar de estabilidade foi realizada por meio do método do decremento logarítmico, obtido através da solução do problema de autovalor da equação de movimento do rotor. Analisaram-se, separadamente, os efeitos da adição de diferentes mancais, selos e níveis de amortecimento interno, para visualizar a influência de cada componente na dinâmica de um mesmo eixo. As análises envolvendo o mancal segmentado incluíram ambos os modelos de coeficientes (reduzido e completo). Em seguida, foram combinados, em um mesmo eixo, diferentes tipos de mancais, selos e amortecimentos internos, em diversas análises para determinar as interações existentes entre os componentes envolvidos. A partir destes resultados, procurou-se, em todas as análises, observar os efeitos na rigidez do sistema, no nível de amortecimento e a variação do limiar de estabilidade / Abstract: The work¿s goal is to analyze the dynamics of rotating systems, considering different kinds of instabilizing elements or factors. The factors accounted in this thesis are the hydrodynamic bearings, flow seals, and internal damping of the shaft, whose dynamic interactions occurring during the system¿s operation may cause instable behavior. Besides, the tilting-pad journal bearing were studied, which behavior is considered to be inherently stable. The shaft was modeled through the finite element method, due to its robustness, ease to implement and solution of the involved equations. Hence, the instabilizing elements were modeled in order to allow their addition in the shaft¿s model, through equivalent dynamic coefficients. The tilting-pad journal bearings allow two different coefficient models: reduced and full, with the last one explicitly exhibiting the degrees of freedom of the pads, being necessary modifications to the finite elements model to contain them. The evaluation of the stability threshold was performed through the logarithmic decrement method, obtained from the solution of the eigenvalue problem of the equation of motion of the system. The effects of the addition of different bearings, seals and levels of internal damping were analyzed separately in order to visualize the influence of each component on the dynamic of the same shaft. The models with tilting-pad bearing were analyzed twice, with each one considering a different coefficients model (reduced and full). Finally, different kinds of bearings, seals and internal damping were combined in the same shaft, allowing the definition of the interactions between the involved components. From this work, the effects in the system¿s stiffness, damping level and changes in the stability threshold were observed in all analyses / Mestrado / Mecanica dos Sólidos e Projeto Mecanico / Mestre em Engenharia Mecânica

Ultraprecision, single point diamond turning (SPDT) is a tool based machining technology that allows the ability to produce high quality surface finishes on the order of nanometers while meeting tight form tolerances on the order of micrometers. It is generally agreed that surface finish in SPDT is primarily affected by four factors: Tool edge quality, relative vibration between the tool and workpiece, material properties and microstructure, and tool geometry (nose radius and machining parameters) machining. To the author’s knowledge, no work has been done to combine all the factors to study their effect on surface generation in SPDT. This is important given that the factors are highly interdependent. Two diamond tools with nose radius of 12mm were used; however, one of them was chemically honed. Results suggest that the honed tool provides a much better surface finish with a significantly reduced amount of running-in stage tool wear. The cutting edge radius of the diamond tools was measured using a novel 3D confocal laser microscope to analyze the chemical honing process and to measure tool wear. The presence of built-up edge (BUE) is more prominent on the honed tool earlier in its life which results in unpredictable surface roughness to appear sooner than on the regular tool. To understand the dynamics of the machine, a redesign of the tool holder bracket was done to increase stiffness. Modal tests were then performed on it to verify performance improvement. With an understanding of the vibration and its effect on the cutting force, a 400Hz disturbance frequency was detected in the cutting forces. From a 3D scan of the surface, a total of 24 undulations on the surface of the part were observed when the spindle speed was set to 1000RPM The machine was instrumented and a rotordynamic investigation was carried out to determine the cause and nature of the vibration in an effort to reduce it and in so doing improve surface form accuracy. / Thesis / Master of Applied Science (MASc)

Rotor stability is essential to the life span of any piece of rotating machinery; it becomes increasingly critical in high-speed machinery such as turbochargers. Large turbochargers, such as those found in marine diesel propulsion engines where the rotor alone often exceeds forty pounds, require careful consideration regarding stability as well as load support during the bearing selection process. Logarithmic Decrement is the primary consideration for rotor stability. Commercial software is used to model and analyze a proven unstable turbocharger rotor. After confirming that the model exhibits unstable characteristics, the same turbocharger is then analyzed with various fluid-film bearing configurations. Finally, the tilting-pad bearing is determined to be the best bearing for this turbocharger application, stabilizing the rotor throughout the entire designed operating range. / Master of Science

This thesis presents a novel method of locating imbalance faults in rotating machinery through the study of bearing nonlinearities. Localisation in this work is presented as determining which discs/segments of a complex machine are affected with an imbalance fault. The novel method enables accurate localisation to be achieved using a single accelerometer, and is valid for both sub and super-critical machine operations in the presence of misalignment and rub faults. The development of the novel system for imbalance localisation has been driven by the desire for improved maintenance procedures, along with the increased requirement for Integrated Vehicle Health Management (IVHM) systems for rotating machinery in industry. Imbalance faults are of particular interest to aircraft engine manufacturers such as Rolls Royce plc, where such faults still result in undesired downtime of machinery. Existing methods of imbalance localisation have yet to see widespread implementation in IVHM and Engine Health Monitoring (EHM) systems, providing the motivation for undertaking this project. The imbalance localisation system described has been developed primarily for a lab-based Machine Fault Simulator (MFS), with validation and verification performed on two additional test rigs. Physics based simulations have been used in order to develop and validate the system. An Artificial Neural Network (ANN) has been applied for the purposes of reasoning, using nonlinear features in the frequency domain originating from bearing nonlinearities. The system has been widely tested in a range of situations, including in the presence of misalignment and rub faults and on a full scale aircraft engine model. The novel system for imbalance localisation has been used as the basis for a methodology aimed at localising common faults in future IVHM systems, with the aim of communicating the results and findings of this research for the benefit of future research. The works contained herein therefore contribute to scientific knowledge in the field of IVHM for rotating machinery.

[pt] Este trabalho analisa a influência dos mancais hidrodinâmicos no comportamento rotodinâmico das turbomáquinas, no que diz respeito na resposta ao desbalanceamento, modos de vibrar e, principalmente, a instabilidade, que tende a manifestar-se em rotações elevadas ou baixas cargas. As propriedades de rigidez e amortecimento do mancal são determinadas a partir da solução analítica da Equação de Reynolds, usando a aproximação do mancal curto. Um procedimento é apresentado para modelagem dinâmica do sistema rotor-mancal. O modelo de elementos finitos inclui a influência da ação giroscópica. A análise rotodinâmica completa de um rotor concebido e projetado para apresentar o fenômeno da instabilidade é feita com auxílio do programa ROMAC da Universiry of Virginia. O programa calcula as propriedades do mancal a partir da solução numérica completa da Equação de Reynolds e o cálculo das velocidades críticas, dos modos e da análise de estabilidade é feito pelo Método dos Elementos Finitos. Finalmente, documenta-se o projeto do protótipo, o estudo realizado e os ensaios desenvolvidos. A partir das medições realizadas, valida-se a solução numérica. / [en] This work analyses the effect of fluid-film bearings on the dynam- ics of turbomachinery with respect to unbalance response, vibration mode shapes and, specially, instability that tends to occur, mainly, at high speeds or light loads. The bearing stffiness and damping bearing properties are calculated using the analytical solution of the Reynolds Equation, based in a short bearing approach. Following, a procedure is presented for the dynamic modelling of rotor-bearing systems based in the Finite Element Method, including the gyroscopic effect. The complete rotordynamic analysis of a rotor designed to undergo instability problem is performed by software ROMAC from University of Virginia. The software predicts the bearing properties by complete numerical solution of Reynolds Equation and critical speeds, mode shapes and stability analysis is performed using the Finite Element Method.Finally, it is presented the design of the rotor kit , accomplished studies and performed tests. The numerical solution is validated by measurements that were made.

Active control constitutes the state of the art in vibration management in rotating machines. However, existing designs are impractical and costly, and hence not yet widely applied. The goal of the research reported here was to develop a design which would allow the implementation of active technology in a wider range of rotating machine applications. Thus, this study focuses on a novel active rotor topology, consisting of a hollow rotor with internally mounted sensors and actuators. This layout provides greater freedom to select the sensor and actuator positions along the rotor, and naturally protects the devices from harsh working environments. The research was structured according to four themes. Firstly, the concept feasibility was explored by constructing a fully functioning prototype. MEMS accelerometers and mass balancer actuators were mounted in an assembled rotor, together with a microcontroller and radio unit to enable wireless transmission of data. Secondly, the behaviour of MEMS accelerometers in a rotating frame of reference was studied. An output model was derived and applied to the study of whirl orbits and transient vibration. Further, techniques were developed to extract mean displacement and angular velocity information from the sensor signals. An analysis of potential sources of measurement error was conducted, and methods for their mitigation devised. The third theme focused on developing active vibration control techniques suitable for use with active rotors. The core of this work is the development and successful implementation of a non a priori method, Algorithmic Direct Search Control. This technique enables vibration to be minimised without knowledge of the system characteristics, by applying a direct search optimisation technique as a control law. Finally, the combination of active rotors and Active Magnetic Bearings was considered to tackle the problem of sensor/actuator non-collocation. The challenge of levitating a rotor on AMBs using only internal accelerometers was approached via integration-based displacement information extraction, to exploit existing PID controllers. This method proved unfeasible in practice, but valuable lessons were derived from the study. The key finding of this work is that active rotor technology is versatile, cost-effective, powerful and feasible. As such, it offers great potential as a route to achieving a more practical and generalised implementation of active control technology in rotating machinery.

A new closed-loop frequency-domain model is developed to incorporate the water hammer effect with pump rotordynamics, in order to investigate the sub-synchronous instability problem observed in a field pump. Seal flow-rate perturbations due to eccentricity are calculated from Soulas and San Andres's seal code. A complete transfer function matrix between rotor motion and reaction force due to pressure perturbation is developed in detail. Stability analysis with transfer-function'add-in' modules is conducted in XLTRC2. Seal clearances and the reaction force angle are found to be important in shifting natural frequencies and damping. The sub-synchronous instability observed in field is duplicated successfully with double-clearance seals.

A new closed-loop frequency-domain model is developed to incorporate the water hammer effect with pump rotordynamics, in order to investigate the sub-synchronous instability problem observed in a field pump. Seal flow-rate perturbations due to eccentricity are calculated from Soulas and San Andres's seal code. A complete transfer function matrix between rotor motion and reaction force due to pressure perturbation is developed in detail. Stability analysis with transfer-function'add-in' modules is conducted in XLTRC2. Seal clearances and the reaction force angle are found to be important in shifting natural frequencies and damping. The sub-synchronous instability observed in field is duplicated successfully with double-clearance seals.