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Aluminum Case History - Operating Deflection Shape Analysis

Operating Deflection Shape (ODS) analysis provides animated deflection shapes of vibrating systems under operating conditions. This document discusses using multi-channel ODS analysis on an aluminum rolling mill experiencing chatter. 63 accelerometers were used to collect ODS data at different mill speeds in under 2 minutes. The analysis identified relative motion between the work rolls as the source of chatter, informing redesign efforts to improve roll stack dynamics.

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27 views2 pages

Aluminum Case History - Operating Deflection Shape Analysis

Operating Deflection Shape (ODS) analysis provides animated deflection shapes of vibrating systems under operating conditions. This document discusses using multi-channel ODS analysis on an aluminum rolling mill experiencing chatter. 63 accelerometers were used to collect ODS data at different mill speeds in under 2 minutes. The analysis identified relative motion between the work rolls as the source of chatter, informing redesign efforts to improve roll stack dynamics.

Uploaded by

rony silva
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOC, PDF, TXT or read online on Scribd
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Operating Deflection Shape Analysis Applied to an Aluminum Rolling Mill

Robert L. Sayer

Introduction:

Operating Deflection Shape Analysis, hereinafter referred to as ODS Analysis, provides an animation of
the deflected shape of a vibrating system under actual operating conditions. ODS testing can be
performed with either a single channel or multi-channel analyzer, although the use of single channel
techniques limits the scope and affects the accuracy of the analysis. This discussion shall be limited to
multi-channel ODS methods.

Multi-channel ODS testing not only provides the animated deflected shape at the operating frequency of
the equipment but also provides animated deflection shapes at any other frequency. Single channel ODS
is limited to the animation of the deflection shape at lx operating speed of the equipment or integer
multiple thereof. Multi-channel ODS testing can be used to define the response of a vibrating system to
forces produced by drive belts, gear mesh, bearings, turbulence and other aerodynamic affects which
usually do not occur at an integer multiple of the operating frequency.

The most common reasons for performing ODS testing and analysis include:

Defining areas of structural "weakness", including looseness in bases and bolted joints. This information
can be used to direct the analyst toward the area for which structural/mechanical modifications will be
most effective.
Prove that a natural frequency is actually being excited. If Experimental Modal Analysis (EMA) testing is
performed along with ODS testing and the animated mode shape associated with the excitation of a
resonance matches the animated ODS shape, then it can be concluded that dynamic forces are present
which are exciting a natural frequency.
Identify the nature and source of a troublesome dynamic force produced by the equipment. Information
relative to the magnitude, direction and type of force can be inferred from an ODS.
Obtain a mode shape for a natural frequency. EMA testing is usually the best method for determining a
mode shape associated with a natural frequency. However, there are cases where tune and/or access
restrictions do not permit the performance of a complete modal test.

Case History:

A multi-stand aluminum rolling mill was experiencing chatter which affected the quality of the finished
sheet. The rolling mill operates at different speeds depending on the product. The vibration monitoring
program identified a frequency range in which the rolling mill appeared to be more sensitive. The
excitation of a natural frequency was suspected as the probable cause of the chatter problem.

It was not possible to perform an EMA test for several reasons. The rolling mill is a massive structure
which could not easily be excited. Access to the mill was limited. Finally, time constraints made an EMA
test impossible. Therefore, an ODS test was performed to identify the relative motion of the work rolls,
back-up rolls and mill housing in the frequency range of concern.

A work roll with a known defect was used as an exciter. This work roll supplied a harmonic force with a
frequency equal to many times the rotational speed of the roll.

One major drawback to this test setup was that the defective work roll would produce a reject product.
Because all material rolled during this test would have to be scrapped, the test was limited, for economic
reasons, to using only two coils of aluminum. The total rolling time for two coils was less than ten minutes
and ODS shapes at several different speeds were desired. Therefore, the time provided to collect a
complete set of ODS data was approximately 2 minutes for each test.
A ODS model containing sixty three degrees-of-freedom was developed for the test. Sixty three
accelerometers were attached to the mill. These transducers were connected to 2 CSI 32-channel multi-
plexers. The signal for one of the transducers was split a sent to each of the multi-plexers to serve as a
common reference signal. Two computers equipped with CSI WAVEPAK were used to control the
multiplexers. A computer program was written which automatically provided the keystrokes in Wavepak to
obtain and archive the Transfer Functions and advance the multi-plexor. A complete set of ODS data was
obtained for each test in approximately 2 minutes! However, it should be noted that the reduction of this
data took several man-days.

Figure 1 includes one of the ODS shapes Obtained from the data. This analysis provided some
interesting information regarding the relative motion between the work rolls. This relative motion can
affect the deformation process, resulting in a chatter pattern being established in the finished coil. The
size of the chatter pattern will be dependent upon the frequency of the vibration.

Figure 1. ODS Shapes of Rolling Mill

This analysis also showed that the deformation of the mill housing was not a significant contributor to the
chatter problem. Therefore, redesign efforts could concentrate on the roll stack dynamics (work roll &
backup roll). The ODS data was subsequently used to correlate Finite element models developed to
investigate design changes which would eliminate the chatter problem.

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