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Online Condition Monitoring For Detection of Crack in The Shaft Using Vibration Analysis Method

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Online Condition Monitoring For Detection of Crack in The Shaft Using Vibration Analysis Method

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Industrial Lubrication and Tribology

Online condition monitoring for detection of crack in the shaft using vibration analysis method
Bhumi Ankit Shah, Dipak P. Vakharia,
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Bhumi Ankit Shah, Dipak P. Vakharia, (2018) "Online condition monitoring for detection of crack in the shaft using vibration
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Online condition monitoring for
detection of crack in the shaft using
vibration analysis method
Bhumi Ankit Shah
Mechanical Engineering, Sarvajanik College of Engineering and Technology, Surat, India, and
Dipak P. Vakharia
S.V. National Institute of Technology, Surat, India

Abstract
Purpose – The purpose of this study is to identify the crack in the shaft at incipient stage. Transverse crack is the most common type of crack found on the
periphery of the shaft. The changes in dynamic behaviour of the rotor at high speed are enormous. The reliable operation of the machinery is paramount for
the safety of individual and plant. Condition-based maintenance monitors the mechanical and operational condition of the machine. During such inspection,
if any unhealthy symptoms are detected, then affected part is identified and taken out for the maintenance at most appropriate time.
Design/methodology/approach – Simulating the transverse crack of different depth and location is the most challenging part of the experimental
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analysis. To optimize the total experimental cost for simulation of crack in the shaft, inverted crack is proposed to be produced in shaft and
investigation shall be carried out for of early crack detection in shaft using vibration analysis. The set of experiments has been conducted on healthy
shaft, inverted cracked shaft and actual cracked shaft. Inverted crack methodology provides flexibility of simulating crack of any size and at any
location, and it can be reconfigured for several times to obtain various set of results.
Findings – To derive objective of the study, steady state response analysis and transient response analysis are performed on the experiment test rig.
Vibration signals are acquired from the bearing locations to detect the crack. The paper addresses the influence of the inverted crack on critical
speed of the shaft and deviation of first and second harmonic component of the shaft because of introduction of inverted crack. The resultant
Nyquist plots, orbit plots and frequency plots are compared with the baseline data (obtained with the healthy shaft) to identify the crack.
Originality/value – The present study focuses on methodology by which inverted crack is developed in the healthy shaft, which resembles the
behaviour of actual crack, and it shall be used to study the changes in rotor stiffness caused by transverse crack. The experimental results obtained
using the inverted crack shaft have same vibration characteristics but in reverse direction as it would have occurred with the cracked shaft.
Keywords Condition monitoring, 1x and 2x harmonic component, Actual crack, Critical speed, Inverted crack
Paper type Research paper

1. Introduction position for mounting sensors from where signals related to the
fault can be obtained. Vibration measurement during the
The rotating machinery is extensively used in an industry. transient state is significant in identifying the rotor faults.
Defect in the rotating machine always generates the symptoms
Online monitoring can be adopted at steady state speed. Time
of elevated vibration and noise. Measuring the vibration
waveform information obtained at steady state condition is
amplitude of a new and correctly installed machine can be used
meaningful information and can be used as an indicator of
as a baseline data for detection of faults in future. In online
presence of crack in the shaft. The vibration behaviour of the
monitoring system, data are acquired automatically from
machine depends upon the dynamic stiffness of the system.
the machine. Operational and mechanical conditions are
Presence of transverse crack in rotor would change the original
monitored during start-ups, coast downs and at steady state
running conditions. Severity of the fault can be measured in dynamic stiffness of the system. Crack development on the
terms of the vibration amplitude. All rotating equipment are circumference of the shaft reduces the bending stiffness at the
supported by number of bearings. Vibrations generated crack affected area. Cracked shaft will bow significantly in
because faults have tendency to go to earth through its bearing amplitude during operation. It will result in amplification of 1x
support. Bearing supports are the location from where vibration and 2x harmonic component.
passes from rotor to stator to the ground. Thus, it is the best Muszynska (1995) has shown that changes in 1x
synchronous amplitude and phase can be monitored in
conjunction with second harmonic component. Because of
The current issue and full text archive of this journal is available on crack, 1x component increases at lower rate, but there is
Emerald Insight at: www.emeraldinsight.com/0036-8792.htm significant change in 2x harmonic component. Presence of 2x
component is important measure of crack. 2x vibration

Industrial Lubrication and Tribology Received 23 February 2017


© Emerald Publishing Limited [ISSN 0036-8792] Revised 5 March 2018
[DOI 10.1108/ILT-11-2017-0348] Accepted 8 April 2018
Online condition monitoring for detection of crack Industrial Lubrication and Tribology
Bhumi Ankit Shah and Dipak P. Vakharia

component is associated with the asymmetry of the shaft. 2x Vibration response data are acquired with the standard
component is especially dominant when the rotating speed is in accelerometers as shown in Figure 1.
the region of half of natural frequency of any system. Three phase HP motor, pre-wired and self-aligning
Papadopoulos and Dimarogonas (1988) and Sekhar (1999) mounting system are used for easy installation and removal.
used simplified models where drop in the stiffness because of Drive system of motor is having variable frequency drive with
induced crack is discussed. Researchers also stated that LCD display. Built-in tachometer is used to measure the speed.
vibration response in a supercritical region may not give any Drive can run the motor in the range of 0-3,600 RPM.
useful information about the existence of crack. Grabowski Variability is taken as 1Hz during the transient test.
(1982) observed that 1x and 2x harmonic components are Dual channel analyser is used to acquire two sets of data
pronounced in closing crack, and 2x component is an indicator simultaneously at two measurement points. One set of data is
in case of open crack. Schmied and Kramer (1984) found that acquired at drive end bearing location (DE) and other at non-
1x harmonic component depends upon unbalance mass, if drive end bearing location (NDE) in a lateral direction of the
unbalance is opposite the crack, 1x harmonic component rotor. Vibration data were acquired using mobile industrial
decreases. Mayes and Davies (1984) indicated that 2x and accelerometer (PRUFTECHNIK-VIB 6.142) having single
higher harmonic component is weakly dependent on axis data logging capacity. Accelerometer is broadly used in
unbalance. These harmonic components generated because of condition monitoring. Sensitivity of the sensor is specified
crack, and it is expected to be a function of crack depth and between 2 Hz and 1 KHz. Stud type of mounting is used. It is
shape. Fatigue crack is induced in a rotor by Darpe et al. (2003) incorporated by screwing the sensors at different location on a
using three-point bending machine. Initially, fine slit is made
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bearing block.
using jeweller’s saw and then cyclic load is applied on the slit. Parameters selected on the vibration analyser are as follows
Slit will act as source of fatigue crack. Extra care was taken to when data are collected. Sampling rate for the time signal is
minimize the error. The shortfall in this procedure is that in first 16,384. Fmax is selected on the analyser is 1 KHz. No. of lines
place shaft is dismounted from the test rig for simulating fatigue used to display frequency spectrum is 3,200. Synchronous time
crack and then complete rotor is assembled. averaging method is used to remove all non-synchronous
Many researchers have adopted different methods for frequency components. The set-up of test rig with
generating crack. The response of crack is mainly related to its instrumentation and sensors location is shown in Figure 2.
depth and location. Chen et al. (2016) presented a new method
to identify the main errors of machine tool in time and 3. Simulation of transverse crack and inverted
frequency domain. The signals of work piece are decomposed crack in the shaft
in to low and high frequency zone using wavelet transform. The
features related to spindle unbalance is extracted in the One way to generate the actual transverse crack in the shaft is to
frequency domain. A unique technique is presented by G omez introduce small notch and put this shaft under fatigue and as a
et al. (2016) for the detection of crack in rotating machinery. result crack shall be propagated. However, chances of bending
Experimental measurements were performed at different of shaft will be more in this case. Another way is to use electro-
steady state rotational speeds using accelerometer mounted on corrosion machine which is used to generate cut instead of
a bearing housing. crack. It is better to generate the crack by making cut in the
In all earlier research studies of identifying the crack, many shaft with the help of saw. In cracked shaft, 1 mm width and
shafts were used for experimental study for seeding artificial 4 mm depth cut are generated with the help of saw. The
crack. These shafts cannot be used further. If proper care is not location of the crack is made near to the disc of DE side.
taken during simulation, the crack in the shaft then it loses its Inverted crack means to generate the crack in the reverse
straightness. To optimize the cost of the experimentation and direction. This can be done by putting or adhering a wire to the
to acquire required vibration characteristics, inverted crack shaft having the same dimension as that of crack.
methodology is proposed through this study. Methodology
used here, provides flexibility to induce the crack at different Figure 1 Picture of the rotor test rig with speed controller
depths and locations on a single shaft without dismounting the
shaft from the test rig. The remaining operating conditions will
be unaltered and responses generated because of inverted crack
and actual crack are acquired to compare with healthy shaft.
This study introduces an efficient technique for studying the
primary behaviour of actual crack by using inverted crack
methodology.

2. Experiment set-up
The test rig consists of a steel shaft of 16 mm diameter and
520 mm long, which is supported on two roller bearings. The
left end of the shaft is coupled with an electric motor by means
of a flexible coupling. Two discs of 150 mm diameter with 12
threaded holes at 30 degree of intervals are mounted on the
shaft for introducing known mass for introducing unbalance.
Online condition monitoring for detection of crack Industrial Lubrication and Tribology
Bhumi Ankit Shah and Dipak P. Vakharia

Figure 2 Rotor test rig with instrumentation can be maintained. Inverted crack can also be used to save
material and total experimentation cost as repeated use of the
same shaft can be done. Healthy shaft presents the normal
condition of the shaft. So, data acquired from healthy shaft are
considered as a baseline data. Baseline condition cannot
actually be considered as a true situation because of the
presence of the small residual unbalance; nevertheless, it has
been used to calculate the vibration difference generated
because of crack. The series of experiments are done on
cracked shaft and inverted cracked shaft. Transient response
analysis and steady state response analysis are important
measures in vibration response analysis technique.

4. Transient response analysis


Many rotating components are subject to frequent start-ups
and coast down. Start-up and coast down data are valuable
diagnostic tools. For getting accurate deviation from the
baseline data, coast down data are recorded at both bearing
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locations. VIBXPERT-data analyser records the current


rpm and automatically begins with measurement as soon as
the selected “start RPM” (400 rpm) is exceeded.
Measurement is stopped when the “stop RPM” (3,000
Inverted crack is made by attaching 1 mm diameter wire to RPM) is reached. Transient test is carried out in the range of
healthy shaft with metallic adhesive. Mounting and 0-3,000 rpm.
dismounting of the shaft is also not required during Figures 3 to 5 show the comparison of transient response
introduction of inverted crack, and hence, making changes in variation for healthy shaft, inverted cracked shaft and cracked
the various parameters is easy, and accuracy in measurement shaft. Transverse crack can be related to variation in rotor

Figure 3 Coast down vertical plot of healthy shaft

Figure 4 Coast down vertical plot of inverted cracked shaft


Online condition monitoring for detection of crack Industrial Lubrication and Tribology
Bhumi Ankit Shah and Dipak P. Vakharia

Figure 5 Coast down vertical plot of cracked shaft

stiffness in the lateral direction of crack. Cross section area of Figure 6 Critical speeds at different unbalance orientation angle for
the affected section of the shaft is small which consequently healthy shaft and inverted cracked shaft
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reduces the bending stiffness of the shaft and reverse is the


case for the inverted cracked shaft (increase in bending 2,400

stiffness). It may be noted that the critical speed of the 2,380


inverted cracked shaft is highest (2,810 rpm) because of the
2,360
increase in bending stiffness of the rotor. First critical speed Critical Speed (mm/sec)
of the healthy shaft (baseline condition) is 2,604 rpm. 2,340
Critical speed of the cracked shaft for the same test
2,320
parameters is 2,490 rpm because of reduced bending
stiffness. The modified stiffness is only in one direction 2,300
which causes anisotropy in the rotor. Significant shift is
2,280
observed in critical speed in Figures 3 to 5 because of crack
generated anisotropy in the shaft. The magnitude of the 2,260
peak response of the cracked shaft is 7.57 mm/sec which is 2,240
Crtical Speed of healthy shaft
higher than the peak response of healthy shaft (5.37 mm/
Critical speed of Inverted cracked shaft
sec), and in case of inverted cracked shaft, it is reduced to 2,220
0 30 60 90 120 150 180 210 240 270 300 330
2.78 mm/sec. Unbalance orientation angle (deg)
The next step of transient response analysis is to attach
unbalance weight on to the disc at different angle to
introduce unbalance excitation. This operation is repeated
for 12 different unbalance orientation angles ( b ) in steps of
Figure 7 Nyquist plot for healthy shaft
30°. An unbalance mass of 13.87 grams is placed on a disc 2.
The start-up time responses are measured for each Healthy shaft
orientation angle.
v rms [mm/ s] D E M O N S T R A T I O N \ 2 7 -6 -1 4 c d a n d s u p
The magnitude of the critical speed at different unbalance
orientation angle for inverted cracked shaft is higher than M 90°

the healthy shaft as shown in Figure 6. Clear distinction in


regards to the critical speed can be made by referring the 30

Figure 6. This important feature can be used to distinguish


20
variation in response, which is generated because of the
crack. 10
Nyquist plot of measured transverse response for healthy
shaft and inverted cracked shaft are plotted in the Figures 7 –30 –20 –10 0
0
10 20 30
and 8 which display the amplitude and phase with respect to
–10
the shaft speed in polar coordinate. A notable change is
observed in resonance frequency of inverted cracked shaft. –20
The critical speed of the shaft always decreases because of the
presence of the transverse crack. The effect of transverse crack –30
on the critical speed of the cracked rotor is consistent with the
results presented by Darpe et al. (2004); Sekhar and Srinivas 270°
v [mm/ s]
(2002); and Sinou (2009), while critical speed of inverted
cracked shaft increases (Figure 4) which is reverse in the case of
cracked shaft (Figure 5). The cause of reduction in the resonant
Online condition monitoring for detection of crack Industrial Lubrication and Tribology
Bhumi Ankit Shah and Dipak P. Vakharia

Figure 8 Nyquist plot for inverted cracked shaft (Figure 10) in account of increase in lateral stiffness, and
16.41 per cent increment is measured in case of cracked
Inverted Cracked shaft shaft (Figure 11) because of reduced bending stiffness.
v rms [mm/ s] D E M O N S T R A T I O N \ 2 7 -6 -1 4 c d a n d Rotor stiffness asymmetry causes rise in 2x harmonic
component. Therefore, only 2x harmonic components are
90°
M
M
considered in crack identification procedure. The amplitude of
2x harmonic component increases in case of cracked shaft and
30
decreases in case of inverted cracked shaft as illustrated in
20 Figures 12-14 (Table I).
The next step in the steady state response analysis is the
10 unbalance response analysis. The objective of the experiment is
to study the effect of crack and unbalance interaction on 1x and
0
–30 –20 –10 0 10 20 30 2x harmonic components.
–10
When operating speed is less than critical speed, only spring
stiffness is a dominant component. Mass and damping effect to
–20 the stiffness are small and can be neglected. When stiffness
related changes are needed to be investigated, speed used in
–30 experiment should be away from critical speed. Shaft is
operated at 1,800 rpm (30 Hz) which is away from the first
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270°
critical speed of the rotor. Referring to the Figures 15 and 16,
v [mm/ s]
amplitude of 2x harmonic component is reduced from
0.74 mm/sec to 0.15 mm/sec for the inverted cracked shaft.
Cross section area of the inverted cracked shaft is more, which
frequency is mainly because of decrease in bending stiffness of result in increased bending stiffness of the shaft. This behaviour
the rotor. is responsible for diminishing behaviour of the 2x harmonic
component (Figures 15 and 16) and increase in critical speed
!
5. Steady state response analysis qffiffiffi
v ¼ m of the shaft at different unbalance orientation
k
In industries, rotor is always operated at constant running
speed for a longer duration. Steady state response analysis is angle as illustrated in Figure 6.
carried out for online condition monitoring. The steady Figures 17 and 18 compare the unfiltered orbital plots for
state response obtained in a subcritical region gives useful healthy shaft and inverted cracked shaft. Notable difference can
information about the presence of the crack. The be observed for both the case. Keyphasor is also required to
accelerometers are attached on the top of bearing for provide reference during measurement. Some rotating
capturing a signal and transmitting to display on the machinery faults have the characteristic orbit shape.
monitor. Main cursor is used to show the second harmonic Comparison with the baseline condition is used to detect the
response (2.00 order) in the following frequency plots. fault. Crack causes shift in neural stiffness axis and stiffness
Selection of operating speed is so much important during anisotropy in the lateral directions which generate an elastic
experimentation. Experiments have been conducted on healthy unbalance force. This causes small change in orbit path and
shaft, inverted cracked shaft and cracked shaft at 35 and 40 Hz helps in the identifying the machine fault which directly affect
steady state speeds. the path of the shaft such as a shaft crack.
The inverted crack and actual crack causes elastic Remarkable rise can be seen in 1x harmonic response of
unbalance force which is synchronous to the rotor rotational inverted cracked shaft (Figure 19), while drop in 2x
speed and it will magnify the 1x harmonic response. harmonic response is observed at each unbalance
Modification of rotor stiffness causes change in rotor lateral orientation angle (Figure 20). Generally, 1x and 2x
responses. Healthy shaft response is shown in Figure 9. In vibration response vector increases because of pending
total, 29.85 per cent reduction is measured in double crack. 1x harmonic component is mainly related to the
harmonic response in case of inverted cracked shaft unbalance in the rotor system.

Figure 9 Frequency domain response of healthy shaft at 35 Hz operating speed


Online condition monitoring for detection of crack Industrial Lubrication and Tribology
Bhumi Ankit Shah and Dipak P. Vakharia

Figure 10 Frequency domain response of inverted cracked shaft at 35 Hz operating speed

Figure 11 Frequency domain response of cracked shaft at 35 Hz operating speed


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Figure 12 Frequency domain response of healthy shaft at 40 Hz operating speed

Figure 13 Frequency domain response of inverted cracked shaft at 40 Hz operating speed

Figure 14 Frequency domain response of healthy shaft, inverted cracked shaft and cracked shaft at 40 Hz operating speed

Table I Deviation of 1x and 2x harmonic components for healthy shaft, inverted cracked shaft and cracked shaft
Healthy shaft Inverted cracked shaft Cracked shaft
1x Harmonic 2x Harmonic 1x Harmonic 2x Harmonic 1x Harmonic 2x Harmonic
Operating component component component component component component
speed (Hz) (mm/sec) (mm/sec) (mm/sec) (mm/sec) (mm/sec) (mm/sec)
35 Hz 2.08 0.67 4.18 0.47 2.21 0.78
40 Hz 2.63 0.98 5.34 0.7 2.16 2.11
Online condition monitoring for detection of crack Industrial Lubrication and Tribology
Bhumi Ankit Shah and Dipak P. Vakharia

Figure 15 Frequency plot for healthy shaft at 30 Hz operating speed

Figure 16 Frequency plot for inverted cracked shaft at 30 Hz operating speed


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Figure 17 Orbit plot for healthy shaft at 1,800 rpm Figure 18 Orbit plot for inverted cracked shaft at 1,800 rpm

Inverted cracked shaft


Healthy shaft
Y2 [mm/ s] D E M O N S T R A T I O N \ 2 6 -6 -1 4 -1 8 0 0 -sp e e d -u b -w it h w
Y2 [mm/ s] D E M O N S T R A T I O N \ 2 6 -6 -1 4 -1 8 0 0 -s p e e d -u b -w it h w ir
90°
90°
25
25
20
20
15
15
10
10
5
5

0
–25 –20 –15 –10 -5 0
0
5 10 15 20 25 –25 –20 –15 –10 –5 0 5 10 15 20 25

–5 –5
–10 –10
–15 –15
–20 –20
–25 –25
270° 270°
Y1 [mm/ s] Y1 [mm/ s]

As inverted crack is introduced in the healthy shaft, amplitude an optimal cost. The detectable difference in vibration
of 1x response increases. Unbalance orientation angle with responses of inverted crack shaft are observed and can be
respect to the crack affect the 1x harmonic component, while harmonized with the actual crack. This experimental study
stiffness anisotropy affects the amplitude of 2x harmonic focuses on the deviation of vibration synchronous component
component. 2x harmonic response of healthy shaft and inverted generated because of crack. It has been shown that there is
cracked shaft is shown in Figure 13. rise in 1x harmonic component due to unbalance weight
attached at different orientation angle and inverted crack. 2x
6. Conclusion vibration components diminish due to increased bending
stiffness. A significant change is observed in first critical speed
The vibration response obtained from the inverted crack may during start-up and coast down of rotor. The above findings
help in developing the actual crack identification procedure at can be used to detect the crack in the shaft in operation.
Online condition monitoring for detection of crack Industrial Lubrication and Tribology
Bhumi Ankit Shah and Dipak P. Vakharia

Figure 19 1x Harmonic component of healthy shaft and inverted Darpe, A.K., Gupta, K. and Chawla, A. (2003), “Experimental
cracked shaft at different orientation angle at 1,800 rpm investigations of the response of a cracked rotor to periodic
axial excitation”, Journal of Sound and Vibration, Vol. 260
11.5
No. 2, pp. 265-286.
Darpe, A.K., Gupta, K. and Chawla, A. (2004), “Transient
11 response and breathing behaviour of a cracked Jeffcott
1x Harmonic response (mm/sec)

rotor”, Journal of Sound and Vibration, Vol. 272 Nos 1/2,


10.5 pp. 207-243.
Gomez, M.J., Castej on, C. and García-Prada, J.C. (2016),
10 “Crack detection in rotating shafts based on 3 energy:
analytical and experimental analyses”, Mechanism and
9.5 Machine Theory, Vol. 96, pp. 94-106.
Grabowski, B. (1982), “Shaft vibrations in turbomachinery
excited by cracks”, in 2nd Workshop on Rotordynamic
9
1x Harmonic response of healthy shaft Instability Problems in High Performance Turbomachinery,
1x Harmonic response of Inverted cracked shaft Texas A&M University, TX.
8.5
0 30 60 90 120 150 180 210 240 270 300 330 Mayes, I.W. and Davies, W.G.R. (1984), “Analysis of the
Unbalance orientation angle (deg) response of a multi-rotor-bearing system containing a transverse
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crack in a rotor”, Journal of Vibration Acoustics Stress and


Reliability in Design, Vol. 106 No. 1, pp. 139-145.
Figure 20 2x Harmonic component of healthy shaft and inverted
Muszynska, A. (1995), “Vibrational diagnostics of rotating
cracked shaft at different orientation angle at 1,800 rpm
machinery malfunctions”, International Journal of Rotating
0.8 Machinery, Vol. 1 Nos 3/4, pp. 237-266.
Papadopoulos, C.A. and Dimarogonas, A.D. (1988),
0.7 “Coupled longitudinal and bending vibrations of a cracked
2x Harmonic response (mm/sec)

shaft”, Journal of Vibration Acoustics Stress and Reliability in


0.6 Design, Vol. 110 No. 1, pp. 1-8.
Schmied, J. and Kramer, E. (1984), “Vibrational behaviour of
0.5 a rotor with a cross sectional crack, proceedings of institution
of mechanical engineers”, Journal of Mechanical Engineering
0.4 Science, Vol. 195, pp. 57-73.
Sekhar, A.S. (1999), “Vibration characteristics of a cracked
0.3 rotor with two open cracks”, Journal of Sound and Vibration,
Vol. 223 No. 4, pp. 497-512.
0.2
2x harmonic component of healthy shaft
Sekhar, A.S. and Srinivas, B.N. (2002), “Vibration
2x harmonic component of inverted cracked shaft characteristics of slotted shafts”, Journal of Sound and
0.1
0 30 60 90 120 150 180 210 240 270 300 330 Vibration, Vol. 251 No. 4, pp. 621-630.
Unbalance orientation angle (deg) Sinou, J.J. (2009), “Experimental response and vibrational
characteristics of a slotted rotor”, Communications in
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pp. 3179-3194.
Chen, D., Zhou, S., Dong, L. and Fan, J. (2016), “An
investigation into error source identification of machine tools Corresponding author
based on time-frequency feature extraction”, Shock and Bhumi Ankit Shah can be contacted at: bhumi.Ashah@scet.
Vibration, Vol. 2016. ac.in

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