Simple Rotor Analysis Through Tutorial Problems 1st Edition Rajiv Tiwari - The ebook in PDF format with all chapters is ready for download
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Simple Rotor Analysis Through Tutorial Problems 1st
Edition Rajiv Tiwari Digital Instant Download
Author(s): Rajiv Tiwari
ISBN(s): 9781032555560, 1032555564
Edition: 1
File Details: PDF, 23.54 MB
Year: 2023
Language: english
Simple Rotor Analysis through
Tutorial Problems
This book discusses various rotor systems, rotor dynamics and dynamics of rotating machinery
problems through tutorials. Most of the covered problems can be derived and solved using hand
calculations for deeper understanding of the subject. It correlates the examples provided in this
book with real machinery where it can be used, and readers can analyse their own simple rotor
system based on the variety of examples presented. All problems are supplemented by independent
MATLAB® codes for exploring the subject with more ease with graphical outputs.
Features:
• Rotordynamics terminology and phenomena are introduced with very simple rotor-bearing
models.
• In-depth analytical dynamic analysis of rotors mounted in flexible bearings and the effect
of gyroscopic effects in simple rotor systems are covered.
• Offers the possibility for the reader to reproduce the results and see how the equations are
derived and solved in rotor dynamics.
• A few examples of simple rotor-bearing-coupling systems, rotor-bearing-foundation sys-
tems, and two-spool rotors are covered.
• Directions are provided to extend the present exercise problems and their solutions.
• Examples are supplemented by MATLAB® codes with detailed solution steps.
• Includes multiple-choice questions and their solutions.
Rajiv Tiwari
MATLAB ® is a trademark of The MathWorks, Inc. and is used with permission. The MathWorks does not warrant the
accuracy of the text or exercises in this book. This book’s use or discussion of MATLAB ® software or related products
does not constitute endorsement or sponsorship by The MathWorks of a particular pedagogical approach or particular
use of the MATLAB ® software.
Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot
assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers
have attempted to trace the copyright holders of all material reproduced in this publication and apologize to
copyright holders if permission to publish in this form has not been obtained. If any copyright material has not been
acknowledged please write and let us know so we may rectify in any future reprint.
Except as permitted under U.S. Copyright Law, no part of this book may be reprinted, reproduced, transmitted, or
utilized in any form by any electronic, mechanical, or other means, now known or hereafter invented, including
photocopying, microfilming, and recording, or in any information storage or retrieval system, without written
permission from the publishers.
For permission to photocopy or use material electronically from this work, access www.copyright.com or contact the
Copyright Clearance Center, Inc. (CCC), 222 Rosewood Drive, Danvers, MA 01923, 978-750-8400. For works that are
not available on CCC please contact [email protected]
Trademark notice: Product or corporate names may be trademarks or registered trademarks and are used only for
identification and explanation without intent to infringe.
DOI: 10.1201/9781032638218
Typeset in Times
by codeMantra
Contents
Preface..............................................................................................................................................vii
About the Author...............................................................................................................................ix
Introduction........................................................................................................................................xi
Index............................................................................................................................................... 267
v
Preface
This tutorial book is of its first kind in the field of rotor system, rotor dynamics, or the dynamics
of rotating machinery. Hardly any tutorial book is available on this topic, so definitely students,
researchers and practice engineers, who are new in this field, will welcome this introductory book
very well. An attempt is made to correlate examples provided in this book with real machinery,
where it has an application. Readers can analyse their own simple rotor system based on a variety
of examples presented in this book. Also, every chapter is supplemented with a large amount of
multiple-choice questions (MCQs) and their descriptions, so that basic concepts can also be clarified
in a capsule form.
The basic idea of writing this book in the form of solution to various exercise problems is that
certain problem-solving skills cannot be described in a textbook in a detailed manner. Especially in
the rotor system, a lot of concepts can be understood when a variety of different cases are attempted
numerically. In this, the approach is not only to reach the end of solution but to try to discuss
and have the possibility of exploring more concepts and methods during the process of solving it.
Moreover, almost all problems are supplemented by MATLAB codes for exploring the subject with
more ease with graphical outputs whenever it is necessary (Additional resources can be found for
this publication at: https://www.routledge.com/authors/i16997-rajiv-tiwari). As a cautionary note,
these computer codes are not general codes. These help to avoid tedious calculations and to under-
stand step-by-step calculations more easily. Especially, if readers want to try out different numerical
inputs of rotor configuration, then it is quite a time-saving exercise without such codes.
In this book, detailed steps are provided so that concepts can be understood more easily.
Exploring more on the exercise problems through MATLAB codes so that one should not get stuck
in the calculation of numbers. Graphical as well as detailed output of each step help in checking
and comprehending the overall procedure. Throughout this book, it is ensured to make a point to
the reader to give some hints in which direction they can explore more on a given exercise problem,
and it broadens the thinking of reader so that they themselves can formulate new exercise problems
and explore them with an understanding of the exercises presented herein. Wherever needed, the
problem has been attempted with a fundamental approach, and the necessary background is covered
so that reader should not feel gaps in grasping the concepts. However, a detailed and comprehensive
coverage of related theory is given in my previous book Rotor System: Analysis and Identification
by CRC Press, Boca Raton, USA, 2017.
Rotor systems have a lot of practical applications in all fields of industries. Rotor system theories
have evolved through solving practical problems using simple mathematical models of various
kinds of rotor systems. This tutorial book covers simple aspects of rotor systems, especially for
linear analysis. This book begins with historical background and basic terminologies in rotor-
bearing systems in Chapter 1 and then analysis of very simple rotor systems in Chapter 2 for the
transverse vibration. Chapter 3 covers rolling element bearings (with some advanced analysis) and
hydrodynamic bearings to have a theoretical calculation of stiffness and damping for rotordynamic
analyses. Chapter 4 covers simple rigid/flexible long rotor mounted on flexible bearings/foundations
to obtain critical speeds. The most important aspect of the gyroscopic effect on simple rotor systems
is analysed in Chapter 5 using both quasi-static and dynamic approaches. Overall, this book con-
tains around 110 Exercise Problems (a few of them descriptive) and 150 MCQs.
The author would like to acknowledge the contribution of various undergraduate, graduate and
research scholar at IIT Guwahati who undertook this particular course on rotor dynamics dur-
ing the past two and half decades. My heartfelt thanks to the help offered by the graduate stu-
dents (notably Mr. Aakash Dewangan, Mr Shashikant K. Verma, Mr Thashreef A., Ms. Twinkle
Mandawat, Ms. Beni J. Doley, Mr Manpreet Singh and Mr. Aditya S. Gangan), research scholars
(Dr Gyan Ranjan, Mr Pantha Pratim Das, Mr Atul K Gautam, Dr Siva SrinivasR, Dr Nilakshi
vii
viii Preface
Sarmah, Dr Prabhat Kumar and Dr D. Gayen) and the faculty at IIT Guwahati. I thank my
gurus (Prof. (Late) J. S. Rao, Prof. K. Gupta, Prof. N. S. Vyas, Prof. M. I. Friswell, Prof. A. W.
Lees, Dr. Arun Kumar and Prof. R. Markert) who introduced me to this subject and aspire me
to excel in this field). I also acknowledge faculties (Prof. Jyoti K Sinha, Prof. Hassan Ouakad,
Prof. Athanasios Chasalevris, Prof. F. Dohnal and Prof. Raghu Echempati), researchers and
practice engineers (Dr. Soumendu Jana and Mr San Rajendra) who approached me for their
own issues related to this topic or interacted with them during conferences, and that gave me a
broader perspective of the subject, which is reflected in this book during the illustration of v arious
examples. The difficult period of lock-down, during COVID-19 pandemic, forced me to com-
plete this book early. I thank the publishing house (Dr. Gagandeep Singh, Senior Publisher, and
Ms. Aditi Mittal, Editorial Assistant, (she/her) of CRC Press, Taylor and Francis Books India Pvt.
Ltd.; Aimée Crickmore (she/her), Production Editor from Taylor & Francis, UK and Sathya Devi
(she/her), Production Manager from CodeMantra, India) and its very efficient members for bringing
out this book in a very short time and improving the overall quality of this book through rigorous
editing. Finally, I thank my family members – my wife Vibha, son Antariksh and daughter Rimjhim
– for their patience and supportive nature.
R. Tiwari
About the Author
Dr. Rajiv Tiwari was born in 1967 at Raipur, Madhya Pradesh,
India. He graduated with a BE in 1988 (Mechanical Engineering)
from Government College Engineering and Technology, Raipur,
under Pt. Ravishankar University, Raipur, an M. Tech. (Mechanical
Engineering) in 1991 and a PhD (Mechanical Engineering) in
1997 from the Indian Institute of Technology (IIT) Kanpur, India.
He started his career as a lecturer in 1996 at Regional
Engineering College, Hamirpur (Himachal Pradesh), India, and
worked there for 1 year. In 1997, he joined the Indian Institute of
Technology Guwahati, as an assistant professor in the Department
of Mechanical Engineering. He worked as a research officer at
the University of Wales, Swansea, UK, for 1 year in 2001 on
deputation. He was elevated to associate professor in 2002 and
to Professor in 2007 at IIT Guwahati. He was the head of the
Center of Educational Technology and Institute Coordinator of
the National Programme on Technology Enhanced Learning (NPTEL) during 2005–2009, and the
National Coordinator of the Quality Improvement Programme (QIP) for engineering college teach-
ers during 2003–2009. He also visited the University of Darmstadt, Germany, under DAAD fellow-
ship during May–July 2011.
He has been deeply involved in various research areas of rotordynamics, especially identifying
mechanical system parameters (e.g. bearings, seals, gears and rotor crack dynamic parameters), diag-
nosing the faults of machine components (e.g. bearings, couplings, gearbox, pumps and induction
motors) and applying active magnetic bearings to monitoring the condition of rotating machinery.
His research areas also include rolling element bearing design and analysis for high-speed applica-
tions. He has completed three projects for the Aeronautical Research & Development Board (ARDB),
India, on these topics. He has been offering consulting services for the last several years to Indian
industries, like the Indian Space Research Organisation (ISRO), Trivendrum; Combat Vehicle
R&D Establishment (CVRDE), Chennai; Gas Turbine Research Establishment (GTRE) Bangalore,
National Bearings Company Ltd. (NBC) Jaipur, and Tata Bearings, Kharagpur, as well as other
local industries in the northeast of India. One of the European power industries, Skoda Power, Czech
Republic, has also consulted him on seal dynamic parameter estimates for steam turbine applica-
tions. Dr. Tiwari has authored more than 250 journal and conference papers. He has guided 57 M.
Tech. students, and 17 PhD students and 7 more are currently pursuing research projects.
He has successfully initiated and organised a national-level symposium on rotor dynamics (NSRD-
2003), four short-term courses on rotor dynamics (2004, 2005, 2008 and 2015) and a national work-
shop on “Use and Deployment of Web and Video Courses for Enriching Engineering Education”
(2007) at IIT Guwahati, India. He has jointly organised an International Conference on Vibration
Problems ICOVP 2015 at IIT Guwahati, Vibration Engineering and Technology of Machinery
(VETOMAC-2021) jointly with BMS College of Engineering, Bengaluru, VETOMAC-2022 with
Tribhuvan University, Nepal and VETOMAC-2023 with Indian Institute of Technology Roorkee.
He has developed two web- and video-based freely available online courses under NPTEL: (1)
Mechanical Vibration and (2) Rotor Dynamics, and under MHRD-sponsored virtual lab on the
“Mechanical Vibration Virtual Lab.” He has authored a textbook on Rotor Systems: Analysis and
Identification from Taylor & Francis Group, CRC Press, USA, 2017. For consecutively last 3 years
ix
x About the Author
(2020 through 2023), Prof. Tiwari has been featured among World’s Top 2% Scientists List cre-
ated by Stanford University. He has recently joined as Associate Editor to the Journal of Vibration
and Control (JVC), Sage Publications, and Journal of Vibration Engineering and Technology
(JVET), Springer. Nature Publications. Also, now he is in Worldwide Technical Committee on
Rotor Dynamics of International Federation of Machines and Mechanisms (IFToMM). Recently, he
has been included in The Bearings Sectional Committee, PGD 13, of Bureau of Indian Standards
(BIS), which is responsible for the development of the national and international standards on the
‘Magnetic Bearings’, 'Aerospace Bearings' and 'Railway Bearings’.
Introduction
Rotor systems are known for high-power density with minimum vibrational energy, which makes
them quieter as compared to reciprocating machines. Hence, as compared to reciprocating machines,
the rotating machines are preferred for high-speed applications. The application of rotating machin-
ery can be found in a variety of places, such as engines, turbines, generators, pumps, compressors,
machine tools, dredgers, reaction flywheels, energy storage flywheels, mobiles, etc.
The reciprocating engines are preferred since they have internal combustion as compared to
turbines, which have external combustion. The reciprocating pumps have applications for high-
pressure generation, while centrifugal pumps have applications where high volumes need to be
pumped. Apart from these in transmission systems, the rotating machinery has advantages, which
involve shafts, bearings, couplings, gears, seals, flywheels, etc.
Due to the dynamic nature of the rotor systems apart from the static design, the dynamic design
is also very important, especially with respect to critical speeds and instability conditions. The vast
majority of the analysis involves finding the natural frequencies of the rotor system in the trans-
verse, axial and torsional vibrations. Sources of instabilities in rotor systems are several, and the
most common source is fluid-film bearings. Apart from this, the instability comes from seals, shaft
asymmetry, rotor asymmetry, shaft material damping, bearing cage instability, etc. To perform such
analysis, the rotor systems need to be modelled. As compared to the structural vibration, the rotor
system differs due to gyroscopic effects, which makes the rotor whirl in the same direction as the
spin speed of the rotor (i.e., forward whirl) and in the opposite direction (i.e., the backward whirl),
along with associated whirl natural frequencies and critical speeds. The scope of this book is lim-
ited to simple rotor analysis for its dynamics.
xi
1 A Brief History of Rotor Systems
and Basic Terminologies
Exercise 1.1 Who was the famous person in 1869 who first analysed the rotor dynamics problem
but wrongly predicted that it is impossible to operate industrial rotors at very high speeds?
Solution: He was a famous Scottish mechanical engineer William John Macquorn Rankine (5 July
1820–24 December 1872). He predicted critical speed correctly by equating elastic force kx to
centrifugal force mrω 2 of a whirl mass, m, attached by a spring, k, at a radius of r. The condition
that these two forces are equal gives the critical speed condition ω2 = k/m. Since centrifugal force is
proportional to the square of spin speed so he concluded that response will grow (unbounded) after
critical speed. However, considering centrifugal force or Coriolis force as real force, it gives errone-
ous results (Meriam and Kraige, 2013) and he predicted instability above critical speed (supercriti-
cal speeds). Detailed discussion can be found in Vance et al. (2010) and Tiwari (2017).
Exercise 1.2 Who was the first engineer who experimentally demonstrated and reported that it was
possible to rotate the rotor safely at very high speeds?
Solution: Gustaf de Laval, a Swedish engineer, ran a steam turbine to supercritical speeds in 1889
in a stable condition. However, this critical speed invension was contrary to Rankine’s prediction,
i.e. unstable regimes at supercritical speeds.
Exercise 1.3 Who clarified theoretically the confusion of whether it is possible to rotate the rotor
safely above critical speeds?
Solution: Jeffcott (1919) developed a simple rotor model to clarify that it is possible to rotate the
rotor safely above critical speeds. In honour of his name, the rotor model is now called as Jeffcott
rotor model. Herein, he first published a clear understanding of rotor behaviour due to unbalance
in the presence of damping using a mathematical model. The model consists of a massless flexible
shaft simply supported at ends, and a rigid disc is mounted at its mid-span (Figure 1.1). Variant of
Jeffcott rotor model in various ways has been extensively used by many researchers to understand
several rotordynamic phenomena, and it is still being used for newer investigations. Already, more
than 100 years have passed since the publication of this classical paper.
Exercise 1.4 Who were the first to use the terms the whirling motion and the critical speed?
Solution: Rankine first used the term whirling motion (refer Figure 1.2) and Dunkerley used the
term critical speed. Dunkerley (1894) showed that the critical speed of a rotating simply supported
shaft and its natural frequency of transverse vibration are same. Relations of two different motions
DOI: 10.1201/9781032638218-11
2 Simple Rotor Analysis through Tutorial Problems
were provided, i.e. the former as orbital motion and the latter as oscillatory motion. He clarified that
any unbalance would give force, which will excite natural frequency to give resonance condition of
critical speeds, a synchronous whirl condition.
Exercise 1.5 Define the natural frequency and the critical speed of a rotor system.
Solution: The natural frequency is a system property and depends upon the system stiffness and
the mass distribution. When a dynamic system is given perturbation, it oscillates with a frequency
equal to its natural frequency. Rotors can have the longitudinal (axial), transverse (bending) and/or
torsional natural frequencies depending on the application in which they are used and their associ-
ated inertia and stiffness distribution.
In a rotor, due to unbalance, it gets a force called centrifugal force with an excitation frequency
equal to its spin speed. When the spin speed coincides with the natural frequency of the system, it
is called the critical speed (refer Figure 1.3). It is a resonance condition. In general, a rotor can have
longitudinal (axial), transverse (bending) and torsional critical speeds.
Exercise 1.6 How many transverse critical speeds would there be for a two-disc (point masses),
massless-flexible shaft rotor system?
Solution: There will be two transverse critical speeds for a two-disc (point masses) massless-flex-
ible shaft rotor system. It will have two degrees of freedom (DOFs) corresponding to transverse
FIGURE 1.3 Plot of rotor amplitude with spin speed showing critical speed corresponding to peak amplitude.
A Brief History of Rotor Systems and Basic Terminologies 3
FIGURE 1.4 Variation of amplitude and phase with spin speed of the shaft showing (a) two critical speeds
and (b) associated phase changes.
translational motion. If the discs are thin discs, then they will have four critical speeds since they
will have diametral mass moments of inertia and will have four DOFs corresponding to transverse
translational and rotational motions. A typical Bode plot showing two critical speeds is shown in
Figure 1.4. At critical speeds, the phase change of order of π rad can be seen.
Exercise 1.7 Is natural frequency dependent on the spin speed of the rotor? If yes, then under what
conditions?
Solution: If we consider the gyroscopic effect, then the natural frequency of the rotor will depend
upon the spin speed. Apart from this, often bearing dynamic parameters are speed-dependent (e.g.
the hydrodynamic bearings) and that makes natural frequency dependent on the rotor spin speed.
Exercise 1.8 What is the most common cause of a synchronous motion in a rotor system?
Solution: In the synchronous motion of the shaft, the orbital speed and its own spin speed are
equal. The sense of rotation of the shaft spin and the whirling are also the same. The unbalanced
force, in general, leads to synchronous whirl condition. Such force gives basically a forced response.
Under this motion, the shaft will not have flexural vibration but whirls as a rigid body about the
bearing axis.
Exercise 1.10 For a perfectly balanced rotor rotating at a speed, what is the frequency of whirl
when it is perturbed from its equilibrium?
Solution: Since no external force is present hence it will whirl (vibrate) at its natural frequency.
Exercise 1.12 Do bearings and foundations have any effect on the critical speed of a rotor system?
Solution: Bearings give stiffness and damping to the rotor system, and foundations give mass,
stiffness and damping to the rotor system. So, yes, they affect the critical speed of a rotor system.
We will see them in Chapter 4 through some simple examples.
Exercise 1.13 What is the internal and external damping in a rotor system?
Solution: If the energy dissipation is due to the external interactions of the system like viscosity
and from drag then it is called the external damping. The direction of external damping does not
change with the rotor speed.
If the energy dissipation is due to the internal interactions of the rotor system, like internal fric-
tion between the inter-molecular layers (or between disc and shaft interface or shaft crack faces rub-
bing together) as a result of differential straining, then it is called the internal damping (or material
(hysteretic) damping). The direction of internal damping does change with the rotor speed, and this
may lead to instability in the system.
Exercise 1.14 How do you distinguish between rigid and flexible rotors?
Solution: When the rotor rotates much below its first critical speed, it is considered a rigid rotor.
But when it rotates near or above its first critical speed, it is considered as the flexible rotor. Near
or above critical speed, flexible mode of vibration of rotor shafts are present and that has the effect
of changing unbalanced force distribution in the rotor system. Due to this the balancing of the rigid
and flexible rotors are quite different. In a rigid rotor case for dynamic balancing, only two balanc-
ing planes are sufficient, but in the case of a flexible rotor, it requires more than two balancing
planes, depending on the speed of operation.
Exercise 1.15 Is there any difference between rigid and flexible rotor dynamic balancing?
Solution: In general, two-plane balancing is used in the case of rigid rotors, and (N + 2) balancing
planes are used in the case of flexible rotor system, where N is the number of natural modes that
we want to balance. As mentioned in the answer to Exercise 1.14, the balancing force changes with
vibration mode of rotor, so rigid and flexible rotor balancing have differences.
Exercise 1.17 Explain the inertia asymmetry and shaft asymmetry in a rotor system. What are the
effects of these asymmetries on rotor behaviour?
Solution: When inertias of rotor system in two principal radial directions are different (e.g., bladed
disc), then it is called inertia asymmetry. Whereas, when the stiffness of the shaft system in two
principal radial directions is different (e.g., non-circular shaft), it is called stiffness asymmetry.
Both asymmetries give time-dependent system parameters and that leads to parametrically excited
rotor systems. Such systems are prone to instability.
Exercise 1.18 What are the different active control mechanisms that can be applied in rotor systems?
Solution: In general, for suppressing excessive vibrations, dampers are used in rotor systems.
Electrorheological and magnetorheological fluids are often used for active control of rotor. Such
fluid damping properties can be changed by supplying appropriate electric or magnetic field in very
short time. Active magnetic bearings, which are non-contact type bearings, are being used to pro-
vide not only variable damping but stiffness based on feedback of rotor vibrations.
Exercise 1.19 Splitting of whirl natural frequencies occurs due to which factors in rotor systems?
Solution: Commonly due to gyroscopic effect the rotors have the forward and backward whirls
(refer Figure 1.5). Since the gyroscopic effect changes with the spin speed of the shaft, it is found
that the whirl frequency of the rotor systems has splitting behaviour; one increases with speed and
another decreases with speed. The one that increases is called the forward whirl, and the one that
decreases is called the backward whirl. Such behaviour can be seen when bearings have anisotropy
or rotor/shaft have asymmetry (either of inertia of rotor or stiffness of shaft), for example, a trans-
verse crack on the shaft surface.
FIGURE 1.5 A typical Campbell diagram for the rotor system showing variation of whirl natural frequency
with the spin speed of the shaft also showing critical speeds at intersection points (solid line: forward whirl,
dashed line: backward whirl).
6 Simple Rotor Analysis through Tutorial Problems
Exercise 1.23 What is the curve veering in the Campbell diagram? Why does it happen in rotor-
bearing systems?
Solution: Campbell diagram shows the whirl frequency variation with the spin speed of the rotor.
In general, these whirl frequency curves do not intersect. However, in special cases, these do appear
to intersect, but they swap the whirl frequency at the point of intersection (i.e., two modes form a
coupled system and the curves repel each other, avoiding an intersection). Mathematically, it is the
so-called curve veering in the eigenvalue problem.
Figure 1.6 shows a typical Campbell diagram with curve veering phenomenon, on which solid
lines are for forward whirl and dashed lines for backward whirl. At intersection point of two
frequency curves, swapping of the forward and backward whirl can be seen.
A Brief History of Rotor Systems and Basic Terminologies 7
FIGURE 1.6 Campbell diagram showing curve veering phenomenon at intersection points of natural fre-
quency curves.
i. In a rotor system, the whirl natural frequency depends on the spin speed of the rotor due to
A. Gyroscopic couple only
B. Fluid-film bearing only
C. Both gyroscopic couple and fluid-film bearing
D. Whirl natural frequency does not depend on the spin speed of the rotor
CHAPTER XXII.
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