International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)

Volume VII, Issue VI, June 2018 | ISSN 2278-2540

Vibration Analysis of Simple Rotor with Transverse

Crack
Sushmita P.1, Kiran Prasad D.2, Kishor Kumar K.Ch.3
1
PG Student, Gudlavalleru Engineering College, Gudlavalleru, Andhra Pradesh, India
2,3
Associate Professor, Department of Mechanical Engineering, Gudlavalleru Engineering College, Gudlavalleru, Andhra
Pradesh, India

Abstract - To examine the vibration characteristics of cracked a breathing crack model have been studied. An attempt has
rotor, a mathematical model for cracked shaft is developed and been made to reveal crack specific signatures by using
solved using matlab and simulink. The results are validated by additional external excitations. Qing He, Huichun Peng,
experimentation and using Ansys. A shaft with disk mounted Pengcheng Zhai, Yaxin Zhen [3] et.al. have taken the angular
between two bearings is used. An artificial crack is introduced to
acceleration into the consideration for the modeling of
detect the vibration characteristics of the rotor. Initially, the
signature data was obtained with no crack using spectrum equations of coupling vibration in rotational operation. The
analyzer. Later, crack was introduced with depths ranging from effects of angular acceleration on the amplitude of both lateral
2 mm to 8 mm with four steps on the rotor of 15 mm diameter. and torsion vibration of the breathing cracked rotor are
On observing the peak amplitudes of right and left bearings, a studied. Yan liLin , Fule Chu et.al.[4] analysed steady
difference in the values was observed. This indifference in the responses and indicated that the combined frequencies of the
magnitude of the peak amplitude is because of the combined rotating speed and the torsional excitation in the transversal
effect of coupling and position of the crack. A simplified model is response and the frequency of the torsional excitation in the
solved using ANSYS and the harmonic analysis was performed longitudinal response can be used to detect the slant crack on
for different combinations of crack depths and results were
the shaft of the rotor system. Rugerri Toni Liong , Carsten
obtained. The results obtained by using the three analysis
methods gives almost same peak amplitudes. Proppe [5] et.al. proposed a method for the evaluation of the
stiffness losses in the cross-section that contains the crack.
Key words: Cracked rotor, Spectrum Analyser, Harmonic This method is based on a cohesive zone model (CZM)
analysis , Vibration characteristics, peak amplitudes. instead of linear elastic fracture mechanics (LEFM).

I. INTRODUCTION The following aspects of the crack greatly influence the

dynamic response of the structure.

F laws in the components of a structure can influence the

dynamic behavior of the whole structure. It is well known
from the literature that one form of damage that can lead to
I.
II.
The position of crack
The depth of crack
catastrophic failure if undetected is fatigue cracking of the III. The orientation of crack
structure elements. The recognition of the vibration effects of IV. The number of cracks
cracks is important in practice since vibration monitoring has
revealed a great potential for investigation of cracks in the last II. PROBLEM DESCRIPTION AND ANALYSIS
three decades. Usually the physical dimensions, boundary PROCEDURE
conditions, the material properties of the structure play A rotor having Diameter D is considered for analysis. A
important role for the determination of its dynamic response. transverse surface crack of depth a, is assumed at the midspan
Their vibrations cause changes in dynamic characteristics of of the rotor. The crack is assumed to have a straight edge. The
structures. In addition to this presence of a crack in structures objective is to determine the effect of crack on the amplitude
modifies its dynamic behavior. of vibrations wrt the frequency. A mathematical model is
A.K. Darpe, K. Gupta, A. Chawla, et.al. [1] studied the effect developed and it is solved by writing mat lab code along with
of the presence of the single transverse crack on the response the simulink model. The analysis is performed using Ansys
of the rotor The results of the study are useful in diagnosing and the results are validated by conducting experimentation
fatigue cracks in real rotors, which invariably have some using FFT analyser.
asymmetry. A.K. Darpe, K. Gupta, A. Chawla, [2] studied the Mathematical model for Cracked Rotor
coupling between longitudinal, lateral and torsional vibrations
together for a rotating cracked shaft. Coupled torsional– Fracture mechanics concept is used to determine stress
longitudinal vibrations for a cracked rotor that has not been intensity factors (SIF ) at the crack and these SIFs are used in
reported earlier and coupled torsional–bending vibrations with solving the equations of motion. The crack model and
geometry are shown in Fig.1 and Fig.2.

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 International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VII, Issue VI, June 2018 | ISSN 2278-2540

Total deflection in both directions (ξ and η):

𝑄𝜉 𝐿3
𝑢𝜉 = + 𝑢𝜉
48𝐸𝐼
𝑄𝜉 𝐿3 2 8𝑄𝜉 𝐿𝛼′ 𝜋𝛼𝐹
= +
48𝐸𝐼 𝐸 𝜋𝐷4
16𝑄𝜂 𝐿𝜔 𝜋𝛼𝐹′ 8𝐿𝛼′ 𝜋𝛼𝐹
+ 𝑑𝛼𝑑𝜔
Fig.1 Transverse crack on rotor 𝜋𝐷 4 𝜋𝐷4
The stress intensity factor 𝐾1𝐼 on the crack is given by 𝑄𝜂 𝐿3
equation (1) 𝑢𝜂 = + 𝑢𝜂
48𝐸𝐼
𝐾𝑄𝜉 I = 𝜎𝜉 𝜋𝛼𝐹 1 𝑄𝜂 𝐿3
=
𝑄𝜉 𝐿 𝛼 ′ 48𝐸𝐼
4 2 2 8𝑄𝜉 𝐿𝛼′ 𝜋𝛼𝐹
𝑤ℎ𝑒𝑟𝑒 𝜎𝜉 = +
𝐼 𝐸 𝜋𝐷4
16𝑄𝜂 𝐿𝜔 𝜋𝛼𝐹′ 16𝐿𝜔 𝜋𝛼𝐹′
+ 𝑑𝛼𝑑𝑤
𝜋𝐷4 𝜋𝐷4
The equations of motion are

𝜉 − 2𝜂 + 2𝛾𝑃0 𝜉 + 𝜉 𝑃𝜉 2 − 1 + 𝜂 𝑃𝜉𝜂 2 − 2𝛾𝑃0 =

𝜀𝑐𝑜𝑠𝛽 − 𝑃0 2 𝑐𝑜𝑠𝜏 and

𝜂 − 2𝜉 + 2𝛾𝑃0 𝜂 + 𝜂 𝑃𝜂 2 − 1 + 𝜉 𝑃𝜉𝜂 2 + 2𝛾𝑃0

= 𝜀𝑠𝑖𝑛𝛽 − 𝑃0 2 𝑠𝑖𝑛𝜏
The above equations of motion are solved by writing matlab
Fig.2 Crack Geometry code and simulink model and the frequency Vs amplitude
plots for different crack depths are obtained.

𝑄𝜉 𝐿𝛼′
𝐾𝑄𝜉 I = 𝜋𝛼𝐹
8𝐼
The stress intensity factor in 𝜉 direction is given by equation
(2)

𝐾𝑄𝜂 I = 𝜎𝜂 𝜋𝛼𝐹 ′ 2
𝑄𝜂 𝐿
𝜔
4
Where 𝜎𝜂 = ,
𝐼

𝑄𝜂 𝐿𝜔
𝐾𝑄𝜂 I = 𝜋𝛼𝐹 ′
4𝐼
𝜋 Analysis using Ansys:
Where 𝐼 = 𝑑 4 and functions F and F’, which depend on
64
crack parameters α and α’, are given as under A Simple Rotor of length 0.4m length and diameter 0.02 m is
considered for analysis. Bearings are modeled at both the
𝜋𝛼 4
ends. Contact pair is used at contact surfaces between shaft
2𝛼 ′ 𝜋𝛼 0.923 + 0.199 1 − 𝑠𝑖𝑛 2𝛼′ and bearing surface . Tetrahedron 10 node 187 element is
𝐹= 𝑡𝑎𝑛 𝜋𝛼
𝜋𝛼 2𝛼′ 𝑐𝑜𝑠 used for meshing. Outer surface of bearings are constrained
2𝛼′ and angular velocity of rotating shaft is given as input so that
𝛼 𝜋𝛼 3
the centrifugal force is considered while performing analysis .
2𝛼 ′ 𝜋𝛼 0.752 + 2.02 𝛼′ + 0.37 1 − 𝑠𝑖𝑛 2𝛼′
𝐹′ = 𝑡𝑎𝑛 𝜋𝛼 Disc weight of 0.8 Kg is applied at 2 cm on the right side of
𝜋𝛼 2𝛼′ 𝑐𝑜𝑠
2𝛼′ the crack. Vibration analysis is completed for un cracked and

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 International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VII, Issue VI, June 2018 | ISSN 2278-2540

different crack depths of 2mm , 4 mm , 6 mm and 8 mm. with first bearing and wait for some time then FFT analyser
Frequency Vs amplitude plots are drawn for each case. gets the all information about the bearing.
1
VOLUMES
TYPE NUM
U
OMEG
MAR 14 2018
14:14:42

Fig.4 Crack in Rotor Shaft

Fig.3 Cracked Shaft Model

Experimental Procedure:
A 20mm diameter shaft with a length of 360mm is considered
for analysis. The machining operations like turning, facing,
finishing and parting off on the lathe machine are completed.
After completing all the machining operations the shaft
dimensions are shaft diameter 15mm and length of the shaft
350mm. Next step is preparation of crack on the shaft.
Preparation of crack with 0.2mm width is difficult task with
less cost. But for preparing the crack of different depths we
used jewel saw.
Another important aspect is the depth of the crack as depth
variations effect the amplitude of vibrations. Five shafts with Fig.5 Experimental Set up
the same dimensions are considered for experimentation. First
sample is shaft is without crack and then second shaft is with III. RESULTS
the crack depth of 2 mm. The depth of the shaft is measured By solving the mathematical model with the aid of simulink
with the help of tool makers microscope. The remaining three model frequency Vs Amplitude plot is drawn for crack depths
shaft are with 4mm,6mm and 8mm depths. After completing of 0 mm ( uncracked ) , 2mm , 4mm ,6 mm and 8 mm. Using
the five shafts with various crack depth with same width , we Ansys , the frequency Vs Amplitude plot is drawn for crack
proceeded to conduct experimentation with the FFT analyser . depths of 0mm ( uncracked ) , 2mm , 4mm ,6 mm and 8 mm.
FFT analyser means fast fourier transformer and it gives the Experimental results are also obtained for the above five
complete information of amplitudes, frequencies, velocity, cases. In experimental analysis , in addition to the frequency
acceleration with respect to time. For conducting the FFT Vs amplitude plots , time Vs plot amplitude plots are also
analyser test ,it requires electric motor, couplings with rubber taken for different crack depths. The results obtained are
bushes, two high speed steel ball bearings, table with grooves shown in figures given below.
which the two bearings and weight (800gm).Operational
producer for FFT analysers starts with shaft setting. First step
is inserting the shaft into the two bearings and adjust the
length between the two bearings and place a disc having
weight of 800gm at a place of 2cm right from the crack. Next
step is to fix the two bearings in the grooves with the help of
nuts and bolts. After completing all the arrangements related
to shaft setting , experimentation starts with starting the
electric motor and regulate the speed slowly up to the fixed
speed of 1000rpm. Contactless tachometer is used to observe
the speed. The FFT analyser consists of magnetic probe.
When using the FFT analyser , the magnetic probe is attached
Fig.6 Frequency Vs Amplitude plot and Time Vs Amplitude plot for
uncracked shaft

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 International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VII, Issue VI, June 2018 | ISSN 2278-2540

1
POST26
AMPLITUDE MAR 14 2018
U_9 23:12:50

.27

.243

.216

.189

.162

Amplitude .135

.108

.081

.054

.027

0
0 200 400 600 800 1000
100 300 500 700 900
Frequency

Fig.7 Frequency Vs Amplitude plot and Time Vs Amplitude plot for

uncracked shaft (Left bearing )-Using ANSYS
Fig.11 Frequency Vs Amplitude plot for 2mm cracked shaft (Left bearing)-
Using MATLAB code and SIMULINK

Fig.8 Frequency Vs Amplitude plot and Time Vs Amplitude plot for

uncracked shaft (Left bearing )-Using MATLAB code and SIMULINK

Fig.12 Frequency Vs Amplitude plot for 4mm cracked shaft (Left bearing)-
Experimental analysis
1
POST26
AMPLITUDE MAR 14 2018
U_11 23:27:43

1.2

1.08

.96

.84

.72

Amplitude .6

.48

.36

.24

.12

0
0 200 400 600 800 1000
100 300 500 700 900
Frequency

Fig.9 Frequency Vs Amplitude plot for 2mm cracked shaft (Left bearing )-
Experimental Analysis
Fig.13 Frequency Vs Amplitude plot for 4mm cracked shaft (Left bearing)-
1
POST26 Using ANSYS
AMPLITUDE MAR 14 2018
U_8 23:20:54

.7

.63

.56

.49

.42

Amplitude .35

.28

.21

.14

.07

0
0 200 400 600 800 1000
100 300 500 700 900
Frequency

Fig.10 Frequency Vs Amplitude plot for 2mm cracked shaft (Left bearing)-
Using ANSYS Fig.14 Frequency Vs Amplitude plot for 4mm cracked shaft (Left bearing)-
Using MATLAB code and SIMULINK

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 International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VII, Issue VI, June 2018 | ISSN 2278-2540

1
POST26
AMPLITUDE MAR 14 2018
U_9 23:36:06

1.8

1.62

1.44

1.26

1.08

Amplitude .9

.72

.54

.36

.18

0
0 200 400 600 800 1000
100 300 500 700 900
Frequency

Fig.19 Frequency Vs Amplitude plot for 8 mm cracked shaft (Left bearing)-

Fig.15 Frequency Vs Amplitude plot for 6mm cracked shaft (Left bearing)- Using ANSYS
Experimental
1
POST26
AMPLITUDE MAR 14 2018
U_8 23:31:59

1.4

1.26

1.12

.98

.84

Amplitude .7

.56

.42

.28

.14

0
0 200 400 600 800 1000
100 300 500 700 900
Frequency

Fig.20. Frequency Vs Amplitude plot for 8 mm cracked shaft (Left bearing)-

Using MATLAB code and SIMULINK.
Fig.16 Frequency Vs Amplitude plot for 6mm cracked shaft (Left bearing)-
Using ANSYS

Fig.21. Frequency Vs Amplitude plot for uncracked shaft (Right bearing )-

Fig.17 Frequency Vs Amplitude plot for 6mm cracked shaft (Left bearing)- Experimental Analysis.
Using MATLAB code and SIMULINK
1
POST26
AMPLITUDE MAR 14 2018
U_10 23:43:21

1.2

1.08

.96

.84

.72

Amplitude .6

.48

.36

.24

.12

0
0 200 400 600 800 1000
100 300 500 700 900
Frequency

Fig.22.Frequency Vs Amplitude plot for uncracked shaft (Right bearing )-

Fig.18 Frequency Vs Amplitude plot for 8 mm cracked shaft (Left bearing)- Using ANSYS.
Experimental analysis

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 International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VII, Issue VI, June 2018 | ISSN 2278-2540

Fig.27.Frequency Vs Amplitude plot for 4mm cracked shaft (Right bearing )-

Fig.23. Frequency Vs Amplitude plot for uncracked shaft (Right bearing )- Experimental Analysis.
Using MATLAB code and SIMULINK 1
POST26
AMPLITUDE MAR 14 2018
U_8 23:51:53

1.8

1.6

1.4

1.2

Amplitude 1

.8

.6

.4

.2

0
0 200 400 600 800 1000
100 300 500 700 900
Frequency

Fig.24. Frequency Vs Amplitude plot for 2mm cracked shaft (Right bearing )-
Fig.28. Frequency Vs Amplitude plot for 4mm cracked shaft (Right bearing )-
Experimental Analysis
Using ANSYS.
1
POST26
AMPLITUDE MAR 14 2018
U_8 23:48:23

1.2

1.08

.96

.84

.72

Amplitude .6

.48

.36

.24

.12

0
0 200 400 600 800 1000
100 300 500 700 900
Frequency

Fig.25. Frequency Vs Amplitude plot for 2mm cracked shaft (Right bearing )-
Using ANSYS Fig.29.Frequency Vs Amplitude plot for 4mm cracked shaft (Right bearing )-
Using MATLAB code and SIMULINK.

Fig.26.Frequency Vs Amplitude plot for 2mm cracked shaft (Right bearing )- Fig.30.Frequency Vs Amplitude plot for 6 mm cracked shaft (Right bearing)-
Using MATLAB code and SIMULINK. Experimental Analysis.

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 International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VII, Issue VI, June 2018 | ISSN 2278-2540

1
POST26
AMPLITUDE MAR 14 2018
U_8 23:55:53

1.8

1.6

1.4

1.2

Amplitude 1

.8

.6

.4

.2

0
0 200 400 600 800 1000
100 300 500 700 900
Frequency

Fig.31. Frequency Vs Amplitude plot for 6 mm cracked shaft (Right bearing)- Fig.33. Frequency Vs Amplitude plot for 8 mm cracked shaft (Right bearing)-
Using ANSYS. Experimental Analysis
1
POST26
AMPLITUDE MAR 14 2018
U_8 23:59:55

1.8

1.6

1.4

1.2

Amplitude 1

.8

.6

.4

.2

0
0 200 400 600 800 1000
100 300 500 700 900
Frequency

Fig.32.Frequency Vs Amplitude plot for 6 mm cracked shaft (Right bearing)- Fig.34. Frequency Vs Amplitude plot for 8 mm cracked shaft (Right bearing)-
Using MATLAB code and SIMULINK Using ANSYS

Fig.35. Frequency Vs Amplitude plot for 8 mm cracked shaft (Right bearing )-Using MATLAB code and SIMULINK.

IV. COMPARISON OF MAXIMUM AMPLITUDE

Max. Amplitudes (Left Bearing) Max. Amplitudes (Right Bearing)

mm mm
S No. Crack Depth
Mathematical Mathematical
Experimental Ansys Experimental Ansys
Model Model
1 Without crack 0.28 0.26 0.27 1.03 1.02 1.04
2 2mm 0.63 0.65 0.66 1.21 1.2 1.22
3 4mm 1.09 1.1 1.2 1.65 1.64 1.66
4 6mm 1.23 1.22 1.25 1.66 1.68 1.67
5 8mm 1.69 1.71 1.68 2.01 1.97 2

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 International Journal of Latest Technology in Engineering, Management & Applied Science (IJLTEMAS)
Volume VII, Issue VI, June 2018 | ISSN 2278-2540

V. CONCLUSION transverse breathing crack, Engineering Failure Analysis, 51 ,

2016, 1-15
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give approximately same maximum amplitudes. It is also [7]. Huichun Peng, Qing He , Pengcheng Zhai, Yaxin Zhen,
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rotational damping in rotating operation, Applied Mathematical
crack depth increases. Modeling ,45 ,2017, 405–421
[8]. Oh Sung Jun, Mohamed S. Gadala, Dynamic behavior analysis
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