Full Rubs, Bouncing and Quasi Chaotic Orbits in Rotating Equipment

by
F. K. CHOY, J. PADOVAN

and

J.

C.

YU

Department U.S.A.

of Mechanical

Engineering,

University

of Akron,

Akron,

OH 44313,

ABSTRACT : In order to improve performance, closer tolerances are usually required in high performance turbomachinery. This often results in an increase in rotor casingJrea1 rub sensitivities. The objective of this paper is to investigate the eflects of mass, support sti@ess and blade sttjrness during a rotor-casing rub event. Special emphasis will be given to de$ning the tuningldetuning effects of the system during such variations in mass and sttj%ess. The overall model will incorporate the influence of: (i) casing and rotor inertia, (ii) casing and rotor support stt@tess, (iii) contact friction induced during rub interaction, (iv) single and multiple blade contact, as well as (v> lateral and radial blade st@ness eflects. The main thrust will be to investigate the dtyerent regimes of rubbing, i.e. the development of full rubs, rigid bouncing and essentially chaotic behavior due to the changes in rotor-to-casing mass and sttjrness ratios, as welI as blade sttjrness andfriction efSects.

Nomenclature

C CC
E e, (f;,) c G)c (.L) R F)n P;;, (F,)c (F,.), (FJR (F,)R I KC K I m, m, (C)c (t)c

casing damping coefficient shaft equivalent damping coefficient blade Youngs modulus rotor eccentricity rub forces exerted in the casing radial direction rub forces exerted in the casing transverse direction rub forces exerted in the rotor radial direction rub forces exerted in the rotor transverse direction normal rub force tangential friction force between the tip and the casing casing external load in X-direction casing external load in Y-direction rotor external load in X-direction rotor external load in Y-direction moment of inertia stiffness of casing support shaft equivalent stiffness blade radial length casing mass rotor mass unit vector for casing radial direction unit vector for casing transverse direction

I The Franklin Instaute 0016 0032!YO $3 OO+O.OO

25

F. K. Choy et al. unit vector for rotor radial direction unit vector for rotor transverse direction
rotor center angular precession acceleration phase angle between timing mark and rotor mass center blade radial deflection casing motion vector rotor motion vector mass center phase angle frictional coefficient between blade tip and casing casing precession angle angle between casing motion vector and relative motion vector rotor center precession angle angle between rotor motion vector and relative motion vector rotational speed of rotor I. Introduction In recent years increased attention has been given to analysing the dynamics of rub interactions in high performance rotating equipment, i.e. turbines, pumps etc. To improve performance, closer tolerance is typically required. This has led to increased rub sensitivities. In studies to date prototypically the rub interaction models have either considered the casing as rigid (l-lo), or as purely an elastically supported structure (6,11,12). Such assumptions do not account for the potential tuning/detuning effects of casing inertia. In the context of the foregoing, this paper will consider the effects of casing inertia on the overall rotor-bladecasing interaction problem. Special emphasis will be given to defining the tuning/detuning effects. Overall, the model will incorporate the influence of

(i) (ii) (iii) (iv) (v)

casing and rotor inertia, casing and rotor support stiffness, contact frictions induced during rub, single and multiple blade contact, as well as lateral and radial blade stiffness effects.

To gain a thorough understanding of the overall influence of casing mass, a wider ranging parametric study is presented. This considers system sensitivity to variations in (i) rotor/casing mass ratio, (ii) rotor/casing stiffness and (iii) blade stiffness and friction

effects. full rubs,

Special emphasis will be given to ascertain parameter ranges wherever rigid bouncing and essentially chaotic behavior are noted. In the sections which follow, detailed discussions are given on

(0 model development, (ii) solution procedure and (iii) the system response to wide-ranging
26

parameter

variations.
Journal

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Chaotic Behavior in Rotating II. Equations of Motion

Equipment

For the rotor/casing system shown in Fig. 1, the equations of motion can be developed for both rotor and casing motion (4,5, 9) independently when no rub interaction occurs. The rotor equation can be written in the radial and transverse coordinates shown in Fig. 2 as: (ir), direction rn,(Jr -@S,) : + C,B, + K,6, = m,eu { o(cos - a(cos 0 sin O, -sin and (i,J R direction m,(6,6, : 0 cos @, - cos 0 sin B,,) (2) 9 cos Q, + sin 8 sin ar)

8 cos Qr)> + (F.JR cos @,+ (F,)R sin QD, (1)

+ 2&J,) + C,&,S, = m,e,(m2(sin

-cz(sin6sin@,,+cos8cos@~)}-(F,),sin<D,+(FY),coscD,. Similarly, the casing equations and transverse directions as : (ir)c direction : m,.(J<- @S,.) + CJ,. + K,6, = (F-J,. cos Qc+ (I$), sin @c ; of motion

can also be written in the casing radial

(3)

FIG. 1. Simplified rotor-bearingxasing

Vol 32:. No. 1, pp. 2547, Prmted in Great Bntam 1990

model 27

F. K. Choy et al.

FIG. 2. Rotor-bladeecasing

coordinate

system

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28

Chaotic Behavior in Rotating (iO)L.direction : m,(6<8,. + 263,) + C,6,,S, = - (F,),. sin a, + (F,)<
COS CD,

Equipment

(4)

where the subscripts R and C designated respectively the rotor and casing system. During rotor-casing rub interactions, the rub forces exerted between the rotor blades and the casing can be expressed in rotor radial and transverse directions as

(L)R = F, cosQrr -pFn

sin Q,,.,
as

(5) (6)

(~;Q)R = F, sin Q,, + pF, cos%,

and in the casing radial and transverse directions

(fib- = (- FJ ~0s @,( -14 - FJ sin %,

(J;O)c = (-F,,) Thus, the equation as (i,.)R direction : of motion sin @Cc + p( -F,J cos Q,.<. rubbing

(7) (8)

for the rotor during

events can be written

rn,.(Jr+ 6,?6,.) + C,& + K,6, -F,, cos Q,, + ,uF, sin @lr = m,e, {02(cos 8 cos a, + sin 8 sin 0,) - ~(~0s 0 sin @, - sin 0 cos Qr)} + (FJR cos Q, + (F,,), sin a, and (iO)R direction : sin BD,, -pFn cos Q,, -cos 0sin Q,) -cr(sin i3sin @,,+cos QcosQ,,)} (10) (9)

mr(&fir + 26,,&) + C,6,,S, -F, = m,e,{02(sin 8cosQ,

-(FJRsin@,,+(FV).cos@,,. Similarly, the casing equation : of motion can be written as :

(il)c direction

m,(S, - 6c2S,) + C,.6, + Kg?,. + Fn cos a,<- pF, sin @Cc = (F,), cos Qc + (F,jc sin Q, (11) and (&Jc direction :

m,.(ifi.b,. + 2&,,.8,,)+ C,.&,,.S,+ F,, sin @Cc +,uFn cos D,<= - (Fh)(. sin Qr + (Fy)c. cos a,. (12)
Vol. 327. No I, Pp. 2547. Printed in Greal Britam 1990

29

F. K. Choy et al. III. Solution Procedure In order to simulate a realistic rub event, the rotor system is assumed to be operating a steady state orbit with some initial mass imbalance without any rub interaction between the rotor and the casing. With a suddenly induced massimbalance, the rotor vibration orbit is increased and eventually rub interactions occur, For the purpose of capturing the transient dynamics of the system, (9))(12) are rewritten in the form (4, 5) Jr = (l/m,){m,e,[02(cos OcosQ,+sin 0 sin O,,)

- a(cos 0 sin @,-sin

0 cos a,.)] + (F,)R cos D,+ (Fy)R sin @, -t-@S,, (13)

+F,,cos@,,-pF,,sin@,,-C&-K,&} 6, = (1 /m,6,) {m,e,,[w(sin 19 cos Q, - cos 0 sin 0,)

- a(sin 8 sin O,+ cos 0 cos <Dr)]- (F,)R sin rD,+ (Fv)R cos O, + F,, sin @,,- pF,, cos @,,- C,6,,S,} - 26,,8,/S,, 8,. = (1 /mc) [ - F, cos @Cc + pFn sin @Cc - C,.$, - K,.6, + (F,),. cos Oc + (F,.)( sin @,.I+ b,,S,. and 6,. = ( 1/mc6c) [ - F,, sin @cc- pF,, cos Oc, - C,b,,.S, - (t,), sin @<+ (I$),. cos@<] - 2&c8,./S,. (16) (1.5) (14)

Equations (13) and (14), (15) and (16) are integrated separately to give the transient vibration for both rotor and casing at each time interval. The radial rub force due to radial blade deflection is given (5, 6) as

n2EI WW~i2 _
4P p + (7c/2)(b/l) !2 .

A vibration magnitude dependent variable time stepping Newmark-Beta type of integration scheme is used to integrate a,, Qr, 6,., Q,,. A very small time step interval is used during rotor-casing rub interactions to handle the large nonlinearity effects in the blade stiffness. Dynamics of both the rotor and the casing are examined in time and frequency domain using a FFT procedure.

IV. Model Development To investigate the dynamics of rotor/blade/casing actions, a simplistic rotor/casing model is employed possesses the following general characteristics : systems during rub interin this study. The model

30

Journal oftheFranklin

Institute Pergamon Press plc

Chaotic Behavior in Rotating

Equipment

Radial Blade Deflection (nils)

FIG. 3. Nonlinear blade stiffness due to single/multiple blade rub interaction.

(9 The rotor-bearing
(ii) (iii) (iv) (v)

(vi)

assembly is assumed to be a Jeffcott rotor simulation, see Fig. 1, linearized effective damping and stiffness characteristics are assumed at the rotor and casing geometric center, the turbine/impeller blades are assumed to be fixed at the rotor disk mounting (cantilevered), the effect of nonlinear blade stiffnesses are generalized to handle multiple blade participation rub interaction (Fig. 3) the casing structure is assumed to be supported by linearized stiffness and damping characteristics which can vibrate independently of the rotor motion, the rotor assembly is assumed to operate initially at steady-state motion under a small imbalance wherein the casing is initially at rest. An additional mass imbalance is suddenly induced into the rotor system to excite the transient vibration of the system.

Vol 327,No. I,pp.25-47. 1990 Printed I"Great Brilarn

31

F. K. Clzo_v et al. With the above assumptions, the equations presented in the following section. V. Discussion As noted earlier, the main thrust of this paper is to establish : of motion for the analytical model are

(i) The tuningdetuning effects of the relative rotor/casing stiffness and mass ratios, (ii) the nonlinear effects of blade stiffness, i.e. multi-blade interactions and (iii) the system parametric characteristics leading to full rubs. For instance, Figs 46 illustrate the effects of casing stiffness. In particular, the rotor, casing and relative orbits are displayed. As can be seen, as the casing is gradually stiffened, its orbit progressively shrinks. In contrast, for softening characteristics, increasingly bouncier/loopier type trajectories are excited. These are an outgrowth of the potential excitation of subharmonics, i.e. the natural frequencies of some system subcomponents. For example, Fig. 7 illustrates the development of l/3 harmonic loops. These involve excitation of the casing where the frequency is l/3 of the rotating imbalance. Similar responses may be excited at l/2, I /4, l/S etc. . . of the rotating speed. Continuing, the tuning and detuning effects of mass variations are depicted in Figs S-10. Three basic response types are excited, i.e. (i) full rubs for very light casings, (ii) rigid bouncing for very heavy casings and (iii) essentially chaotic behavior for intermediate

values.

Three-dimensional views of the stiffness and mass effects on the steady-state rub force, blade stress and blade deflection are depicted in Fig. 11. Note that for low casing to rotor mass ratios, significantly lower steady-state response levels are attained. As the mass ratio is increased, significantly higher steady-state values are excited. Similar trends are also depicted for the transient -three-dimensional plots given in Fig. 12. Here the various isolated peaks are a result of the tuning and detuning of the various system component frequencies. Next, we consider the generation of continuous and intermittent rubs. These are illustrated in Figs 13-l 5. Figures I3 and 14 depict the effects of blade stiffness on the generation of rubs. As can be seen, blade stiffness is reduced when the intermittent rub is replaced by a full rub. Similar trends are noted as the casing to rotor mass ratio is raised. Here the response varies between full rub to highly intermittent trajectories, see Fig. 15. Lastly, we shall consider the nonlinearity effects induced by multiple blade rubs. Note Fig. 13, it follows that transitions from single to multiple blade rubs are marked by discontinuous load deflection behavior. In particular, the response is highly stiff at transitions and gradually softens until the next transition occurs. Such behavior leads to a saturation of peak loads. This is clearly seen in Figs 16 and 17 where a distinct saturation is noted in the various responses. 32
Journal of the Franklm Pergamon Institute Press plc

Chaotic Behavior in Rotating

Equipment

0.004 1

Kc = 2000 lb/in.

0.004

= 5000 lb/in.

-0.004 -

-0.004

T -0.004 0.004 -0.004 0.004

Kc - 200000 lb/in.

IFIG.

-0.004

0.004

-0.004

0.004

ROTOR

ORSILT

IN

INCHES

4. Rotor motion

orbit trajectories

with change in casing stiffness.

Vol 327, No. I.pp.25-47. 1990 Pruned inGreat Britam

33

F. K. Choy et al.

0.003

Kc = 2000 lb/in.

0.003.

0.003

Kc

= 50000

lb/in.

0.003

Kc = 200000 lb/in.

-0.003 -

-0.003

-0.003

0.003

-0.003

0.003

CASING

ORBIT

IN

INCHES

FIG.

5. Casing motion

orbit trajectories

with change in casing stiffness.

34

Journal of the Franklin Institute Pergamon Press plc

Chaotic Behavior in Rotating

Equipment

0.004

Kc = 2000

lb/in.

0.004.

Kc = 5000

lb/in.

-0.004

-0.004

-0.004

0,004

-0.d04

0.004

0.004

Kc = 50000

lb/in.

0.004

= 200000

lb/in.

-0.004

-0.004

-0.006

0.006

+
-0.004 0.004

RELATIVE

ORBIT

IN

INCHES

FIG. 6. Rotor-casing

relative motion

orbit trajectories

with change in casing stiffness.

Vol 32,. No. I, PP. 2-7. Printed vn Great Brmm

1990

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F. K. Choy et al.

0.004

Kc = 5000 lb/in

c-4

-0.004

I
-0.004 0.004 0

lil
0.06

0.004

Kc = 2000 lb/in.

-0.004

L
-0.004 0.004 RELATIVE ORBIT IN INCHES MAXIMUM BLADE STRESS

0.06

FIG. 7. Relative orbit and blade stress with change in casing stiffness.

36

Journal of the Franklin Insdtute Pergamon Press plc

Chaotic Behavior in Rotating

Equipment

0.004

WC = 64

lb

0.004

WC =

16 lb

-0.004

-0.004

-0.004

0.004

-0.004

0.004

0.004

WC = 8 lb

O.QO4

-0.004

-0.004

-0.004

0.004

-0.004

0.004

ROTOR FIG. 8.

ORBIT

IN

INCHES

Rotor motion

orbit trajectories

with change in casing mass.

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31

F. K. Choy et al.

0.003

WC = 64 lb

0.003

WC = 16 lb

4
-0.003 -0.003

T -0.003 0.003

F -0.003 0.003

0.003

-8lb

0 .003

-0.003

-0.003

0.003

-0.003

0.063

CASING FIG.

ORBIT

IN

INCHES

9. Casing motion

orbit trajectories

with change in casing mass.

38

Journal of the Franklin lnst~tutc Pergamon Press plc

Chaotic Behavior in Rotating

Equipment

0.004

= WC

64

lb

0.004

= 16 WC

lb

-0.004

-0.004

-0.004

0.604

-0.004

0.004

0.004

WC = 8 lb

0.004

wc

= 2 lb

-0.004

-0.004

-0.004

0.004

-0.004

0.004

RELATIVE

ORBIT

IN

INCHES

FIG. 10. Rotor-casing

relative orbit trajectories

with change in casing mass.

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1990

39

Steady Force Blade Displacement Steady State

State

Rub

T
t

Steady Blade

State Stress

T
plot of steady-state

FIG. 11. Three-dimensional

rub force with change in casing stiffness and mass.

Transient Rub Force Transient Blade Displ.

Transient Blade Stress

FIG. 12. Three-dimensional

plot of transient

rub force with change in casing stiffness and mass.

F. K. Choy et al.

E = 50000000
.4

0.4

I I

E = 30000000

0.2 E = 5000000

E = 1000000

Time in

Seconds

Txme

in Seconds

0.07

FIG. 13. Normalized

blade stress with change in blade stiffness.

42

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Chaotic Behavior in Rotating

Equipment

0.04

E -

50000000

0.04

E -

30000000

2 .a

0.07

0:07

E -

5000000

0.2

FIG. 14. Radial blade displacement

with change in blade stiffness.

Vol. 327. No. I. pp. X-47. Prlnkd in Great Bnlaln

1990

43

F. K. Choy et al.

0.004

WC = 0.5

lb

IL

, _,
0.07

-0_.004

0.006

I
-0.004 -0.bo4 -0.004 Relative

0
0.004 0.004

-0.004

0.004

Time

in

Seconds

FIG. 15. Radial blade displacement

1
WC = 8 lb

0.004 Orbit in Inches

and rotor relative orbit with change in casing mass.

Journal of the Franklin lnstltute Pergamon Press plc

Chaotic Behavior in Rotating

Equipment

Time in

Seconds
radial rub force and maximum

FIG. 16. Nonlinearity

between

blade radial displacement, blade stress.

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1990

4.5

F. K. Chov et al.
E =

1000000

E =

1000000

Time

in Seconds

FIG. 17. Nonlinearity

between blade radial displacement and maximum blade stress during a full rub event.

VI. Conclusions Overall, the foregoing case studies lead to the following conclusions concerning the influence of rotor/casing/blades and stiffness and associated mass effects namely :

(1) Large

nonlinearity due to rub interactions is induced by the discontinuities due to single/multiple blade participation rub interactions. (2) The decreasing in casing stiffness will result in larger and bouncier/loopier rotor orbit trajectories. (The increase of subharmonic orbit components.) Rotor orbit trajectories can shift from rigid bouncing to chaotic behavior then (3) to full rub phenomena with decrease of casing stiffness for very lightweightcasing system. (4) Level of rotor steady response will decrease with the decrease of casing mass. behavior to full rub under similar (5) The system can shift from intermittent operating conditions with either a decrease in blade stiffness or a decrease in casing mass.
Journal

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Chaotic Behavior in Rotating References

Equipment

(1) R. F. Beatty, Differentiating rotor response due to radial rubbing, Trans. ASME, J. Vibration Acoust. Stress Reliability Des., Vol. 107, p. 151, Apr. 1985. (2) D. E. Bently, Forced Subrotative Speed Dynamic Action of Rotating Machinery, ASME paper 74-DET-16, Petroleum, Mech. Engng Conf., Dallas, TX, 1979. (3) D. W. Childs, Rub induced parametric excitation in rotors, ASME. Mech. Des., Vol. 10, p. 640, 1979. (4) F. K. Choy and J. Padovan, Investigation of rub effects on rotor-bearing-casing system response, Proc. 40th Mech. Failure Prevention Group Symp. Nat1 Bureau Standards, Gaithersburg, MA, Apr. 1985. (5) F. K. Choy and J. Padovan, Nonlinear transient analysis of rotor-casing rub events, J. Sound Vibration, Vol. 113, No. 2, 1987. turbomachinery : (6) F. K. Choy, J. Padovan and W. Li, Rub in high performance modelling; solution methodology; and signature analysis, J. Mech. Syst. Signal Process., Vol. 2, No. 2, p. 113, 1988. (7) E. F. Ehrich, The dynamic stability of rotor/stator radial rubs in rotating machinery, ASME J. Engng Ind., p. 1025, Nov. 1969. (8) A. Muszynska, Partial Lateral Rotor to Stator Rubs, ZMech. E. Conf. Publication on Third Int. Conf. on Rotating Machinery, Sept. 1984. (9) J. Padovan and F. K. Choy, Nonlinear dynamics of rotor/blade/casing rub interactions, ASME J. Turbomachinery, Vol. 198, No. 4, p. 527, Oct. 1987. (10) A. Tondl, Note on the identification of subharmonic resonances of rotors. J. Sound Vibration, Vol. 3 1, p. 119, 1973. (11) Y. Choi and S. T. Noah, Nonlinear steady state response of a rotor support system, ASME J. Vibration Acoust. Stress Reliability Des., Vol. 109, p. 255, July 1987. (12) H. D. Nelson, W. L. Meacham, D. P. Fleming and A. F. Kascak, Nonlinear analysis of rotor-bearing systems using component mode synthesis, ASME J. Engng Power, Vol. 105, p. 606, July 1983.

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1990

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