Modal and Operating Deflection Shape Analysis

as Damage-Analysis Tools

Tracking Down
Vibrations
RUDOLF STRCHLER
SULZER INNOTEC

4216

In most cases of damage, failure of materials,

structures, and components is attributable to
excessive loading. This may involve static loads,
dynamic loads or a combination of both. Forces
and stresses that result from components
function are known at the design stage already
and are taken into account in the design.
Perturbations arising from operation, on the
other hand, e.g., vibrations or oscillations, are
difficult to evaluate at that point in time. Sulzer
Innotec carries out vibration analyses that are
important in the investigation of vibration-induced
damage events.

SULZER TECHNICAL REVIEW 3/2007

17

1 Wind-induced
resonances led to
the collapse of the
Tacoma Narrows
Bridge in the State
of Washington, USA,
on November
7, 1940. Sulzer
Innotec also investigates less spectacular damage
events using
vibration analyses.

tions include emissions (e. g.

noise), reduction of product quality, failure to comply with design
data (e. g. rate of production),
andin the worst casedamaging and destruction of components
or systems.
Generally, simulation methods are
unable to reproduce all influences
on a system in operation. Mostly,
one depends on additional experimental investigations.

Sensors for Relevant Parameters

The natural frequencies of a

frequency-response system
are the frequencies at which this
system oscillates after a nonrecurring excitation. If vibrations at
these frequencies are imposed on
a system, it reacts with especially
large
amplitudesresonances,
which can lead to damage or perturbations (Fig. 1). The effects of
dynamic loads depend largely on
the inherent dynamics of the structure or the component.

Detecting Operational Influences

Dynamic excitations and the resulting stresses can impair the
functioning of a component in
many different ways. Possible consequences of operational vibra-

2 Comparison of
operating vibration
analysis and modal
analysis.

18

There are 2 methods of analysis in

the field of experimental vibration
technology (Fig. 2).
Modal analysis is the study of the
dynamic behavior of oscillatory
systems using their natural vibration values. By determining the
modal parametersnatural frequencies, natural modes, and
dampingit provides information
about the inherent dynamics of a
structure.
Operating vibration analysis, on
the other hand, measures vibration
behavior under specific operational conditions. This tool shows
how a structure reacts to the operational forces acting upon it. Sensorswhich may be of the contact
or noncontact varietymeasure
the oscillation values at the points
that are relevant for the problem in
question and provide the data for
a comprehensive analysis.

The readings (vibration amplitudes, frequencies, etc.) are often

compared with standards or
guidelines for component acceptance. Beyond this, visualization of
operating deflection shapes (ODS)
makes an essential contribution to
detecting weak points and understanding the dynamic behavior of
the structure in operation (Fig. 3).
ODS analysis, however, only answers the question of which modifications must be made to the
structure.
Experimental modal analysis, on
the other hand, answers the question of where and in what manner
modificationsstiffening, mounting of additional mass (tuning),
etc.are possible and effective
with a specific structure. To this
end, the structure is excitated using suitable methods (Fig. 4).
Whether it consists of a force impulse or controlled functions of
time using shakers, the excitation
is always a broadband one, i.e., it
occurs at multiple frequencies. The
result of this excitation is a free
structural response across a broad
frequency range. These structural
responses are detected using the
same sensors as used in ODS
analysis.
The natural frequencies, mode
shapes, and damping are determined from the comparison of the

Operating Vibration Analysis

Reaction of the structure to the operational forces
acting upon it.
Excitation
Separate excitation (known and measured)
Structure is subject to operational forces, pressures,
etc. (unknown, not measured)
Result
Free structural response to broadband excitation
Forced oscillation, most at discrete frequencies, e.g.,
rotational frequency, blade passing frequency, meshing)
Information
Data regarding the inherent dynamics of a structure Vibration behavior in the operational state investigated
Assessment according No
Yes, frequently purpose of the measurements
to standards. etc.
Conclusions
Where and how are changes possible
Where are changes possible
General

SULZER TECHNICAL REVIEW 3/2007

Modal Analysis
Identifies a dynamically unknown structure

Visualization of the Oscillations

specified excitation and the measured structural response using

transfer functions. Here, too, the
visualization of the mode shapes
determined is an integral part of
the result.

Numerical Simulation
It is possible to detect and remedy
many causes of damage just with
the insights gained from these 2
experimental analyses. In many
cases, a finite element (FE) model
validated and, if necessary, calibrated by means of modal analysis supports the search for suitable
modifications to the structure. A
course of action of this type permits complete dynamic component analysis (Fig. 5).

Damaged Chocolate Molds

A chocolate mold showed cracks
in the ribs on the bottom after a
short period of use. After being
filled with chocolate, the form
passes through the tapping section. This section consists of sliding rails, excitated by unbalanced
masses, which support the flowing
of the chocolate through shaking.
The user suspected excessive

stresses in the tapping section as

the cause of the damage and hired
Sulzer Innotec to conduct a damage analysis. The Sulzer experts installed 5 accelerometers with
which an ODS analysis of the mold
was carried out during the passage
through the tapping section
(Fig. 6). The measurements resulted in 3 dominant frequencies. The
subsequent modal analysis of the
mold showed the modes with
which the component oscillates
when excitated with the dominant
operational frequencies. The results of the modal analysis were
incorporated into the FE model of
the mold. Using the model thus
calibrated, it is possible to calculate very precisely the behavior of
the component when excitated at
the accelerations and frequencies
measured in operation.

Cause of Cracking Determined

For the chocolate mold, this course
of action demonstrated that the
stresses in the tapping section
were equal to or exceeded the
threshold values for the specific
materials. The numerical simulation shows the deflection and

3 Visualization of the measured oscillatory states of

a weaving machine with an overhead warp beam.
Computer programs also show the course of motion
of such oscillatory forms.

4 Separate excitation of the structure: The hammer

is used to impart
a nonrecurring
force impulse.
Controlled functions of time for
excitation can be
achieved with
shakers (right),
among other
things.
Force impulse
Sine sweep
Broadband
noise

SULZER TECHNICAL REVIEW 3/2007

19

Modal analysis
Inherent dynamics

Loads and stresses

Tribological characteristics
Stress analysis
Stresses
Operating vibration analysis
Enforced oscillations

Instrumented mold in the tapping section

Operational life

FEAnalysis

Failure mechanisms
Function

Definition of load cases

Forces and momentum
Influences of environment

Operational safety

5 Using the data from the operating vibration analysis

and a strain-gauge measurement, it is possible to
answer virtually all questions with regard to operational
reliability with great certainty.

loading even at points in the component where measurement with

sensors would be impossible and
thus permits localization of the
maximum stresses. Through selective modification of the parts that
are subject to excessive stress, it
was possible to increase the operating life of the mold, which led to
a significant regulation in operating expenses at the customers.
The oscillation experts at Sulzer
Innotec have also already applied
their expertise to solving vibration
problems in paper machines, turbochargers, turbines, pumps, vehicles, and many other components.

Measurement of vibrations at separate excitation

Measured
mode shapes

f = 36.2 Hz

Contact
Sulzer Innotec
Rudolf Strchler
Zrcherstrasse 58
8401 Winterthur
Switzerland
Phone +41 52 262 26 84
Fax
+41 52 262 00 85
rudolf.stuerchler@sulzer.com

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SULZER TECHNICAL REVIEW 3/2007

f = 49.8 Hz

f = 68.5 Hz

6 Investigation of the chocolate mold: Measurement of the accelerations in operation (top) and detection of the resonant response to
specific excitation (modal analysis).