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Rotordynamics durch Klicken bearbeiten

Simulation
M. Moosrainer, CADFEM GmbH,
ACUM 2014 in Nürnberg am 05.06.2014

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1987 Burst Low Pressure Turbine in Power Plant Irsching (Bavaria)
https://www.allianz.com/de/presse/news/geschaeftsfelder/versicherung/news_
• Rotor of low 2012-11-21.html
pressure turbine
burst in 30 pieces
• 1300 kg piece found
in 1.3 km distance
• Power plant had to
shut down
• Millions of property
damage
• owing to favorable
circumstances no
persons injured

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Workshop Agenda

• Introduction

• Rotordynamic Effects

• Rotordynamics in ANSYS Mechanical & Applications

• Bearing Models in ANSYS Mechanical & Beyond

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Rotating Machinery: Wind Power Plant

~ 10 rpm

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Rotating Machinery: Turbo Engines

• turbojet

~ 10.000 rpm

• turbocharger

~ 100.000 rpm

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Rotating Machinery: Hard Disks & Centrifuges

• hard disk

~ 5.000 rpm

• centrifuge

~ 1.000.000 rpm

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Rotordynamic Effects

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Resulting Bearing Force: Elastic Rotor vs. Rigid Rotor
• Observe the following video of a run-
up of a simple elastic rotor
http://www.youtube.com/watch?featu
re=player_detailpage&v=dO51IjGKr
TM
• imbalance force amplitude F of an
elastic rotor with increasing
rotational speed
• result presented as ratio of force F
referred to elastic restoring force =
eccentricity ε times stiffness k
• note rigid rotor force increasing
quadratically whereas elastic rotor
force is approaching static elastic
restoring force in the limit of high
rotational speed after having passed
the critical resonance case Ω/ω=1.

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What is Rotordynamics?
• Static balancing of a rigid
rotor

90% of all RD tasks

• Dynamic balancing of a
rigid rotor

• Dynamic response of an
elastic rotor

• key task: avoid instable

behavior in operation mode

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Rotordynamic Effects: Self-Centering
• one disk:
• sign shift for deformation ρs at
resonance Ω=ω from positive to
negative
• asymptotic behavior: center of gravity
G approaches axes of rotation (self-
centering of the rotating mass)

• N disks:
• more complex, but no new
phenomena J

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Rotordynamic Effects: Instable Behavior
For many rotors self-excited bending vibrations occur beyond a certain limit
frequency Ωl. Reasons for instabilities:
• internal rotor friction & internal (= rotating) damping mechanisms (!)
• journal bearing effects at high rotational speed
• self-excitation due to sealing gap
• insufficient parameters for magnetic bearing regulator

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Rotordynamic Effects: Forward Whirl – Backward Whirl – Orbit
• Ω=0: symmetry à two stationary
orthogonal bending modes in y and z

• Ω<ω: sub-critical motion of shaft S

centerline point S rotational speed Ω O
rε G
• ω: modes shows two counter-rotating
circular motions with eigenfrequency
Ω
ω (don’t mix up with rotational speed Ω!)
Ω
ω (BW)
rˆh 2
• forward whirl FW: ω same direction as Ω rˆh1
• backward whirl BW: ω oposite direction of Ω y, Im
• superposition of those rotating vectors
yields an elliptical orbit ω (FW)
z, Re
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Rotordynamic Effects: Gyroscopic Matrix
• balance of moment of momentum j&ys x
z

é M x ù éQ pj&&xs ù é 0 ù z’ x’
ê M ú = êQ j&& ú + ê Q Wj& ú Mz Ω
ê y ú ê a ys ú ê p zs ú
êë M z úû êë Q aj&&zs úû êë- Q p Wj& ys úû [M]{&u&} + ([C] + [C gyr ]){u& } + [ K ]{u} = {F}

• 1st line simply gives the torque moment balancing the angular acceleration of
the shaft.
• gyroscopic moments: 2nd & 3rd line are the effects of the moments of inertia of
the disc which work against any inclination of the disc à sort of “stiffening”
• gyroscopic moments: 2nd & 3rd line show coupling of two DOFs, e.g. φys and
φzs à unsymmetric matrix à prone to instability
• gyroscopic moments are a function of angular velocity à gyroscopic matrix
[Cgyr]= sort of unsymmetric „damping matrix“à special ANSYS solvers

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Rotordynamic Effects: Gyroscopic Matrix – Campbell Plot
• ANSYS shaft eigenfrequencies • ANSYS shaft eigenfrequencies
without gyroscopic moments with gyroscopic moments

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Rotordynamics in ANSYS & Applications

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Rotordynamics in ANSYS means …
• Doing rotordynamics (modal, harmonic, transient) within a unique
environment
• Established, persistent workflow: parametrized CAD geometry, automeshing,
simulation, sensitivity studies, optimization
• Easy modelling with required accuracy: beam … solid models

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Rotordynamics in ANSYS: GUI Workflow
• Task: compute the stability
of a rotor
• stabilizing external stationary
damping à damping in
bushing
• destabilizing (!) internal
rotating damping à material
damping in the rotor
• define Bushing for bearings
• GUI or ASCII file
• apply rotational velocity &
Coriolis Effect

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Rotordynamics in ANSYS: Campbell Diagram Frequency

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Rotordynamics in ANSYS: Campbell Diagram Stability

exp(σt)
§σ neg.: stable
§σ pos.: unstable

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Rotordynamics in ANSYS: Animate Stable/Instable Modes

Rotor Stable Backward Mode1@1000rpm Rotor Unstable Forward Mode2@1000rpm

Rotor Undetermined Mode3@0rpm Rotor Unstable Forward Mode5@2000rpm

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Rotordynamics in ANSYS: Modelling Options
Multi spool: beam models displayed in HDD: solid models
solid shape, N shafts @ N rpm

Shaft: 2.5D axiharmonic models

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Rotordynamic Application: Siemens Generator Basic Research
• test rig for basic research on high-temperature (-250°C) superconductors
• significant improvement of efficiency for power plant generators
• rotordynamic simulation to investigate characteristics of eigenfrequencies and
modal damping of a 4t rotor taking into account gyroscopic effects within a
range up to 3600 rpm

Courtesy of Siemens
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Solid Model of the Rotor
• Apply point masses
• Spring-damper
properties of bearings
• Rotational velocity

Courtesy of Siemens

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Mode #2@3000rpm: Forward Whirl – Observe Damped Rotation in +X

© CADFEM 2014 Courtesy of Siemens 26

Mode Comparison: 3D Solid – 1D Beam – 2.5D Axiharmonic Model

Excellent
agreement

Courtesy of Siemens
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Campbell Plot of Eigenfrequencies for 3D Solid Model

• Mode #2: f=11.446 Hz

Courtesy of Siemens
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Campbell Plot of Modal Damping for 3D Solid Model

• Mode #2: ξ=3%

Courtesy of Siemens
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Performance Comparison of Rotor Models on 8 Cores
A:3D-Modell B:1D-Modell C:2.5D-Modell
Anzahl Knoten 178319 265 28701
Anzahl Elemente 106355 132 2612

Elapsed Time [s] for Complex Modal Analysis

120%

100%
• conclusion:
80%
• 2.5D axiharmonic 3D Solid
model is the 60% 1D Beam
optimal 2.5D Axiharmonic
compromise 40%
between accuracy
(3D) and 20%
performance (1D) 0.4%
0%

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 Structural Elements for Rotating Parts
Element Type Detail
Structural Mass MASS21

3D Beam BEAM188
BEAM189

3D Pipe PIPE288
PIPE289

Structural Shell SHELL181

SHELL281

SOLID185
3D Structural Solid SOLID186
SOLID187
General Axisymmetric Solid SOLID272
SOLID273

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In Brief: Rotordynamics Gives an Answer To …
• Unbalance Response

Centrifuge

Courtesy of Beckman
Coulter, Inc.

• Transient Analysis – Stability

Verification @ different rpm
run-up: rpm ↑

Stable Orbits @ rpm1 Unstable Orbits @ rpm2

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Bearing Models in ANSYS Mechanical

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 Bearing Models in ANSYS Mechanical
Element Description Characteristics Nonlinear
cross terms characteristics
COMBIN14 Uniaxial spring/damper None None
COMBI214 2D spring/damper Unsymmetric Function of W and
eccentricity
MATRIX27 General stiffness and Unsymmetric None
damping matrices
MPC184 Multipoint constraint Symmetric for both Function of the
linear and nonlinear displacement

e.g. COMBI214
stiffness and
damping incl. cross
coupling terms import
from ASCII file
or
MPC184
Bushing
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Flexible Support: Chiller – Full Model & CMS Superelement
Finite element model of rotor
Solid Model of Compressor Shaft plus and impellers
Chiller Assembly in ANSYS Workbench

Courtesy of Trane, a business of American Standard, Inc.

Housing and entire chiller assembly
represented by a CMS superelement:
à accurate dynamic behavior of both full
rotor & support structure
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Advanced: Elastohydrodynamics (EHD) e.g. Radial Journal Bearings
• Bartel, D., Uni Magdeburg, IMK:
Reibungsreduzierung von Cavitation
mischreibungsbeanspruchten Beginning of the zone
Tribosystemen durch Simulation. pressure distribution

Flow direction
8. CADFEM CAE Forum (2011)
• Reduction of Navier Stokes
Equation: Reynold’s Approach for
Thin Fluid Films in Gaps à Tribo-X
End of the pressure
distribution
fluid EHD result:
pressure distribution

structural EHD result:

shaft displacement curves
after different operating times
(wear calculation)
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ANSYS Customization: FEM & EHD bidirectional coupled simulation
• Radial journal bearing
gap
• challenge: tiny clearances (≈1‰ of Ø) and
even smaller oil film thickness
• FSI coupled FEM/CFD still too expensive
for every-day engineering design decisions
• CADFEM solution (in progress): bi-
directional coupling of two solvers
• ANSYS (FEM): flexible bearing and shaft
dynamics
• Tribo-X (EHD): Reynolds solver for fluid oil
film dynamics bearing
• consistent, bi-directional coupling via
ANSYS interface programming:
Euler-Lagrange-Mapping

shaft

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FEM/EHD Validation Example: Radial Journal Bearing from DIN 31652

Quantity Value
Bearing Diameter D 120 mm
Bearing Width B 60 mm
Bearing Clearance y 1,558 ‰ (C = 186,96 µm)
Load F 38000 N
Speed of rotation n 2000 rpm
Oil viscosity h 28,7 mPas (ISO VG 100 at 75°C)
Oil density r 900 kg/m³
Oil supply via circumference
Oil supply pressure pzu 0,5 MPa
Material parameter of the shaft E = 210000 N/mm² / n = 0,3
Material parameter of the bearing brass E = 150000 N/mm² / n = 0,3

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FEM/EHD Rigid Shaft & Rigid Bearing: Motion & Pressure Distribution
• gradual increase of hydrodynamic pressure with increasing rpm and shaft displacement
• correct values for gap, pressure maximum and bearing force for a given eccentricity
à validation successful

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 FEM/EHD Rigid Shaft & Elastic Bearing vs. Elastic Shaft & Elastic Bearing
Pressure Distribuion

decreasing
pressure
maximum

pmax = 35,1 MPa Rigid analysis not sufficient pmax = 31,2 MPa
Elasticity significant: FEM/EHD
Gap Distribution

decreasing
gap minimum

hmin = 12,6 µm hmin = 11,7 µm

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 FEM/EHD: Transient Simulation of Piston – Crankshaft Assembly

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 ANSYS & 3D-TEHD-Simulationsprogramm Tribo-X
Simulation auf Makroebene Simulation auf Mikroebene
(Bei kleinen Kontaktflächen rau, bei großen Kontaktflächen glatt.) (Wenn Makroebene glatt gerechnet wird.)

ANSYS Mechanical TEHD-Modul + MR + Verschleiß Flussfaktoren

Kennfeldlösungen
lin/nichtlin. Dynamik Hydrodynamischer Druck
Festkörper-
Materialgesetze kontaktdrücke
Festkörperkontaktdruck
Kontaktformulierungen
Verformung Grenzreibungs-
effiziente Solver Schmierspalthöhe zahlen
Ordnungsred.: CMS
Spaltfüllungsgrad
Prozess: CAD, Param. Kavitation

à v, gap ßt Reibung

Temperatur

Verschleiß

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Summary
Doing rotordynamics via FEM using ANSYS means:
• CAD import & automatic meshing
• A wide range of elements supporting gyroscopic effects: 1D, 2D, 3D, 2.5D (!)
• Accurate modeling of the mass and inertia
• analysis types - including prestress: modal, harmonic, transient
• proper solver technology: UNSYM, QRDAMP, DAMP accounting for damping,
gyroscopic matrix and unsymmetric system of equation not just for simple beam
models but also for huge solid models.
• multi-spool dynamics simulation
• The ability of solid element meshes to account for the flexibility of the disk as well
as the possible coupling between disk and shaft vibrations.
• account for flexibility of supporting structure and/or the disks (e.g. CMS approach)
• library of bearing elements + option to extend it by customization, e.g. FEM/EHD
• dedicated postprocessing for rotor dynamics: Campbell diagram, critical speed
table extraction, orbit plots, …

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