Conceptual Design, Analysis & Optimization of Turbomachinery

ROTOR DYNAMICS & BEARING

ANALYSIS FUNDAMENTALS
TRAINING COURSE

LET’S WORK TOGETHER TO CREATE ENERGY

EFFICIENT TURBOMACHINERY AND A GREENER
WORLD FOR FUTURE GENERATIONS

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 Rotor Dynamics & Bearing Analysis Fundamentals Training Course

FOR YOUR NOTES

Rotor Dynamics & Bearing Analysis Course Description

In the modern industrial world, rotating machinery is used extensively. These machines play a vital role in
the power and transportation industries. The rotor is the most critical component of any rotating
machinery. Usually these rotors operate at high speeds and often within a wide speed range. In
operation, they are subjected to extreme centrifugal and gas bending loads and experience bending,
torsional and axial vibrations.
Rotor lifetime and reliability depend, first of all, on the level of rotor vibrations. In order to meet highest
requirements of reliability each step of the rotor design should be based on accurate rotor dynamics
calculations. These calculations obviously include the rotor along with the different components (mass-
inertia combinations) but also take into account what the rotor(s) is(are) supported by; bearings and
structural supports. The bearings discussed in this course include hydrodynamic (journal) bearings (to
carry both radial and axial load/thrust) with fixed and variable geometries as well as rolling element
bearings.

This course lasts 3 days (8 hours per day) and is aimed toward mechanical engineers and engineering
managers looking to learn or refresh their knowledge on what rotor dynamics are, how they work, how
their design influences vibrations and system natural frequencies and so on. This course also benefits to
engineers willing to receive software training (for future use and/or evaluation) on SoftInWay’s tools for
the design, analysis and optimization of rotor dynamics systems (rotors, bearings and supports).

The first chapter provides trainees with an introduction to what rotor dynamics is along with some
common failures that proper system analysis should prevent. The different types of rotor and bearing
designs are presented and some basic definitions used throughout the course (Campbell diagram, critical
speed, whirl, unbalance, etc.) are explained before providing an history of rotor dynamics.
After this first, introductory chapter, this course focuses on some basics of rotor dynamics analysis.

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 Rotor Dynamics & Bearing Analysis Fundamentals Training Course

This second chapter discusses the purposes and objectives of performing rotor dynamics analysis and FOR YOUR NOTES
bearings calculations before discussing the concept of equivalent discrete systems that help
understanding rotor-bearing systems through some simplified examples represented by mass-spring
systems. One of the most fundamental results of rotor dynamics calculations is also presented in details
in this chapter; critical speeds. These represent the natural excitation frequencies of a given rotor-
bearing-support assembly and allow making the distinction between flexible and rigid rotors. Before
digging into some of the different methods used to calculate rotor dynamics systems and introduction to
aerodynamic cross-coupling forces is provided to give an understanding of this destabilizing force that
lead to assembly vibrations. Finally, some of the different standards and acceptance criteria for such
types of analyses are introduced.
To be able to rotate as frictionlessly as possible rotors are mounted onto bearings which can be of
different kinds; some use lubricants (gaseous, liquid or even solids) while some don’t, some use a
different family of geometries, some have fixed geometries while other have variable geometries (like
tilting pads), etc. An overview of rolling element bearing (mostly used for low load, low speed application)
as well as hydrodynamics (journal) bearings and their typical materials is given in this third chapter of this
course along with explanations on the calculations and concepts of stiffness and damping in each case.
Once bearings have been conceptually designed their stiffness and damping characteristics should be
modeled with the rotor train to study its deflections in the lateral (bending) and torsional directions. These
analyses are the topic of interest of chapters 4 and 5, respectively. These two chapters introduce the
corresponding concept and scope, present some approaches to modeling them and discuss their
similarities and distinctions.
Finally, chapter 6 deals with rotor balancing. No practical amount of manufacturing and assembly
precision can ensure perfect homogeneity of a rotor or its components or even the exact alignment of the
bearings supporting a shaft. Understanding these phenomena allows creating ways to counter-balance
the unbalances and therefore reduce the amount of vibrations in the system. This is the focus of this last
chapter.

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 Rotor Dynamics & Bearing Analysis Fundamentals Training Course

To accompany all this theoretical knowledge a strong emphasis is also made on hand exercises and FOR YOUR NOTES
software use which allow the attendees to apply the concepts presented and help with the retention and
understanding of the information provided. The hands-on software workshop uses SoftInWay’s
AxSTREAM® suite and covers the full design process of turbomachinery, including rotor dynamics and
bearing analysis.

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SoftInWay, Inc., 1500 District Avenue, Burlington, MA 01803. Tel: (781) 685-4942 3/6
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 Rotor Dynamics & Bearing Analysis Fundamentals Training Course

Contents FOR YOUR NOTES

Chapter 1. Introduction to Rotor Dynamics ............................................................................................. 4

1.1 The Role of Rotor Dynamics in Machine Design ................................................................................. 4
1.2 Rotor-Bearing System Failures ............................................................................................................ 4
1.3 Rotor-Bearing Systems Designs .......................................................................................................... 7
1.3.1 Rotor Designs........................................................................................................................ 8
1.3.2 Bearing Types ..................................................................................................................... 10
1.4 Basic Definitions ................................................................................................................................ 12
1.4.1 Static and Dynamic Forces in Turbomachinery ................................................................... 13
1.4.2 Resonance and Campbell Diagram ..................................................................................... 14
1.4.3 Unbalance Definition ........................................................................................................... 15
1.4.4 Whirling Motion.................................................................................................................... 16
1.4.5 Damping Definitions ............................................................................................................ 18
1.4.6 Moment of Inertia ................................................................................................................ 21
1.4.7 Cross-Coupled Forces......................................................................................................... 22
1.4.8 Gyroscopic Couple .............................................................................................................. 24
1.5 Brief History of Machinery Rotor Dynamics and Basic Nature of the Various Rotor Dynamics
Problems 25
Chapter 2. Rotor Dynamics Analysis Basics ......................................................................................... 35
2.1 Purpose and Objectives of Rotor Dynamics Analysis and Bearing Calculation ................................. 35
2.2 Equivalent Discrete Systems ............................................................................................................. 36
2.2.1 Single degree-of-freedom Rotor Model ............................................................................... 36
2.2.2 The Two degrees-of-freedom model ................................................................................... 40
2.2.3 Jeffcott Rotor Analysis ......................................................................................................... 42
2.3 Critical Speed Definitions. Rigid and Flexible Rotors ......................................................................... 52
2.4 Effect of Flexible Structural Supports................................................................................................. 53
2.5 Instability due to Aerodynamic Cross Coupling ................................................................................. 54
2.5.1 Aerodynamic Cross Coupling in Axial Stages ..................................................................... 55
2.5.2 Aerodynamic Cross Coupling in Centrifugal Stages ............................................................ 57
2.6 Methods for Rotor Dynamics Analysis. FE method ............................................................................ 57
2.6.1 Discretizing Rotor into Finite Elements ................................................................................ 58
2.6.2 Approximating Element Displacement Functions and Nodal Displacement ........................ 59

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 Rotor Dynamics & Bearing Analysis Fundamentals Training Course

2.6.3 Formulating Equations of Motion for Each Element ............................................................ 62 FOR YOUR NOTES
2.7 Standards and Acceptance Criteria for Rotor Dynamics Analysis Overview ..................................... 63
Chapter 3. Journal Bearings and Their Effect on Rotor Dynamics ........................................................ 64
3.1 Rolling Element Bearings .................................................................................................................. 64
3.1.1 Introduction.......................................................................................................................... 64
3.1.2 Rolling Element Bearing Types ........................................................................................... 65
3.1.3 Bearing Materials ................................................................................................................ 71
3.1.4 Rolling Bearing Lubrication.................................................................................................. 75
3.1.5 Linear radial stiffness of rolling bearing ............................................................................... 78
3.1.6 Bearing Life Prediction ........................................................................................................ 85
3.2 Fluid Film Journal Bearings ............................................................................................................... 91
3.2.1 Stiffness and Damping Properties ....................................................................................... 91
3.2.2 Hydrodynamic lubrication of journal bearings ...................................................................... 95
3.2.3 Oil Whirl and Shaft Whip ................................................................................................... 111
3.2.4 Fixed Geometry Journal Bearings ..................................................................................... 112
3.2.5 Tilting Pad Bearings .......................................................................................................... 117
3.2.6 Fluid Film Journal Bearings Materials................................................................................ 124
Chapter 4. Lateral Rotor Dynamics ..................................................................................................... 126
4.1 Introduction in Lateral Analysis ........................................................................................................ 126
4.2 Rotor Modeling Methods and Considerations .................................................................................. 126
4.2.1 Division of Rotor into Discrete Sections............................................................................. 129
4.2.2 Addition of External Masses and Inertial Loadings ............................................................ 130
4.2.3 Addition of Stiffening Due to Shrink Fits and Irregular Sections ........................................ 131
4.2.4 Location of Bearings, Seals, and Radial Probes ............................................................... 131
4.2.5 Built-up Rotors................................................................................................................... 132
4.2.6 Train Lateral ...................................................................................................................... 133
4.3 Undamped Critical Speed Analysis.................................................................................................. 134
4.4 Damped Unbalance Response Analysis.......................................................................................... 139
4.5 Stability Analysis .............................................................................................................................. 145
4.5.1 Level I Stability Analysis .................................................................................................... 149
4.5.2 Level II Stability Analysis ................................................................................................... 153
4.6 Overall Process ............................................................................................................................... 155
Chapter 5. Torsional Rotor Dynamics ................................................................................................. 156

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 Rotor Dynamics & Bearing Analysis Fundamentals Training Course

5.1 Introduction and Scope .................................................................................................................... 156 FOR YOUR NOTES

5.1.1 Torsional Analysis Objectives............................................................................................ 157
5.1.2 Torsional and Lateral Vibration – The Key Differences ..................................................... 157
5.2 Modeling .......................................................................................................................................... 158
5.3 Undamped Torsional Natural Frequency Analysis ........................................................................... 163
Chapter 6. Rotor Balancing ................................................................................................................. 166
6.1 Background and Introduction to Balancing ...................................................................................... 166
6.2 Balance Terminology ....................................................................................................................... 166
6.3 Rotors Classification with Regards to Balancing ............................................................................. 167
6.4 Rotor Unbalance .............................................................................................................................. 170
6.4.1 Derivation of Forces Due to Unbalance ............................................................................. 170
6.4.2 Types of Unbalance. ......................................................................................................... 173
6.5 Balancing Tolerances ...................................................................................................................... 177
6.6 Balancing machines......................................................................................................................... 180
6.6.1 Soft-Bearing Balancing Machines. .................................................................................... 181
6.6.2 Hard-bearing Balancing Machines .................................................................................... 181
6.7 Balancing Procedures...................................................................................................................... 182
6.7.1 Component Balancing ....................................................................................................... 182
6.7.2 Low-Speed Balancing Techniques .................................................................................... 182
6.7.3 Progressive Component Stack Balancing ......................................................................... 183
6.7.4 Index Balancing ................................................................................................................. 183
6.7.5 Operating-speed Balancing ............................................................................................... 189
6.7.6 Field Balancing .................................................................................................................. 190
Exercises 191
Bibliography List ..................................................................................................................................... 208

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