A comprehensive review on crack detection schemes and modelling techniques in high-speed rotor systems

Abstract

ABSTRACT The combination of a rotor and bearings plays a pivotal role in various industrial applications, including gas turbines, compressors, turbochargers, aircraft engines, and wind generators. Ensuring the structural integrity of the rotor-bearing assembly during static and dynamic conditions is most important, as any failure could lead to unpredictable losses. Due to their continuous operation, high-speed rotors are more susceptible to faults such as misalignment, bow, eccentricity, and cracks. Among these faults, cracks are the most predominant fault that affects the system’s reliability. Despite significant advancements in rotor dynamics, cracks still threaten the integrity and performance of the rotor-bearing assembly. This review paper aims to thoroughly review the challenges and issues associated with crack formation in high-speed rotor systems. Various crack detection methods are also explored using vibration signals obtained from the rotor-bearing unit and their associated processing techniques. This study also gives an extensive overview of different crack modelling and analysis techniques. Furthermore, a novel rotor-bearing model is modelled using the finite element method, and the numerical results obtained from this model are validated with the existing literature model. This review paper will serve as a valuable resource for researchers that offers insights into the latest advancements and emphasises the importance of crack detection for ensuring the reliability of high-speed rotor systems.