Abstract
Crack opening and closing during shaft rotation of a cracked rotor system have long been a focus of many previous studies. Previously published modeling work in the literature uses weight-governed crack breathing model for very large rotor systems. However, for lightweight or vertical or lightly damped rotors the opening and closing statuses of a crack are not always weight dominated as there is significant influence from dynamic loads. Further, the dependence of the breathing mechanism on the crack location has not been investigated yet. In this paper, the crack breathing behavior of an unbalanced shaft at the different crack location of a rotating shaft is investigated. A three-dimensional finite element model, consisting of a two-disk rotor with a transverse crack, is used. Finite element model is simulated using ABAQUS/Standard. Crack breathing behavior is found to strongly depend on its axial position, angular position, depth ratio, unbalanced force ratio and angular position. Two different crack breathing regions along the shaft length are identified, where unbalanced shaft stiffness may be larger or smaller than the balanced shaft, depending on the unbalance force orientation, magnitude and crack location. Further, four specific crack locations along the shaft length have been identified, where the crack remains fully closed or open or just behaves like in the balanced shaft. The results suggest that more accurate prediction of the dynamic response of cracked rotors can be expected when the effects of unbalance force and individual rotor physical properties on the crack breathing have been taken into account.
Highlights
The breathing of fatigue cracks is a primary cause of machine failure
A large number of finite element simulations have been performed to examine the effects of crack axial position, crack angular position, crack depth ratio, unbalanced force ratio and angular position of unbalanced force on the crack breathing
The dependence of crack breathing on the crack location along shaft length is discussed in detail
Summary
The breathing of fatigue cracks is a primary cause of machine failure. The failure of a machine can be catastrophic, and produce economic issues as well as personal injury. The breathing mechanism of a transverse crack in a two-disc rotor is investigated numerically under the coupling influence of unbalance force and rotor weight using a three-dimensional finite element model. Both ends of the shaft are fixed, which represents a more realistic boundary condition than supported ends. It should be mentioned that Rubio’s [13] work employed a classical Jeffcott rotor supported at both ends, with a massless shaft and a disc at the mid-span of the shaft In this rotor and unbalance force configuration, crack breathing will remain the same regardless of the crack location. The effect of unbalance force magnitude on the breathing was not evaluated
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