A novel reduced-order modeling method is presented in this paper for dynamics analysis of rotating impeller–shaft-bearing assembly with cracked impellers. Based on three-dimensional finite element model, the complex component mode synthesis (CMS) method is employed to generate an efficient reduced-order model (ROM) for studying the effects of crack on the global vibration of the rotating assembly. First, a modeling framework for impeller–shaft-bearing systems in rotating frame is presented. Rotational effects, including Coriolis matrix and centrifugal softening, have been taken into account. Then, the governing equation of motion of the damped gyroscopic system is reduced by the complex CMS method. Finally, the obtained ROM is employed to study the effects of crack on assembly׳s vibration. During the steady-state response analysis, external excitations on the impeller due to rotor–stator interactions have been taken into account, which was however neglected in previous investigations on rotordynamics. Numerical results show that the lower-order eigenvalues and the unbalance response of the assembly are not sensitive to the local crack on impeller. Nevertheless, the flexible coupling between impeller and shaft becomes more complex when the air flow-induced excitations are considered. Under EO1 traveling wave excitations, a crack leads to slight changes in the assembly׳s response. In contrast, the effect of crack becomes significant when the assembly is excited by EO2 and higher EO excitations. Moreover, the nonlinear crack breathing effects affect the assembly׳s response obviously. Finally, a potential technique for detecting the crack on impeller during operation is discussed.
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