ADDIS ABABA UNIVERSITY

ADDIS ABABA INSTITUTE OF TECHNOLOGY

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING
Mechanical Project Proposal

Proposal of Rotor Dynamic Analysis of large industrial Rotor using ANSYS

Mesfin Kebede
Advisor: Dr.Daniel T.
Co-Advisor: Ato Tolossa

Date: 9/28/14

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Contents
Abstract ........................................................................................................................................... 3
Introduction ..................................................................................................................................... 4
Statement of the problem ................................................................................................................ 5
Literature Review............................................................................................................................ 6
Hypothesis and Question ................................................................................................................ 9
Conceptual frame work ................................................................................................................. 10
Objectives of Rotordynamic analysis ........................................................................................... 11
Method, Material and procedures ................................................................................................. 12
Work Schedule .............................................................................................................................. 14
Budget ........................................................................................................................................... 16
References ..................................................................................................................................... 17
Appendix A ................................................................................................................................... 19
Appendix B ................................................................................................................................... 20

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Abstract
The study of rotor dynamics is essential to understand the determinant components in
engineering extensively used in industry such as Compressors, turbines and Generators
the ability to perform critical frequencies and forced response analysis is a vital role
while designing rotors of high speed it is of prime importance to consider rotor dynamics
characteristics into account considering these characteristics at the design phase may
prevent the rotor from catastrophic failures and in order to understand the levels of
stresses to which these components are subjected to during their operation .this pre design
analysis can greatly contribute to the troubleshooting the critical issues these analyses can
be a challenge due to the wide variety of components found in rotor dynamic systems
these rotor dynamic characteristics can be determined with the help of much relied finite
element method . Traditionally rotor dynamic analyses were performed with specialized
commercial tools. The most commonly used software is ANSYS the primary goal of the
thesis will be to analyze the behavior of the industrial rotors and address the critical issue
associated with them. The thesis work will also help in understanding, modeling and
simulation techniques for rotor dynamic analyses of large industrial rotors using ANSYS.

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Introduction
Rotordynamics is a discipline within mechanics, in which we study about the vibrational
behavior of axially symmetric rotating structures. The rotating structures are the pivotal
component of high speed turbo machines found in many modern day equipments ranging
from power station, automobiles, marine propulsion to high speed Jet engines. These
rotating structures are commonly referred as "Rotors" and generally spin about an axis at
high speed. The rotors when it rotates at high speed develop resonance. Resonance is the
state at which the harmonic loads are excited at their natural frequencies causing these
rotors to vibrate excessively. This vibration of larger amplitudes causes the rotors to bend
and twists significantly and leads to permanent failures. Also, deflection of shafts in
incongruous manner has a greater chance to collide with the adjacent components at its
closer proximity, and cause severe unrecoverable damages. Hence the determination of
these rotordynamics characteristics is much important.

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Statement of the problem

There are various applications on engineering, where rotors and rotating parts are of vital
importance. They play a determinant role on pumps, compressors, turbines, generators.
Due to its intrinsic dynamic state, vibration is especially relevant in this kind of
machines. Interaction between the rotating motion and the applied forces on the structure
causes some operation points to present intolerable vibration levels; the vibrational
problems in such rotating machines are prominent which necessitates the need for
analyzing their dynamic behavior and addressing these problems.
The dynamic behavior of rotating machines is characterized by their critical speeds, whirl
responses and gyroscopic effects. Due to the gyroscopic effects and the centrifugal
forces, the whirl can take place in both forward and the backward directions. The simple
rotors can be used for analyzing the rotor behavior initially; since such rotors offer ease
of modeling and simulation. A finite element analysis approach using commercial finite
element method software such as ANSYS can be viewed as a powerful solution tool that
can provide realistic information about the dynamic behavior of the rotors during their
operation. Due to the limitations of the finite element method software, it becomes
necessary to modify the calculation time and avoid large number of equations involved
by simplifying the model.

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Literature Review
In Rotordynamic analysis of industrial rotors initially requires full understanding of the
rotordynamic behavior of Jeffcott rotors, and the history of previous methods applied in
this field, their pros and cons considering all aspects of physical features such as
gyroscopic effect, rotor whirl instabilities, curve veering phenomenon in Campbell
diagram, etc. Studies related to these topics considering the objective of the thesis will be
studied and presented
The earliest study in the field of rotor dynamics dates back to the 18th century. J. W.
Rankin can be credited for the initial research in this field [2]. With the rapid
development in the field of rotor dynamics, the engineers felt the need for designing more
flexible and light weight rotors for meeting the ever increasing demands of the modern
industry. The focus of the research program has been to design rotors which require less
power to operate and would minimize the energy loss. However, with the development of
the flexible light weight rotors, the problem of vibrations and the resulting dynamic
stresses becomes a critical issue. The vibration analysis of the rotors plays a vital role in
their design process. In 1895 by the German engineer August Fppl [1] studied amodel
consisted of a single disk, centrally located on a shaft of constant circular cross-section and with
undamped rigid bearings placed at each end of the shaft. Fppl used this model to demonstrate
that such rotor operation was still stable even when its rotating speed exceeded the critical
rotating speed, i.e. he showed that in supercritical operation, tolerable vibration levels are
observed.

In 1919, Jeffcott, a British engineer, modeled a rotor as a simple mass-spring system

consisting of a disk as a lumped mass and a massless shaft assuming an imbalance in the
rotor. He analyzed the dynamic response of the rotor on two identical rigid bearings at
high speeds [4]. A study of the rotors structural dynamics with no consideration of the
bearings was done by Stodola [5]. Biezeno and Grammel suggested the earliest methods

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for finding the critical speeds in the flexible rotors [6]. Also, the rotor dynamics analysis
considering the hydrodynamic bearings was done by Lund and Sterlicht and Lund [6].
For the first main mode shape of a rotor supported on bearings, Lund found two
corresponding critical speeds [7]. Gunter studied the stability issues in rotor dynamics [8]
and his work was combined with Lunds work on the stability problems considering the
damped critical speeds within a rotor-bearing system and it initiated a great deal of
interest in this area [6]. Late in the 18th century, Karl Gustaf Patrik de Laval invented
the first steam turbine [9]. Sir Charles Algernon Parsons invented a special kind of steam
turbine that encountered considerably less vibrations in comparison with the
reciprocating engines, and were named Vibration Free Engines [10].
As mentioned earlier, Jeffcott made the first simple mass-spring rotor with a lumped disk
and a massless shaft [4]. The effect of the bearings was studied by many researchers.
Sommerfeld [11] formulated a parameter to establish the relation between the speed,
pressure and the eccentricity ratio.
The response of the rotors exhibited whirls in the forward and the backward directions
that is studied by Bhat et al. [12] using Vanderplaats method [ [13], [10]]. The effect of
the disk inertia in a rotating state on a shaft was first found by Rayleigh [3]. This
phenomenon, namely, the gyroscopic effect was studied and its effect on increasing the
forward whirl natural frequency and decreasing the backward whirl natural frequency
was analyzed by Stodola [5]. Den Hartog [14] and Timoshenko [15] studied the
gyroscopic effects on the synchronous and the non-synchronous whirls in rotors.
In 1981, Rao investigated the backward synchronous whirl in a flexible rotor with
hydrodynamic bearings [16]. Sinou, Villa and Thouverez studied the forward and
backward critical speeds in a rotor with flexible bearing support [17].
Providing a Campbell diagram for multi degree of freedom rotors using traditional
computational methods takes a long time. Genta published a fast modal analysis
technique based on splitting the gyroscopic and damping matrices into two parts and
comparing these parts with simplified conditions of rotors [18].

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In more recent days, using finite element method softwares such as ANSYS made it easy
to plot the Campbell diagram. Finite element modeling also helped the engineers to study
a variety of features in Campbell diagram such as effect of fluid film bearing properties
on the critical speeds of rotors. This work is done by Kalita and Kakoty [19].

The idea of solid or shell models of stationary structures became evident when the
casings and foundations became a part of the rotating machine and test beds became
flexible when coupled with rotors that interfered in the validating process.Stephenson and
Rouch [20] used axisymmetric solid finite elements with matrix reduction in their
analysis; Yu et al. [21] modeled shafts orbiting with 3-D solid finite elements. Neither of
these included the effects of rotation, stiffening and softening effects that go with solid
elements. Solid rotor dynamics analysis was first presented by Rao [22]. Rao et al. [23]
provided the details subsequently. Rao and Sreenivas [24] have extended the two rotor
system to a three level with the casing included in the analysis. Such an analysis enabled
practical engine rotor dynamics analysis. Surial and Kaushal [24] modeled an industrial
gas turbine en gine and validated it at Rolls Royce Canada. Due to the complexity of the
engine structure the model has been divided into four substructures using super-elements.
The first super-element represents the engine casing, the second the low pressure rotor
(LP rotor), the third the intermediate pressure rotor (IP rotor), and the fourth the high
pressure rotor (HP rotor).

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Hypothesis and Question

Question

How gyroscopic effects Modify critical speeds in large industrial Rotors?

How the critical speed of large industrial rotor related to the machine operation?
How Bearings Affect on rotor dynamics
How machine casing Affect on rotor dynamics
How applied forces and structure of machine related on rotor dynamics

the amplitude of synchronous whirl increases with speed as the critical speed is
approached, and then decreases after traversing the critical speed and approaches
the value of static imbalance at supercritical speeds
Moving of machine away from the critical speed can be achieved either by
changing the operational speed or by changing the critical speed itself.

Hypothesis

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Conceptual frame work

The study will be conducted on purposely chosen industrial Rotor the research will be primarily
a quantitative study. The data collection will come from two main sources: Primary and
Secondary sources. Primary data will obtain from industry. Secondary data collected from the
finite element analysis method the output of the program ANSYS. This data is used in a
corresponding manner throughout the paper with the purpose of supporting the argumentation.
Finally the data simulated from ANSYS can make possible to estimate the potential information
we want in the form of graph and simulated models to see clear information about the Rotor
Dynamic behavior of the rotor.

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Objectives of Rotordynamic analysis

There are several objectives are to be fulfilled within a standard rotordynamic analysis.
Obviously the rotor design is of prime importance in any rotordynamic analysis. Usually
the following issues are addressed:
Predict the natural frequencies and determine the mode shapes of the rotor system
at those natural frequencies.
Identify critical speeds within or near the operating speed range of a rotor system.
Make an unbalance response analysis of a rotor in order to calculate rotor
displacement and quantify the forces acting on the rotor supports that are caused
due to rotor imbalance.
Assess potential risks and operating problems in general related to the rotordynamics of a given rotor system.
Although the aim of the thesis work will include The study of predicting critical speeds
and forced response analysis. Initially simple Jeffcott rotors will be studied in order to
understand the dynamic behavior of such simple rotors before dealing with large
industrial rotors. After a consummate study on the simple rotor model, a finite element
model of a simplified industrial rotor, will be meshed and formulated in ANSYS
software. Gyroscopic effects will be considered in the analysis. Initially free vibration
analysis will be performed followed by forced vibration response due to harmonic
excitation by residual unbalance mass for a simple mode

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Method, Material and procedures

Course Related Study
In order to fulfill the requirements for Senior Thesis, graduate level courses must be
incorporated into the rotor dynamic analysis of large industrial rotor. Material from
the following courses will be utilized in the proposed Analysis to fulfill this
requirement. In MEng6005(Finite Element Method)

the topics of mathematical

foundation of finite element Analysis and Developing finite element Computer

programs for engineering problems was covered. Detailed skill was performed in
using commercial Finite Element Software Packages to model and Solve practical
Mechanical Engineering Problems and the class shows student how to create 2D and
3D Structure Models Using the software package ANSYS this software package used
to analyze the rotor dynamic property of a 3D modeled structure. knowledge learned
from MEng(Machine Dynamics) which covers the basic principles behind Rotor
dynamics such as continuous systems ,excitation of machine vibration and transverse
and torsional vibration of shafts and rotors will be used when evaluating the natural
frequencies and determining the mode shapes rotor system of those natural
frequencies and identifying critical speeds within or near the operating speed range of
a rotor system.

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Methodology
The methodology is outlined as follows:
1. Literature survey: The existing approaches to develop the Dynamic Model of the
rotor, to descritize the 3D Rotor model and equations the critical speed and natural
frequencies will be surveyed.
2. Simulation: Having developed the 3D model followed by the analysis of an actual
industrial rotor in order to understand its dynamic behavior which involves the
detailed analysis of the Combell diagrams, Critical speeds effect of the gyroscopic
moments etc.
3. Study and Analysis: Computer simulation results will be analyzed and the results
will be discussed.

Tools for Analysis

AutoCAD/CATIA Software will be used for the 3D modeling of the test Model and the
actual Rotor System.
ANSYS V11 Analysis Software will be used to represent and Construct the dynamic
mechanical Models.

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Work Schedule
A schedule of work is given on the next page that outlines the various tasks that need to be
completed in order to finish the thesis project outlined in the proposal above. This is only a
tentative schedule that is meant to be flexible and adapt to unforeseen delays or unexpected
lengths of various tasks. The only date that cannot be adjusted is the final presentation date on
October 05, 2015.

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Budget
No

Description

Unit

Quantity Unit

Total cost

price

birr

Duplication paper

,,

100

100

Note book

Pieces

25

75

flash diskettes

8GB

300

300

70

140

350

1050

10

50

Printing of proposal first Pieces

draft and final copies and
binding
Printing of research first ,,
draft and final copies and
binding
Pen
For

,,
ANSYS/CATIA

1500

Software Package
Sub total
2

3215

Transport

Average

125

20

2500

60

12

720

50

15

750

trip
Transport
and
communicati

Internet reading hours

Telephone

Hours

communication Days

on average days

on cost
Sub total

3970

Total cost

7185

Contingency 15 %

1078

Grand total

8263

Table 1.1 Budget estimation

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References
[1] Vance J., Zeidan F. and Murphy B., Machinery Vibration and Rotordynamics, Wiley, 2010.
[3] Rankine W. J., On the Centrifugal Force of Rotating Shafts, Engineer periodical, Vol. 27, pp.
249, 1869.
[20] Rayleigh, J.W.S., Theory of Sound, MacMillan, London, 1877.
[4] Jeffcot H. H., The Lateral Vibration of Loaded Shafts in the Neighborhood of a Whirling Speed:
The Effect of Want of Balance, Philosophical Magazine, Series 6, Vol 37. P. 304, 1919.
[5] Stodola A., Steam and gas turbines, New York: P. Smith, 1945.
[6] Biezeno, C.B. and Grammel, R., Technische Dynamik, Springer Verlag, 1939.
[7] Lund J. W., Rotor Bearing Dynamic Design Technology, Part III: Design Handbook for Fluid
Film Bearings. Mechanical Technology Inc., Latham, New York, AFAPL-Tr-65-45, 1965.
[8] Gunter, E. J., Jr., Dynamic stability of rotor-bearing systems, NASA SP-113, 29, 1966.
[9] Smil, V. Creating the Twentieth Century: Technical Innovations of 18671914 and Their Lasting
Impact, Oxford University Press, 2005.
[10] Rao J. S., History of Rotating Machinery Dynamics, Springer, 2011.

[11] John M. Vance, Rotordynamics of Turbomachinery, New York: Wiley, 1988.

[12] Bhat, R.B., Rao, J.S. and Sankar, T.S. Optimum Journal Bearing Parameters for Minimum
Unbalance Response in Synchronous Whirl, Journal of Mechanical Design, ASME, vol. 104, p.
339, 1982.
[13] Vanderplaats, G.N., Structural Optimization by Methods of Feasible Directions, Computers
and Structures, vol. 3, p. 739, 1973.

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[14] Den Hartog, J.P., Mechanical Vibration, McGraw-Hill Book Co, 1956.
[15] Timoshenko, S.P., Vibration Problems in Engineering, D. Van Nostrand Co. Inc., 1955.
[16] Rao J.S., Conditions for Backward Synchronous Whirl of a Flexible Rotor in Hydrodynamic
Bearings, Mechanism and Machine Theory, Vol. 17, No. 2, 143-152, 1982.
[17] Sinou J.J., Villa C., Thouverez F., Experimental and Numerical Investigations of a Flexible
Rotor on Flexible Bearing Supports, International Journal of Rotating Machinery, Vol.3, pp. 179
189, 2005.
[18] Genta G., A Fast Modal Technique For The Computation Of The Campbell Diagram Of MultiDegree-Of-Freedom Rotors, Journal of Sound and Vibration, Vol. 155, issue 3, pp. 385-402, 1992.
[19] Madhumita K., Kakoty S.K., Analysis of whirl speeds for rotor-bearing systems supported on
fluid film bearings, Mechanical Systems and Signal Processing Vol. 18, pp. 13691380, 2004.
[20] Stephenson, R.W. and Rouch, K.E. (1993) Modeling rotating shafts using axi-symmetric solid
finite element with matrix reduction, ASME Journal of Vibration & Acoustics, vol. 115, p. 484.
[21] Yu, J., Craggs, A. and Mioduchowski, A. (1999) Modeling of shaft orbiting with 3-D solid
finite elements, International Journal of Rotating Machinery, vol. 5, p. 53.
[22] Rao, J.S. (2002) Rotor Dynamics Comes of Age, Keynote address, in Proceedings Sixth
IFToMM International Conference Rotor Dynamics, Sydney, September 30October 3, vol.
I, p. 15.
[23] Rao, J.S., Sreenivas, R. and Veeresh, C.V., (2002) Solid Rotor Dynamics, in Proceedings
Fourteenth US National Congress of Theoretical and Applied Mechanics, Blacksburgh, VA,
2328 June; (2003) Advances in Vibration Engineering, Journal of Vibration Institute of India,
vol. 2, no. 4, p. 305.
[24] Rao, J.S. and Sreenivas, R. (2003) Dynamics of a Three Level Rotor System Using Solid
Elements, ASME GT 2003-38783.
[25]. Surial, A. and Kaushal, A. (2005) Dynamic Analysis of a Variable Speed Industrial Gas Turbine Engine and Drivetrain Analysis and Testing, Advances in Vibration Engineering, vol.
4, no. 3, p. 279.

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Appendix A
List of Tables and Figures
Tables
Table 1: Budget Estimation

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Appendix B
Preliminary Research

Mohammad Razi " Analysis of Rotor Dynamics Acceptance Criteria in Large Industrial Rotors
Concordia University ,Montreal Canada ,December 2013
This article discusses the numerical rotor dynamic analysis with that of ANSYS results and compare
the rotor dynamic results with Standards.

Deepak srikrishnanivas "Rotor Dynamic Analysis of RM12 Jet Engine Rotor using ANSYS
blenkinge Institute of technology Karlskrona,Sweden ,2012
This article discusses the results of rotor dynamic analysis of RM12 Jet Engine Rotor obtained
from the commercial Software ANSYS compared with that of the rotor dynamic analysis
software DyRobes.

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Submitted By
Mesfin Kebede
Student name

Signature

Date

Approved by
1) Dr.Daniel T.
Advisor

Signature

Date

Signature

Date

Signature

Date

2) Ato Tolossa
Co Advisor

3) Dr.Daniel T.
School Director

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