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1999, Vol. 5, No. 4, pp. 263 271 Published by license under

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Numerical and Experimental Investigations of Coupling

Effects in Anisotropic Elastic Rotors*
HORST IRRETIER , GEORGES JACQUET-RICHARDET b’ and FRANK REUTER
Institute of Mechanics, University of Kassel,D-34109 Kassel, Germany," bLaboratoire de Mcanique des Structures,
INSA’ de Lyon, F-69100 Villeurbanne, France

(Received in ji’nal form 7 July 1998)

It is known that in elastic disc-shaft systems in particular, the one-nodal-diameter mode of

the discs can be highly coupled with the bending modes of the shaft. Consequently, when the
system rotates, the elastic modes of the flexible discs are coupled with the gyroscopic modes
of the flexible shaft equipped with rigid discs. In the paper this coupling effect is investigated
numerically and experimentally.
A numerical model, based on a finite element cyclic symmetry approach, is presented. This
model has been developed for studying the wheel-shaft coupling effects on the global
behavior of turbomachinery rotors. In order to better illustrate the phenomenon involved and
to validate the model, the method is applied here to a thin tuned and detuned circular disc
mounted on an elastic shaft. Related frequency and mode shapes of the rotating assembly are
discussed. Additional experimental results, based on an experimental modal analysis
technique for rotating structures, are presented. Both numerical and experimental results
are compared.

Keywords." Rotordynamics, Disc-shaft coupling, Natural frequencies, Campbell diagram

1. INTRODUCTION are usually efficient and accurate enough. However,

there is an increasing number of cases where
Traditionally, the analysis of the dynamic behavior coupling effects between bladed-disks and shafts
of rotating disc-shaft systems is performed using cannot be ignored. Possible couplings have been
two different approaches. The rotordynamic ap- pointed out in early studies by Dopkin and Shoup
proach is focused on shaft behavior and assumes (1974), Chivers and Nelson (1975), Klompas
that the effect of wheel flexibility is negligible. On (1978), and are now better understood owing to
the other hand, the bladed-disc approach assumes the development of various analytical analyses:
that the shaft is rigid and analyses the behavior of Palladino and Rossettos (1982), Br6mand et al.
the different wheels separately. These approaches (1986), Crawley et al. (1983, 1986), Loewy and

This paper was originally presented at ISROMAC-7.

Corresponding author.

263
264 H. IRRETIER et al.

Khader (1984), Khader et al. (1990, 1991), Wu and submitted to centrifugal and gyroscopic effects, is
Flowers (1992). Particular features such as inertial analysed after a modal reduction.
coupling, mistuning influence and forced response In parallel to the analytical and numerical work
behavior have been examined. Even recently, an dealing with rotating flexible bladed-disc-shaft
analytical procedure has been developed by Chun assemblies, efforts are made to extend experimental
and Lee (1996) in order to study the influence of modal analysis techniques on rotating structures
rotation, blade stagger and blade pretwist on (Irretier and Reuter, 1995; 1997). Generally, this
coupled behaviors. requires that the modal identification algorithms
These analytical approaches, while very useful, are based on time-variant systems, to account for
are based on simplified formulations and thus anisotropic effects in the bladed-discs or shafts of
cannot be applied efficiently to real structures the rotating assembly (Reuter, 1997; Irretier, 1998).
with complex geometries. On the contrary, direct In addition to the numerical procedure and
and precise finite element modeling of the whole results described in the paper, corresponding ex-
coupled system would be attractive, but cannot perimental results are presented which are based on
be performed due to the unrealistic computer re- this extended modal testing and identification
sources needed. Consequently, intermediate model- technique.
ing techniques have to be proposed and assessed.
A first type of intermediate model consists in
analysing the shaft with rigid disc and the bladed 2. THEORETICAL BACKGROUND
assemblies separately, and then solving the coupled
problem after a modal reduction based on the The method presented here has been developed in
calculated mode shapes (Zhang et al., 1994). This order to deal with turbomachinery wheels with com-
model should give quite accurate results when the plex shapes and geometry. The motion equations,
link between the shaft and the disc is rigid,, but it is expressed in a body fixed coordinate system, of a
believed to be too restrictive for general applica- flexible bladed-disc mounted on a flexible shaft
tions. Dealing with the whole coupled assembly, rotating at a given uniform angular velocity, can be
direct modeling is possible using an axisymmetrical expressed as:
description of the rotor (G6radin and Kill, 1984;
Stephenson and Rouch, 1993). The resulting model [KE + KG({,:5}s KS]{,:5} {FC(f2)}, (1)
should be effective in certain cases but it is penalised
by the axisymmetrical hypothesis and by the
modeling difficulties associated. Finally, it appears [M]{(’}d if-[CM + CR]{(}d
that the most interesting models are those based on + [KE + KG- KS]{(5}d {0}, (2)
the cyclic symmetrical properties of the structure
(G6radin and Kill, 1986; Hohlrieder et al., 1994; where [M] is the mass matrix, [CM] the mechanical
1997; Jacquet-Richardet et al., 1996). However, damping matrix, [CR] the gyroscopic matrix, [KE]
these models remain heavy and, in this case, special the elastic stiffness matrix, [KG] the geometric
procedures should be developed in order to main- stiffness matrix, [KS] the supplementary stiffness
tain the computer requirements at an acceptable matrix and {FC} the nodal centrifugal force vector.
level. The formulation presented here is based on 6}s is the static equilibrium position of the structure
a global analysis of rotating assemblies modeled under centrifugal loading and {6}d is the small
using a finite element technique. The undamped amplitude dynamic displacement around the static
non-rotating system is first analysed using the wave position. For a given rotation speed f, the solution
propagation method associated with a component of the non-linear system (1) using a Newton-
mode reduction. Then, the whole flexible system, Raphson procedure gives the static displacement
 AN|SOTROPIC ELASTIC ROTORS 265

vector. The stiffness matrix is then known and the problem for each value of the rotation speed in the
dynamic problem can be solved. operating range. In this case, using only the tradi-
When dealing with bladed-disc--shaft assemblies, tional reductions (Craig and Bampton, 1968) leads
the size of the problem can be reduced if their to a lengthy procedure which is still not compu-
rotationally periodic characteristics are taken into tationally efficient. In the following, we shall show
account. Such structures are constituted with N that the analysis cost of bladed-disc-shaft assembl-
identical jointed sectors. According to the wave ies can be considerably reduced, without appreciable
propagation theory in periodic media, Thomas loss of accuracy, provided the rotating mode shapes
(1979), the dynamic displacement vector of the are written as a linear combination of the associated
different sectors p is related to the corresponding non-rotating mode shapes.
quantities of a reference sector by the following
phase relations:
3. REDUCED DYNAMIC PROBLEM
{6}- {6} cos(p- 1)/3n + {(5,} sin(p-
Let us first consider the undamped system at rest
(f 0). Thus (5) reduces to:
where {6} is the vibrational displacement of
sector p, {(5c}, {6,} are generalized quantities
associated with the basic sector and/3n 2rcn/N is
[M,]{,} + {KEn]{(Sn} {0}. (6)
the phase difference between the displacement of The solution of (6) is performed after a condensa-
two adjacent sectors. N is the total number of tion based on the efficient Craig and Bampton
sectors and n, Fourier order, takes the discrete
(1968) substructuring method. This solution gives
values: the frequencies and mode shapes of the non-
rotating system (Jacquet-Richardet et al., 1996).
n=0,1 ,N/2, if N is even, All the mode shapes calculated are grouped into
n 0, 1,..., (N- if N is odd.
(4)
1)/2, modal matrices [], used for the reduction of the
rotating system (5). Assuming that:
Applying the wave propagation relations (3), the
dynamic problem (2) is divided into small size (7)
systems associated with each of the possible phase
angles system (5) becomes:

[Mn]{n} + [CMn + [m]{6,n} + [cn]{dln} + [k]{%} {0} (8)

+ [KEn + KGn KSnJ{Sn} {0}, with:
where {Sn} {5c, 5"s) t. When dealing with isolated
bladed-discs, damping and gyroscopic effects are
[m,] [n]t{MnJ{n],
usually neglected and (5) becomes a Hermitian [Cn] [ n]t{eMn 4- CRn]{ n], (9)
system which is solved only once, for an operat- [kn] [ n]t[KE +
ing speed. When dealing with bladed-disc-shaft
assemblies, gyroscopic effects can no longer be The solution of (6) and (8) is performed for all the
neglected and the variations of frequencies with possible values of the phase parameter/3 2rm/N
respect to the rotation speed are relatively large. given by (4). The frequencies of the rotating system
Consequently, it becomes necessary to solve a are given directly. The corresponding mode shapes
different complex and non-Hermitian eigenvalue are obtained after applying the two successive
266 H. IRRETIER et al.

transformations, (7) and (3), to the calculated

eigenvectors. The modes of the shaft can occur
only with n 0 or n (n 0 torsion and longi-
tudinal modes, n bending modes). The modes
of bladed-discs are always classified using an
analogy with axisymmetric modes, which are
mainly characterised by nodal lines lying along
the diameters of the structure and having a constant
angular spacing. They are either zero (n =0), one
(n 1), two (n 2) or more (n > 2) nodal diameter
bending or torsion modes. Inertial disc-shaft
coupling effects are important for modes associated
with n 0 and n 1, because these modes are the FIGURE Elastic disc on a flexible shaft.
only ones where a shaft motion can occur. The disc
modes with zero-nodal-diameter, which are char- disc on a flexible shaft under rotation, a test stand
acterised by a resultant axial force, interact with the was designed as shown in Fig. (Reuter, 1997). It
longitudinal shaft deformations. The modes with consists of a thin circular steel disc (outer radius
one-nodal-diameter, which exert a net pitching 300mm, thickness 3mm) fixed in an overhung
moment and a shearing force, interact with the position on an elastic circular steel shaft (length
shaft bending modes. 175 mm, diameter 15 mm). The supported shaft
In order to be able to identify possible resonance prolongation (length 101.5 mm, diameter 28 mm)
points, the frequencies are calculated for the whole in two ball bearings can be considered to be rigid in
operating range of the structure and the results comparison to the flexibility of the overhung shaft.
classically reported on a Campbell diagram, which Two different types of disc tuning states were
illustrates the dependence of the natural frequencies investigated: (I) Completely tuned and (II) mis-
on the rotor speed f. When using the proposed tuned by two diametral masses (each 0.047 kg at a
analysis method, the non-rotating mode shapes of radius of 280 mm as visible in Fig. 1). For systems
the assembly are calculated only once. Then, the (I) and (II) numerical calculations were carried out
following steps are involved for each rotation speed at INSA Lyon by the technique described above
considered: while for system (II) additional experimental
investigations were carried out at the University
the static problem is solved;
of Kassel. For these tests, a step sine excitation by a
the dynamic problem (5) is reduced according
magnetic exciter with an integrated force trans-
to (7);
ducer was used (Fig. 2) and the response was
the reduced system (8) is solved.
measured by an eddy current pick-up, both without
Compared to traditional procedures, the computer contact with the rotating disc. Both are visible in
cost saving is considerable and allows precise Fig. 1, too, and the schematic representation of the
analyses of complex industrial structures using test stand is given in Fig. 3 (Irretier and Reuter,
efficient workstations. 1995). From the excitation and response signals,
frequency response functions were determined for
the rotating system based on a theory for time-
4. APPLICATION variant systems and, by curve fitting algorithms in
the frequency domain. The modal parameters were
For the verification of the numerical model and identified with respect to the stationary Dame
analysis and to study coupling effects of an elastic (index s, Fig. 3). If desired, they are converted to
 ANISOTROPIC ELASTIC ROTORS 267

other reference frames, e.g., the rotating frame

(Reuter, 1997).
Considering the numerical model, a portion of
54 of the disk-shaft assembly is meshed using 108
isoparametric brick finite elements with 20 nodes.
The resulting mesh, presented in Fig. 4 (dark zone)
east: comprises about 550 finite element nodes and,
consequently, about 1650 degrees of freedom. The
matrices associated with the disk elements are
evaluated using a reduced Gaussian integration to
avoid numerical shear locking. Damping effects are
neglected. The natural frequencies associated with
the first modes calculated are conveyed onto the
Campbell diagram presented in Fig. 5. At rest, these
modes can be classified as follows. The first mode is
FIGURE 2 Magnetic exciter with piezo-electric force mainly a shaft first bending mode, influenced by the
transducer.
disk mode with one-nodal-diameter. The second
mode is a disk mode without any nodal diameter or
nodal circle (umbrella mode). The third mode is a

nodal diameter
stationary pick-up

stationary magnetic exciter

FIGURE 3 Experimental modal analysis of rotating structures.

268 H. IRRETIER et al.

60.
g
40

20

200 400 600 800 1000 1200 1400

Rotation speed (rpm)

FIGURE 5 Campbell diagram (rotating frame).

100

80
Flexible disc
. . . . . .
. . . . . . . . . . .. . . . . . . . . . . . . . . .
Rigid disc . . . .
"’
g
60

40

..............
20 :-.-_-

200 400 600 800 1000 1200 1400

Rotation speed (rpm)

FIGURE 4 Finite element mesh of the assembly.

FIGURE 6 Influence of disc flexibility.

shaft bending mode strongly coupled with the one-

nodal-diameter disk mode. Finally, the fourth presented in Fig. 6. When examining Fig. 6, it
mode is a disk mode with two nodal diameters. appears clearly that the influence of disk flexibility
The progression of the disk modes with rotation is is considerable here. At rest, the first frequency
only induced by centrifugal effects (stress stiffening given by the rotordynamic approach is overesti-
and spin softening). As predicted, no coupling mated by a factor of 31% and the second one is
occurs between these modes and shaft bending. overestimated by a factor of 87%. This last result
When rotating, each shaft mode splits into back- illustrates the coupled nature of the second shaft
ward and forward branches, due to gyroscopic bending mode with the one-nodal-diameter disk
effects. When the speed increases, there is a clear mode. Considering the evolution of frequencies
coupling between the first and second shaft bending with rotation, the forward branches (lower
modes. branches in the rotating frame) are much more
influenced by disk flexibility effects than the back-
ward branches.
Influence of Disk and Shaft Flexibility
The influence of shaft flexibility is illustrated in
The influence of disk flexibility on the overall Fig. 7, where the flexible disc-shaft assembly
behavior is illustrated by comparison of the results results (solid lines) are compared with results
presented in Fig. 5, with the results obtained using associated with a rigid shaft model (dotted lines).
a rotordynamic approach (rigid disk). The compar- The rigid shaft results were obtained by considering
ison, which naturally involves only shaft modes, is the disk isolated and clamped at its inner diameter.
 ANISOTROPIC ELASTIC ROTORS 269

Figure 7 confirms that the zero- and two-nodal- m=0.047kg each, on the disk, at a radius
diameter disk modes, identified previously, are R 280 mm. Due to these two masses the assembly
not influenced by shaft bending. On the contrary, is no longer axisymmetric and, consequently, the
the highly coupled nature of shaft bending and choice of the basic cyclic sector is no longer free but
one-nodal-diameter disk bending is here also high- should take up half of the structure. The resulting
lighted. For the flexible assembly, the one-nodal- mesh, based on the same element size as previously,
diameter mode has been identified as a component comprises 360 finite elements and 2200 nodes. In
of the first and third modes: at rest fl =2 14.2 Hz and this case, the computational effort needed is
f3=39.4Hz. The pure one-nodal-diameter disk obviously much more considerable.
mode is just between these two frequencies: Frequency splitting can be noticed due to
f--21.6Hz. When the speed increases, it can be mistuning. As the mistuning introduced in the
noticed that the backward branch of the first mode system is relatively low, Table I shows that the
and the forward branch of the third mode of the splitting induced is not very pronounced. For
flexible assembly, evolve toward a pure one-nodal- comparison, the test results are also presented in
diameter disk mode. Table I (with the exception of mode 3 which was not
investigated in the tests). The experimental frequen-
Influence of Mistuning cies for the first shaft bending mode (n= 1) are
almost 6% higher than the numerical results. The
The influence of mistuning has been tested by
main reason for this discrepancy is the slightly
adding two diametrically opposed point masses of longer overhung shaft considered in the numerical
calculations (180 mm instead of 175 mm). For the
Flexible shall elastic disc mode frequencies with n 0 and n 2,
Rigid shall the difference between the test and numerical results
is much less, being around 1%. The splitting
tendency due to mistuning is very well predicted
for the n and n 2 diameter mode as can be seen
20 in Table I.
The Campbell diagram for the mistuned
assembly is presented in Fig. 8 for the modes under
0 200 400 600 800 1000 1200 1400
consideration. Besides the curves representing the
Rotation speed (rpm)
numerical results, test results are also shown by
FIGURE 7 Influence of shaft flexibility. included points. Again, the agreement between

TABLE Frequencies at rest, influence of mistuning

Mode (n) Numerical results Test results
Tuned assembly Mistuned assembly A (%) Mistuned assembly
F (Hz) tl 0 rpm F (Hz) f 0 rpm F (Hz) t2 0 rpm
(1) 14. 13.8 -2.1 14.5 5.1
14.1 14.1 0.0 15.0 6.4
2(0) 31.6 31.1 -1.6 31.5 1.3
31.6 31.1 -1.6 31.5 1.3
3(1) 39.4 39.0 -1.0
39.4 39.1 -0.8
4(2) 44.7 43.4 -2.9 43.8 0.9
44.7 44.7 0.0 44.9 0.4
270 H. IRRETIER et al.

Tuned numerical results

Mistuned numerical results .--’-"-
colleague and friend in 1987. The co-operation
-.,-
...-,-,-’ started then gave rise to a long lasting relationship
Mistuned test results

between the Institute of Mechanics, University of

Kassel and the Laboratoire de M6canique des
Structures, INSA de Lyon. This joint paper is an
20
expression of this relationship which the authors
hope to continue in the future.
200 400 600 800 1000 1200 1400
Rotation speed (rpm)
References
FIGURE 8 Mistuned assembly.
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and Vibration Bulletin 56(2-3), 71-80.
both results is excellent with slightly higher devia- Chivers, D.R. and Nelson, EI.D., 1975, The natural frequencies
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