Jtam-A4.dvi JOURNAL OF THEORETICAL AND APPLIED MECHANICS 55, 3, pp. 751-763, Warsaw 2017 DOI: 10.15632/jtam-pl.55.3.751 STABILITY ANALYSIS AND DYNAMIC BEHAVIOUR OF A FLEXIBLE ASYMMETRIC ROTOR SUPPORTED BY ACTIVE MAGNETIC BEARINGS Molka Attia Hili, Slim Bouaziz, Mohamed Haddar Laboratory of Mechanical Modeling and Production (LA2MP), National School of Engineers of Sfax (ENIS), University of Sfax, Tunisia; e-mail: Molka.hili79@gmail.com The objective of this work is to show the influence of dynamic characteristics of Active Magnetic Bearings (AMBs) on the stability and dynamic response of an asymmetric and unbalanced rotor. Indeed, AMBs have been successfully applied in several industrial machi- nery facilities. Their main advantages are the contactless working principle, frictionless su- spension and operation in very high speeds. Firstly, the AMBs dynamic support parameters havebeen obtained through electromagnetic theory.Then, a generalized systemequations of motion have been derived using the finite element method. The motion of a rotor the shaft cross-section of which is asymmetric is generally governed by ordinary differential equations with periodic coefficients. Floquet’s theory is used to investigate the stability of this system of equations. Finally, numerical simulation results are presented and discussed. Keywords: asymmetric rotor, finite element, Floquet’s theory, dynamic coefficients, stability 1. Introduction A spinning system serves as amodel formany rotatingmachinery elements. It is generally com- posed of a flexible shaft on which a flexible or rigid disk is mounted and supported by bearings. Bearings have a considerable effect on the dynamic behaviour of such systems. Recently, AMBs are increasingly used, especially in machines operating at very high rotational speeds, because of their many advantages (no lubrication, very long life, supporting hard environments, precise control, low power use and high-speed operating) compared to rolling elements, hydrodynamic or elasto-hydrodynamic bearings. On the other hand, the presence of defects is a major concern in rotating machinery; they generate some important loads and vibrations and also stability problems. Asymmetric cross section of the shaft is among commonly encountered defects, it is usually due to machining defects. The study of rotating systems supported by AMBs bearings and analysis of machine faults has resulted in an extensive body of publications. Lei and Palazzolo (2008) presented an approach for the analysis and design of magnetic suspension systems with a large flexible rotor dynamic model including dynamics, control and simulation. Inayat-Hussain (2007) presented a numerical study to investigate the response of an unbalanced rigid rotor supported by AMBs. The mathematical model of the rotor-bearing system used in that study incorporated non-linearity arising from the electromagnetic force-coil and current-air gap relationship, and the effects of geometrical cross-coupling. The response of the rotor was observed to exhibit a rich variety of dynamical behaviour including synchronous, sub-synchronous, quasi-periodic and chaotic vibrations. Inagaki et al. (1980) studied a multi- -disk fully asymmetric rotor with longitudinal variation of the shaft cross section. The temporal equations of motion were obtained using the transfer matrix method. The unbalance response was deduced by the harmonic balance method. 752 M. Attia Hili et al. Oncescu et al. (2001) proposed modifications into a classical finite element procedure deve- loped for rotors with symmetry to incorporate the effect of shaft asymmetry and used Floquet’s theory to investigate the stability of a general system of differential equations with periodic coefficients. Recently, Inayat-Hussain (2010) studied the dynamics of a rigid rotor supported by load- -sharing between magnetic and auxiliary bearings for a range of realistic design and operating parameters. Numerical results of that work show that the unbalance parameter is the main factor that influences the dynamics of the rotor-bearing system. It was also shown that the non-synchronous vibration response amplitude of the rotor with a relatively small unbalance magnitude can be reduced by decreasing the magnitude of the friction coefficient. Tsai et al. (2011) developed a wavelet transform algorithm to identify magnetic damping and stiffness coefficients of the driving rod with a set of 4-pole AMBs. This work further revealed that the identified second-order damping coefficient is negative for a specific rod displacement and speed. The dynamics of the rotor-AMBs system in the axial direction is unstable. Bouaziz et al. (2011) investigated the dynamic response of a rigid misaligned rotor mounted in two identical AMBs. Three simplifiedmodels of current biased radialAMBswere presented,where four, six and eight electromagnetswerepoweredbyabias current and the respective control current.Results of that work show that angular misalignment is such that the 2× and 4× running speed components are predominant in spectra of vibration. Their magnitudes vary with the number of magnets in the bearing. Bouaziz et al. (2016), proposed a dynamical analysis of a high speed AMB spindle in the peripheral milling process. The time history of the response, orbit, FFT diagram at the tool-tip center and the bearings dynamic coefficients were plotted to analyze dynamic behavior of the spindle. Most of the papers found in the literature concerningmagnetic bearings are interested in the dynamic response of unbalanced or misaligned rotors. The shaft is generally considered rigid or massless. On the other hand, the papers dealing with asymmetric shafts, consider that the shaft is supported by two identical elastic bearings. The coefficients of stiffness and damping are given arbitrarily. Stability study is very limited. In this paper, dynamic characteristics of ActiveMagnetic Bearings (AMBs) is first be deter- mined. Then a model of an asymmetric rotor supported by two magnetic bearings is presented using the finite element procedure. A stability analysis will be conducted while showing the influence of various parameters of the bearings on stability areas. In the sameway, the dynamic response of the asymmetric shaft will be calculated and analyzed. 2. Bearing modelling The electromagnetic bearing studied is formed by four electromagnets (n = 4) placed in the bearing around the rotor and producing an attractive force (Fig. 1). Using the electromagnetic theory, the electromagnetic resultant forces produced by every pair of the electromagnets in x and y directions are expressed as (Inayat-Hussain, 2010) Fx =λ [( I0− ix C0−ux )2 − ( I0+ ix C0+ux )2] Fy =λ [(I0− i0− iy C0−uy )2 − (I0+ i0+ iy C0+uy )2] (2.1) where C0 is the nominal air gap, i0 is the bias current (to produce neutralizing force due to weight of the rotor), I0 is the steady state current in the coil, ux and uy are respectively the shaft displacements in the x and y directions, λ is the global magnetic permeability expressed as λ= µ0AN 2 4 cosθ (2.2) Stability analysis and dynamic behaviour of a flexible asymmetric rotor... 753 Fig. 1. Electromagnetic bearing whereA,µ0, θ andN represent, respectively, cross section area of an electromagnet, permeability of vacuum, half angle between the poles of the electromagnet and the number of windings in the coil, and ij (j = x,y) represents the control current expressed using a proportional-differential (PD) controller as ij = kpuj +kdu̇j j=x,y (2.3) where u̇j is shaft velocity in the j direction, kp is the proportional gain and kd is the differential gain. By replacing (2.3) respectively in (2.1), we obtain Fx = a   ( 1− kpux I0 − kdu̇x I0 1− ux C0 )2 − ( 1+ kpux I0 + kdu̇x I0 1+ ux C0 )2   Fy = a   ( 1− i0 I0 − kpuy I0 − kdu̇y I0 1− uy C0 )2 − ( 1+ i0 I0 + kpuy I0 + kdu̇y I0 1+ uy C0 )2   (2.4) where a=λI20C 2 0. Electromagnetic forces that depend on the shaft centre displacement and velocity are line- arized (first order) around the equilibrium position (Bouaziz et al., 2016). This will provide the classic model of a bearing with four stiffness and damping coefficients (Fig. 2) { fx fy } =−KB { ux uy } −CB { u̇x u̇y } (2.5) whereKB is the bearing stiffness matrix expressed as KB = [ Kxx Kxy Kyx Kyy ] =−     (∂Fx ∂ux ) 0 0 0 (∂Fy ∂uy ) 0     (2.6) andCB is the bearing stiffness matrix expressed as CB = [ cxx cxy cyx cyy ] =−     (∂Fx ∂u̇x ) 0 0 0 (∂Fy ∂u̇y ) 0     (2.7) 754 M. Attia Hili et al. In this model, the stiffness and damping cross-coefficients of the bearings are neglected. Nume- rical differentiationmethod is selected for determination of the dynamic coefficients. The partial derivatives are evaluated by the finite difference central method. Fig. 2. TwoDOF bearingmodel 3. Equation of motion Themathematical model (Fig. 3) consists of a flexible asymmetric shaft, one rigid disk and two active magnetic bearings. Fig. 3. Rotor bearing systemwith AMBs Thefinite element procedure for rotorswith the symmetric shaft is considered.Modifications are made to accommodate the effect of shaft asymmetry (Oncescu et al., 2001). 3.1. Equation of motion of the shaft The shaft is considered to be flexible. It is characterized by its kinetic and deformation energies. Its motion results from transverse displacement (ux,uy) and bending deformations (θx,θy) in the x- and y-planes (Fig. 4). Because of the shaft asymmetry, the sectional moments of inertia Ix and Iy are not identical, consequently, the kinetic energy of the shaft can be represented by Oncescu et al. (2001) Ts = ρS 2 L ∫ 0 (u̇2x+ u̇ 2 y + u̇ 2 z) dz+ ρIm 2 L ∫ 0 (θ̇2x+ θ̇ 2 y) dz+2ρImΩ L ∫ 0 θ̇xθy) dz + ρId 2 L ∫ 0 (θ̇2x+ θ̇ 2 y) dzcos(2Ωt)+ρId L ∫ 0 (θ̇xθy) dz sin(2Ωt) (3.1) Stability analysis and dynamic behaviour of a flexible asymmetric rotor... 755 Fig. 4. Shaft modelling and corresponding DOF where ρ is material density, Im = (Ix + Iy)/2, Id = (Ix − Iy)/2 are respectively deviatory and mean area moments of inertia of the shaft cross-section (Ix and Iy are the second moments of area about the principal axes x and y of the shaft). Rayleigh’s dissipation function of the disk is (Gosiewski, 2008) Ed = 1 2 L ∫ 0 cs(u̇ 2 x+ u̇ 2 y) dz+ 1 2 L ∫ 0 ci[(u̇x+Ωuy) 2+(u̇y −Ωux) 2] dz (3.2) where cs and ci are respectively coefficients of external and internal damping. If shear deformations are neglected, the strain energy of the shaft is (Oncescu et al., 2001) U = 1 2 L ∫ 0 EId {[(∂2uy ∂z2 )2 − (∂2ux ∂z2 )2] cos(2Ωt)−2uxuy sin(2Ωt) } dz + 1 2 L ∫ 0 EIm [(∂2ux ∂z2 )2 + (∂2uy ∂z2 )2] dz (3.3) whereE is Young’s modulus. The finite element used to discretize the shaft consists of two node beam elements where each node has four degrees of freedom: two lateral displacements and two bending rotation angles. Applying Lagrange’s formalism to this system permits the development of the equations of motion of asymmetric shaft (Oncescu et al., 2001) Ms(t)δ̈s+(ΩGs+Cs)δ̇s+Ks(t)δs =0 (3.4) with Ms(t)=Mss+Md,ccos(2Ωt)+Md,s sin(2Ωt) Ks(t)=Kss+Kd,ccos(2Ωt)+Kd,s sin(2Ωt) whereMss is the mass matrix of the symmetric shaft (Batoz and Gouri, 1990), Md,c andMd,s are mass matrices induced by the asymmetry of the shaft, Gs is the gyroscopic matrix of the shaft,Cs is the dampingmatrix, Kss is the stiffness matrix of the symmetric shaft (Batoz and Gouri, 1990), Kd,c andKd,s are stiffness matrices induced by the asymmetry of the shaft, δs is the vector of shaft DOFs. 3.2. Equation of motion of the disk The center of mass of the rigid disk coincides with the elastic center of the shaft cross-section. The nodal displacements vector of the disk in fixed co-ordinates is given by: δD = {ud,x,ud,y,θd,x,θd,y}. 756 M. Attia Hili et al. The kinetic energy of the disk, by considering the effect of the unbalance, is expressed as (Oncescu et al., 2001) Td = 1 2 Md(u̇d,x+u̇ 2 d,y)+ 1 2 J(θ̇2d,x+θ̇ 2 d,y)+2Jθ̇d,xθd,y+mudΩ[u̇d,x cos(Ωt)+u̇d,y sin(Ωt)] (3.5) where Md and J are mass and moment of inertia of the disk, Ω is angular speed of the rotor, mu is unbalance mass (assumed to be small if compared with Md), d is the radius defining location of the unbalance. Rayleigh’s function of the disk energy dissipation is (Gosiewski, 2008) Ed = 1 2 cs(u̇ 2 d,x+ u̇ 2 d,y)+ 1 2 ci [ (u̇d,x+Ωud,y) 2+(u̇d,y −Ωud,x) 2 ] (3.6) where cs and ci are respectively the coefficients of external and internal damping. The application of Lagrange’s equations for the disk only gives MDH+ δ̈(ΩGD+CD)δ̇D+KDδD =Fu(t) (3.7) whereMD,GD,CD andKD are respectively mass, gyroscopic, damping and stiffness matrices of the disk,Fu(t) is the unbalance vector. 3.3. General equation of motion of the rotor By assembling the elementarymatrices of shaft elements, disks andbearings (as expressed in Section 2), we obtain a systemofn second order differential equations andnunknown functions, where n is the number of DOFs of the rotor. The global equations of motion are M(t)δ̈+(C+ΩG)δ̇+K(t)δ=Fu(t) (3.8) whereM(t) andK(t) are periodicmatrices of period T1 =π/Ω, for which the time dependency is due to shaft asymmetry, C is a constant matrix including damping effects of AM bearings, G is the gyroscopic matrix, Fu(t) – unbalance vector of period T2 =2π/Ω and δ is the vector of global DOFs. The equations of motion are therefore parametric in nature, which usually causes a stability problem. Floquet’s theory will be used to determine the zones of instability. 4. Floquet’s theory Floquet’s method is a mathematical tool for solving parametric differential equations, such as (3.8). It involves computation of a transfermatrix over oneperiodofmotion (Dufour andBerlioz, 1998). The study of stability of the steady state solution of system (3.8) can be reduced to study of stability of the trivial solution of the associated homogeneous system. A state-space model for system (3.8) (with Fu(t)=0) has the form Ẋ=A(t)X (4.1) where A(t) is a m×m (m= 2n) periodic matrix called the dynamic matrix of period T , and X= {δ, δ̇}−1 is the state variable vector. The transfer matrix Φ(T,t0) (Bauchau and Nikishkov, 2001) is by definition a matrix that relates the initial solution X(t0) to the solution X(T) obtained at t=T , so X(T)=Φ(T,t0)X(t0) (4.2) Stability analysis and dynamic behaviour of a flexible asymmetric rotor... 757 The period T of the matrix A(t) is divided into n intervals of equal length h=T/n (t0 < t1 < ... < tn−1 1, i = 1,2). The fundamental and first secondary harmonics related to the natural frequenciesFn1 andFn2 are respectively marked with spots and squaremarks. These peaks correspond to parame- tric quasi-modes characterizing every linear time-varying system like an asymmetric shaft. These results are in good agreement with the experimental results given in Fig. 12b and found by Lazarus et al. (2010). Indeed, the authors measured the frequency response of 762 M. Attia Hili et al. an asymmetrical shaft. These experimental results are filtered to remove the spin speed subharmonics. The fundamental and first secondary harmonics related to the natural fre- quencies Ωn1 = 15Hz and Ωn2 = 23Hz are, respectively, marked with red square marks and with blues pots. We deliberately chose a low speed rotation (although magnetic bearings operate at high speeds) tovalidate thenumerical simulations.Finally,wenote that the samebehavior is observed in the yz-plane. The parametric quasi-modes also appear regardless of the running speed used. 6. Conclusion In this paper, a finite element procedure for rotor-AMBs systems is generalized to include the effects of shaft asymmetry. Firstly a model describing electromagnetic bearings (with four electromagnets) has been developed allowing to calculation of the dynamic coefficients which are mainly influenced by the air gap C0 between the stator and the shaft, the effective cross-sectional area A and the bias current I0. Then, analysis of the stability by Floquet’s theory shows that the stability is stronglydependenton theparameters of thebearings (whichallowdeterminationof theoptimum parameters providing better behavior). The stability of the system is improved by the choice of AMBs parameters leading to an increase in the damping coefficients. Thedynamic response identifies theasymmetry of the shaft by thepresence of oddharmonics of the rotational frequency and parametric quasi-modes in frequency spectra. 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