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<p>Rotors in mechanical systems are susceptible to crack-induced damage under severe operating conditions and long-term alternating loads, which adversely affects the system’s dynamic behavior and operational efficiency. This paper develops a nonlinear finite element model (FEM) for both healthy and cracked rotors, incorporating the&#xa0;strain energy release rate (SERR) theory to evaluate torsional energy and vibration responses of a cracked rotor under different crack parameters and load conditions. The influence of crack depth and location, load type and magnitude on the vibrational response and stress intensity factors (SIF) is evaluated. Experimental validation confirms the accuracy of the FEM using modal analysis and vibration signatures. Results demonstrates that vibration response spectra, particularly the 1X and 2X components are highly sensitive to the cracks exceeding 2&#xa0;mm in depth, while the&#xa0;3X component serve as early&#xa0;warning indicator of crack initiation and propagation. Additionally, a quantitative correlation between the 3X amplitude and crack-tip stress SIF is established, enhancing the vibration-based indicators. Normalized SIF thresholds and detection metric based on the 3X/1X amplitude ratios are introduced to facilitate early detection and real-time monitoring. The proposed approach establishes a solid and physically interpretable framework for early fault diagnosis and RUL prediction in cracked rotors based on super-harmonic components (2X and 3X), offering a robust tool for monitoring and ensuring the safety, reliability, and structural integrity of rotor systems in various industrial applications.</p>

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Investigating Crack-Induced Vibrations in Rotors: A Finite Element Approach for Structural Integrity and Predicting Rotor Life

  • 期刊论文

  • 发表日期：

    2025年10月13日

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  • Imdad Ullah Khan,
  • Hongzhang Yu,
  • Chunrong Hua,
  • Weiqun Liu,
  • Dingzhong Cai,
  • Abdul Mussawar

摘要

Rotors in mechanical systems are susceptible to crack-induced damage under severe operating conditions and long-term alternating loads, which adversely affects the system’s dynamic behavior and operational efficiency. This paper develops a nonlinear finite element model (FEM) for both healthy and cracked rotors, incorporating the strain energy release rate (SERR) theory to evaluate torsional energy and vibration responses of a cracked rotor under different crack parameters and load conditions. The influence of crack depth and location, load type and magnitude on the vibrational response and stress intensity factors (SIF) is evaluated. Experimental validation confirms the accuracy of the FEM using modal analysis and vibration signatures. Results demonstrates that vibration response spectra, particularly the 1X and 2X components are highly sensitive to the cracks exceeding 2 mm in depth, while the 3X component serve as early warning indicator of crack initiation and propagation. Additionally, a quantitative correlation between the 3X amplitude and crack-tip stress SIF is established, enhancing the vibration-based indicators. Normalized SIF thresholds and detection metric based on the 3X/1X amplitude ratios are introduced to facilitate early detection and real-time monitoring. The proposed approach establishes a solid and physically interpretable framework for early fault diagnosis and RUL prediction in cracked rotors based on super-harmonic components (2X and 3X), offering a robust tool for monitoring and ensuring the safety, reliability, and structural integrity of rotor systems in various industrial applications.