Design of a spin test system for burst phenomen considering nonlinear rotordynamic effects

Abstract

This study presents the development and evaluation of a spin test rig for high-speed rotating components. The innovation of this study is using a discrete model to determine dynamic positioning during the preliminary design phase based on vibration characteristics. The primary aim is to manage vibrations and alternating stress effects from rotor dynamics to prevent issues such as crack propagation or bursts before achieving desired speeds. MATLAB 2023b Simulink-based tool was developed, which played a role in providing the design of bearing support regions and stiffness values. The system underwent rigorous validation through structural, modal, and harmonic finite element analyses. Testing showed a maximum deviation of 4.2% for 10 kg specimen and 4.85% for 4 kg specimen between Simulink predictions and actual data, due to factors such as contact and bearing damping. For the 10 kg specimen, the maximum equivalent stress was 314.92 MPa with an alternating stress of 64.87 MPa at 0.5% damping ratio, representing 37.27% of the yield limit. For the 4 kg specimen, the maximum equivalent stress was 513 MPa with alternating stress below 40 MPa at 3% damping ratio, corresponding to 54.32% of the yield limit. This research enhances the reliability and performance of high-speed rotating machinery.