Frantisek L. Eisi em, ASME Faster Whee Erg Corpor, ‘keton, 1 o8806-000, eal fank_eisigetin co Acoustic Fatigue of Impellers of Rotating Machinery Impellers of air, gas, or steam moving rotating machinery are exposed 10 acoustic pre. sure loading (pressure pulsations} from acoustic waves generated nthe gaseous medion rom flow within the machine casing. The acoustic waves and the impeller structure ‘contain a number of natural frequencies and corresponding mode shapes. The acoustic waves are expressed by pressure pulsations which typically consist of 1) fluctuating wall pressures, 2)plane waves, and 3) higher order acoustic modes. Out of the three excitation Phenomena, the higher-order acoustic modes are the most efficent excitation sources of impeller vibration. The reason for this is the interaction of these modes with impeller structural modes when they become coincident. Of importance is the coincidence of ‘acoustic modes and structural modes with matching wave numbers. The most severe ‘dynamic loading of the Impeller occurs at complete coincidence in which in addition to a match in wave numbers (mode shapes) also matching of acoustic and structural frequen ‘ies occurs. The paper will provide the theorerical background ofthe physical phenomena ‘governing the fluid structure interaction which may lead to extreme loading ofthe impel- ler in an acoustically structurally coupled system. Such loading may result in vibration ‘and structural fatigue (acoustic fatigue) and possibly in the destraction of the impeller (DOK: 10.1115/1.1462622) Introduction ‘Immpellers of rotating machinery, such as fans, compressors, tur- bines, etc. ae exposed to acoustic pressure loading from acoustic waves developed in the air, gas, or team medium surrounding the impellers) within the machine casing or housing. The acovstic waves are excited by te flow through the machine and enhanced by the impeller rotation as confirmed by tests of machines in operation. Significant specific sources of excitation are turbulence both at the inlet and within the casing, and diserete frequency excitaion such as from rotational Now and blade passing fre- quency pulsation. ‘As aresult, specific acoustic waves develop within the machine casing which may interact with strctural modes of the impeller and at certain conditions may lead to vibration, fatigue, and ult- ‘mately to structural failure of the impeller. (The interaction with blades, separate problem, will not be studied here.) ‘This stdy willbe based on theoretical considerations utilizing the theory of coincidence between plane waves and higher order acoustic modes, and the corresponding impeller structural modes. Brief Review of Publications ‘The theory of coincidence between higher order acoustic modes and structural modes played a significant role in analyzing piping systems due to internal acoustic loading for structural vibration. (Ball and Norton [1), Norton [2], Faby (3). ‘Te was also utilized for the development of design guidelines against acoustic fatigue in piping systems (Eisinger [4), Eisinger and Francis (5). For general theory of acoustic/stuctual interaction see forex ample (Fahy [6,73]}, Dowell tal. [8] and Norton [2]. Eckert [9] and Ni [10] described a case of an impeller fatigue evidently caused by acoustie-structural interaction. A disk/acoustic wave in- teraction was studied by Gorman et al. [11], Tn this paper, we will provide a general guideline forthe pre~ diction of acoustically induced vibration and fatigue of impellers, Conroe by the Pressure Vessels and Piping Division and peed atte rere Veet Pig Conforms, et gi ly 2-35, 50), of TH fuaicaN SOCIETY OF MECiAddCAL ENONEERS. Manag recived Oy Be DU Diviion, Suga 24,201 ried enue eaves November 2, 200. Et 8 ¥ Zam 184 / Vol. 124, MAY 2002 Copyright © 2002 by ASME. {or vibration prevention in the design stage, and also guidance for corrective measures needed to eliminate a vibration problem. ‘Theoretical Considerations Due to the high-velocity flow through the machine and dve to the impeller rotation, high-pressure fucwations occur inside the ‘machine casing or housing giving rise to vibrational response of the impeller. The pressure pulsations typically consist of 1) non- propagating fuctating wall pressures, 2) plane waves, and 3) higher-order acoustic modes; for a full description, see, for ex- ample, [2], Out of the thee excitation phenomena, the higher ‘order acoustic modes are the most efficient excitation sources of {impeller vibration. The reason for ths is the interaction ofthese ‘modes with strctural modes when they become coincident. Of {importance is the coincidence of acoustic modes and impeller structural modes at which matching of wave numbers w/e be- tween these modes occurs (where a is the natural citcalar fe- quency and c is the speed of sound in the acoustic medium or the bending wave velocity in the impeller, respectively). The most severe dynamic loading of the impeller is known to occur in the case of complete coincidence in which, in addition to a match ‘between wave numbers, resonance (or matching) of acoustic and structural frequencies also occurs. This leads to a structural- acousticaype self-excited vibration. ‘The acoustic modes are characterized by the (p, g, 7) waves or modes, where p is the number of plane diametal nodal surfaces, @ js the number of cylindrical nodal surfaces concentric withthe machine axis, and r is the axial mode order. Plane waves are characterized by p= q™0. The higher-order acoustic modes can be ofthe symmetric ype with (p=0,g>1), or of the asymmetric ‘ype with (p> 1,g>1). As mentioned befor, the most dangerous acoustic waves from the standpoint of dynamic loading of the impeller are the higher-order acoustic modes which are active above the cutoff frequency at (p=1,9=0), and decay below i “The frequencies of the pq internal acoustic modes ina cylinder are given by [2] 2) pai fos" —aB o where ‘Transactions of the ASMETetiet_Solutons to Bessel tuncton fr accuse mode cua P[d |@a)rq [P [4 | ra T]0 [Tez |S [0 [ease TO [3.0542 |Z [1 | 6.7061 OTT [38517 FO 70156 TPO [42012 [6 [0 | 75013 FTO [33175 |3 [1 | 8.0152 T/T [333s 71 [2 | 85368 (7a), = represent solutions to first derivative of Bessel function for diferent modes, dimensionless (Table 1) ‘¢; ™ speed of sound in medium inside m/s D = cylinder diameter, m Te structural modes of the impeller are characterized by the out-of-plane bending modes (m, n), where m is the number of impeller disk full waves or the number of nodal diameters, and n is the number of circular nodal lines concentric with the impeller disk, The impeller structural modes are of the propagating or tray~ cling type as the periphery of the impeller acis as an unbounded (Gnfinite length) structure inthe circumferential direction. Figure 1 shows strctural and acoustic mode shapes for a cit- cular impeller disk and also for a eylindrcal symmetric machine OO ®@ By © ® CA BY On 30 40 ld 50 21 Fig. 1 Acoustic mods inside a cylindrical shell or structural modes of a circular disk—mode orders: p,q (acoustic), m,n. (structural) Journal of Pressure Vessel Téchnology Seecaral(now-iner) \ Frequency “Acoustic (linear ) \ coincidence Mode Shape Pog myn 10 20 40 > Acoustic (quasilinear ) ‘Mode Shape Pg mq Frequency 3 on ad Cc) Fig. 2. Coincidence conditions between structural and acous- tic’ modes "schematically(a) diametral modes, () mixed ‘iametrallcireumterential modes. casing, Such ideal mode shapes may be distorted, depending upon the actual structural configuration of the impeller or of the ma- chine casing, ‘The interaction of the diametral acoustic modes p with the im- peller out-of-plane structural modes m plays a decisive role in the dynamic loading of the impeller. The most severe loading of the Impeller, and thus the highest vibratory stresses in the impeller velop when the diametral acoustic wave number coincides with the out-of-plane structural wave number, thus when p=m and ‘when alo the frequencies of these two modes coincide (complete incidence). Figure 2 shows schematically complete coincidence conditions for diametral modes (Fig. 2(a)), and combined iameral-circular modes (Fig. 2(0)). In case ‘of the diametral ‘modes, coincidence is likely to occur at one mode only because of, the shape of the acoustic and structural relationships. In case of, the combined modes, one or two coincidences would be possible in te lower mode range. ‘Figure 3 shows examples of matching wave numbers for p ‘=m of 2,3, and 4 nodal diameter modes. Based ‘on experimental evidence, the coincidence (and cou- pling) between the diametral acoustic and diametral structural ‘modes has led to failures in most cases known to the author (Eis- inger [12). Highly swessed vibratory conditions could, however, ‘occur also at coincidence between plane acoustic waves and cor” responding lower-order circumferential (umbrellatype) structural ‘modes {11}. Based on the foregoing, it follows that coincidences between acoustic modes and structural modes must be avoided in order 10 prevent excessive dynamic loading of the impeller. ‘The prediction ofthe structural and acoustic mode shapes and ‘requencies is typically done by finite element modeling. How- ‘ever, for rotationally symmetric circular (cylindrical) conigura- tions, both the acoustic and also the structural modes can be pre- ‘dicted “analytically. For nonsyrmetric or complex structural ‘configurations those representative of actual machines, the finite ‘element method is used almost exclusively. ‘Modal Equations of Motion. The coupled modal equations ‘of motion are given as follows [3] For the structure MAY 2002, Vol. 124 / 185IMPELLER STRUCTURAL MODES HIGHER ORDER ACOUSTIC MODES mando pando Fig. 3 Examples of wave number coincidence between strue- tural and acoustic waves ata, ® 1nd forthe Sid acoustic field S,+02@.=CSIVD WCPO) where w, is the structural displacement, and @, is the acoustic field velocity potential. The summation i taken over the in-vacuo ‘nocmal modes of the structure and the “rigid-wall” acoustic eld ‘potential. (The remaining terms in Eqs. (2) and (3) will be defined in detail in the next paragraph) Equations (2) and (3) describing the strctually acoustically ‘coupled system represent a doubly infinite set of simultaneous ifferential equations. These have to be limited, in order to obtain solutions. In this paper, we will utilize the modal interaction ‘model approach described in the next paragraph to obtain solutions, ‘Modal Interaction Model. We will solve the structural- ‘acoustic vibratory coupled interactions given by Eqs. (2) and (3) by the individual mode approach of modeling just one uncoupled acoustic mode and one uncoupled structural mode. This theory, as, shown by Fahy [6], is based on the findings that in many practical, circumstances each mode of a structural st is only coupled well, to.one mode of an acoustic set and very weakly to all others: see 156 J Vol. 124, MAY 2002 also [3]. This usefil method of combining and analyzing pits of uncoupled modes arses from the omhogonality ofthe uncoupled modes over the whole fui-structure interface. Inthe individual mode approach, we will uilize all the peram- ters given in Eqs. (2) and (3) representative of the uncoupled structural and acoustic components, and combine them on the basis of coupled oscillators of the same uncoupled natural fre- quencies. New natural frequencies, one greater and one lower than the individual uncoupled frequencies, will be the result of the coupling, 2 well-known frequency-spiting phenomenon exhib ited by coupled oscillators ofthe same uncoupled natural frequen- cies. In all the acoustic vibration and acoustic fatigue case studies of impellers known tothe author [12) the frequency-spliting phe ‘nomenon was present, confirming the existence of coupling be- tween the structural (impeller) and the acoustic (air or gas) component. “The parameters characterizing the uncoupled components at a particular mode are given as follows: 1 Generalized Force (Structural) Fe [reas ® ‘where fis the force per unit area, isthe out-of-plane structural ‘mode shape function, and S is the surface area atthe structural- acoustic interface. 2 Generalized Source Strength (Acoustic) ou iF gual 6 ‘where q is the volume acoustic velocity per unit volume, i the acoustic mode shape function, and V isthe volume of the fluid or acoustic medium, 3 Generalized Mass (Structural) Me [vas © where m is the mass of the structural component (impeller) per unit ares 4 Generalized Volume (Acoustic) ven raven eas o where Vi the volume ofthe fi or acai med defined by te imeace aca $F be depo he fu and Scouse mode shape fncon Coupling Coeffcem (Seucurl- Accu) 1 § Jretes © This is a dimensionless coefficient representing the degree of structural-acoustic coupling between the two components. Is value is within the range of OC,,<, and generally increases with lower modes. 6 Structural Spring Stiffness =e (MICS) ° ‘where «, isthe natural uncoupled angular frequency of the struc- tural component (impeller). 7 Structural Mass G mM ICS a0 8 Acoustic Spring Stiffness k= (CSV, ay Where p is the mass density of the uid or acoustic medium, and © is the speed of sound in the fuid. 9 Acoustic Mass to rr) ‘Transactions of the ASME