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Purpose <p>In industrial field, the initial indication of defects in machine parts often appears as small isolated pits. If these problems are not promptly detected and addressed, they can lead to early or even disastrous failures of the rotor system, causing a substantial increase in maintenance expenses and machine downtime.</p> Methods <p>In the present study, a novel approach integrating FFT-based vibration analysis with the Xlrotor simulation tool was investigated to develop a more effective diagnostic framework for rotor assemblies. An undamped critical speed map, Campbell Diagram and unbalanced response analysis were produced using Xlrotor and is validated with experimental vibration results.</p> Results <p>The findings of the present study indicate that the first critical speed increased from 576.2 to 3678.2 cpm when the bearing stiffness was increased from 1.0 × 10⁶ to 1.0 × 10⁹ N/m.This is attributed due to the support rigidity of bearings, which increases the system’s natural frequency, thereby shifting the critical speed to a higher value. At 3000 cpm, resonance resulted in peak vibrations of 0.01 mm (non driven end), which was more than twice the drive ends. This is due to uneven support conditions at the non-drive end, which results in higher displacement amplitudes than at the stiffer drive end.</p> Conclusion <p>The results highlight the importance of understanding the relationship between the input speed and natural frequency, revealing a higher rate of failures at the non-driven end bearings than at the drive end.</p>

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Investigation of Rotor Assembly Model for Vibration Signature Analysis by Xlrotor Tool

  • 期刊论文

  • 发表日期：

    2025年10月23日

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  • Santosh Savanur,
  • I. Sridhar,
  • Murgayya S. Basavankattimath,
  • R. J. Talapati

摘要

Purpose

In industrial field, the initial indication of defects in machine parts often appears as small isolated pits. If these problems are not promptly detected and addressed, they can lead to early or even disastrous failures of the rotor system, causing a substantial increase in maintenance expenses and machine downtime.

Methods

In the present study, a novel approach integrating FFT-based vibration analysis with the Xlrotor simulation tool was investigated to develop a more effective diagnostic framework for rotor assemblies. An undamped critical speed map, Campbell Diagram and unbalanced response analysis were produced using Xlrotor and is validated with experimental vibration results.

Results

The findings of the present study indicate that the first critical speed increased from 576.2 to 3678.2 cpm when the bearing stiffness was increased from 1.0 × 10⁶ to 1.0 × 10⁹ N/m.This is attributed due to the support rigidity of bearings, which increases the system’s natural frequency, thereby shifting the critical speed to a higher value. At 3000 cpm, resonance resulted in peak vibrations of 0.01 mm (non driven end), which was more than twice the drive ends. This is due to uneven support conditions at the non-drive end, which results in higher displacement amplitudes than at the stiffer drive end.

Conclusion

The results highlight the importance of understanding the relationship between the input speed and natural frequency, revealing a higher rate of failures at the non-driven end bearings than at the drive end.