Case Histories in Vibration Analysis and Metal Fatigue for the Practicing Engineer.

By: Sofronas, AnthonyMaterial type: TextTextPublisher: Somerset : Wiley, 2012Copyright date: ©2012Edition: 1st edDescription: 1 online resource (308 pages)Content type: text Media type: computer Carrier type: online resourceISBN: 9781118371718Subject(s): Machinery -- Vibration -- Case studies | Metals -- Fatigue -- Case studies | Vibration -- Testing -- Case studiesGenre/Form: Electronic books.Additional physical formats: Print version:: Case Histories in Vibration Analysis and Metal Fatigue for the Practicing EngineerDDC classification: 620.1/1248 LOC classification: TJ177 -- .S64 2012ebOnline resources: Click to View
Contents:
Intro -- CASE HISTORIES INVIBRATION ANALYSISAND METAL FATIGUEFOR THE PRACTICINGENGINEER -- CONTENTS -- Preface -- 1 Introduction -- Reference -- 2 Basics of Vibration -- 2.1 Spring-Mass Systems and Resonance -- 2.2 Case History: Combining Springs and Masses in a Steam Turbine Problem -- 2.3 Useful Questions to Ask Before Beginning a Vibration Analysis -- 2.4 Linear Spring Constants and Area Moments of Inertia -- 2.5 Vibrating Flat Plates -- 2.6 Two-Degree Tuned Vibration Absorber -- 2.7 Natural Frequencies of Pipes and Beams -- 2.8 Effect of Clearance on the Natural Frequency -- 2.9 Static Deflection and Pendulum Natural Frequency -- 2.10 Coupled Single-Mass Systems -- References -- 3 Vibration-Measuring Methods and Limits -- 3.1 Important Frequencies -- 3.2 Campbell Diagrams -- 3.3 Case History: Systematic Procedure to Identify a Vibration Source -- 3.4 Vibration-Measuring Terms -- 3.5 Cascade Diagram -- 3.6 Shock Pulse Method -- 3.7 Measuring Transducers -- 3.8 Measurements: Time-Based, Bode, and Orbit Plots -- 4 Simple Analytical Examples -- 4.1 Determining Vibration Amplitude -- 4.2 Resonant and Off-Resonant Amplitudes -- 4.3 Case History: Transmitted Force and Isolation of a Roof Fan -- 4.4 Case History: Seal Failure Due to Misalignment of an Agitator Shaft -- 4.5 Case History: Structural Vibration -- 4.6 Case History: Production-Line Grinding Problem -- 4.7 Case History: Vehicle on Springs -- 4.8 Case History: Vibrating Cantilevered Components -- 4.9 Bump Test -- 4.10 Case History: Vibrating Pump Mounted on a Plate Deck -- 4.11 Case History: Misalignment Force -- 4.12 Case History: Vertical Pump Vibrations and Bearing Survival -- 4.13 Case History: Cause of Mysterious Movement on a Centrifuge Deck -- 4.14 Case History: Engine Vibration Monitoring Device -- 4.15 Case History: Natural Frequency of A Midsupport Vertical Mixer.
4.16 Case History: Valve Float Analysis -- References -- 5 Vibration-Based Problems and Their Sources -- 5.1 Fatigue Cracking -- 5.2 Fretting and Wear -- 5.3 Ball and Roller Bearing Failures -- 5.4 Bolt Loosening -- 5.5 Flow-Induced Vibration -- 5.5.1 Case History: Stack Vibration Induced by Wind -- 5.6 Excessive Noise -- 5.7 Pressure Pulsations -- 5.8 Mechanical Seal Chipping and Damage -- 5.9 Surging of Fans and Other Causes of Vibration -- 5.10 Vibration Due to Beats -- 5.11 The Slip-Stick Problem -- 5.12 Drive Belt Vibration -- References -- 6 Causes of Vibrations and Solutions in Machinery -- 6.1 Rotating Imbalance -- 6.1.1 Case History: Motor Imbalance -- 6.2 Causes of Shaft Misalignment -- 6.2.1 Types of Misalignment -- 6.2.2 Thermal Offset -- 6.2.3 Acceptable Coupling Offset and Angular Misalignment -- 6.3 A Problem in Measuring Vibration on Large Machines -- 6.4 Causes of Pump Vibration -- 6.4.1 NPSH Problems and Cavitation -- 6.4.2 Suction Vortex -- 6.4.3 Off Best Efficiency Point -- 6.4.4 Vertical Pump Vibration -- 6.4.5 Pump Vibration Level Guidelines -- 6.5 Other Causes of Motor Vibration -- 6.5.1 Electrical Causes -- 6.5.2 Mechanical Cause -- 6.5.3 Motor Vibration-Level Guidelines -- 6.6 Causes of Gearbox Vibration -- 6.6.1 Cyclic External Reaction Loads -- 6.6.2 Tooth Breakage -- 6.6.3 Gearbox Vibration-Level Guidelines -- 6.6.4 Causes of Cooling Tower Fan System Vibration -- 6.6.5 Complex Gearbox Vibration Spectra -- 6.7 Types of Couplings for Alignment -- References -- 7 Piping Vibration -- 7.1 Types of Piping Vibration Problems -- 7.2 Vibration Screening Charts and Allowable Limits -- 7.3 Case History: Water Hammer and Piping Impacts -- 7.4 Case History: Heat-Exchanger Tube Vibration -- 7.5 Case History: Useful Equations In Solving a Cracked Nozzle -- 7.6 Support and Constraint Considerations in Vibrating Services.
7.7 Case History: Control Valve Trim Causing Piping Vibration -- 7.8 Vibration Observed and Possible Causes -- 7.9 Acoustical Vibration Problems -- 7.9.1 Case History: Compressor Acoustical Vibration Analysis -- 7.9.2 Case History: Tuning Using a Helmholz Resonator -- 7.9.3 Case History: Tuning Using Surge Volume -- 7.10 Two-Phase Flow and Slug Flow -- 7.11 Case History: U-Tube Heat-Exchanger Vibration -- 7.12 Crack Growth in a Flat Plate -- References -- 8 Torsional Vibration -- 8.1 Torsional Vibration Defined -- 8.2 Case History: Torsional Vibration of a Motor-Generator-Blower -- 8.3 Case History: Engine-Gearbox-Pump -- 8.4 Case History: Internal Combustion Engine-Gearbox-Propeller -- 8.5 Case History: Effect of Changing Firing Order On Crankshaft Stress -- 8.6 Case History: Transient Power Surge Motor-Gearbox-Compressor -- 8.7 Case History: Vibratory Torque on the Gear of a Ship System -- 8.8 Torsional Spring Constants and Mass Moments of Inertia -- 8.9 Three-Mass Natural Frequency Simplification -- 8.10 Case History: Torsional Vibration of a Drill String -- 8.11 Case History: Effect of a Suddenly Applied Torsional Load -- 8.12 Sensitivity Analysis of a Two-Mass Torsional System -- 8.13 Case History: Engine Natural Frequency as a Continuous Shaft -- 8.14 Types of Torsionally Soft Couplings -- 8.15 Torsional Vibration Testing -- 8.16 Case History: Out-of-Synchronization Grid Closure -- 8.17 Operating Through a Large Torsional Amplitude -- 8.18 Case History: Engine Mode Shape as a Continuous Shaft -- 8.19 Holzer Method for Calculating Torsional and Linear Multimass Systems -- 8.20 Experimental Determination of Mass Moment of Inertia J -- References -- 9 Turbomachinery Vibration -- 9.1 Unique Vibration Problems of Turbomachinery -- 9.1.1 The Rotor System -- 9.2 Lateral Vibrations of a Simplified System -- 9.2.1 A Simplified Rotor System.
9.2.2 Compressor with High Stiffness Bearings -- 9.2.3 Critical Speed of a Rotor on Spring Supports -- 9.3 Allowable Shaft Displacement Guidelines -- 9.4 Compressor Surge and Rotor Vibration -- 9.5 Rigid and Flexible Rotor Balancing -- 9.6 Case History: Checking the Critical Speed of a Motor Rotor -- 9.7 Case History: Response of a Missing Blade on a Steam Turbine -- 9.8 Case History: Stepped Shaft Into Equivalent Diameter -- 9.9 Case History: Two-Diameter Rotor System -- 9.10 Hydrodynamic Bearing Stiffness -- 9.11 Rotor Dynamics of Pumps -- References -- 10 Very Low Cycle Vibrations and Other Phenomena -- 10.1 Very Low Cycle Vibration Defined -- 10.2 Vessels In High-Cycle Service -- 10.3 Case History: Cracking of a Rotary Dryer -- 10.4 Phantom Failures: Some Failures are Very Elusive -- 10.5 Case History: Troubleshooting Gear Face Damage -- 10.6 Case History: Thermally Bowed Shaft and Vibration -- 10.7 Case History: Effect of Nonlinear Stiffness -- 10.8 Case History: Effect of Clearance on a Vibrating System -- 10.9 Case History: Fatigue Failure of a Crankshaft -- 10.10 Case History: Understanding Slip-Jerk During Slow Roll -- 10.11 Case History: Predicting the Crack Growth on a Machine -- 10.12 Case History: Bolt Loosening on Counterweight Bolts -- 10.13 Case History: Centrifuge Vibration -- 10.14 Case History: Crack Growth In a Gear Tooth -- 10.15 Case History: Vibration of a Rotor In Its Case -- 10.16 Case History: Gearbox Input Shaft Lockup -- 10.17 Case History: Troubleshooting a Roller Bearing Failure -- 10.18 Case History: Using Imprints to Determine Loads -- 10.19 Case History: Extruder BlowBack -- 10.20 Case History: Vibratory and Rotational Wear -- 10.21 Two-Mass System With Known and Unknown Displacement -- 10.22 Case History: Fiberglass Mixing Tank Flexing Vibration -- References -- 11 Vibration Failures.
11.1 Why Things Fail In Vibration -- 11.2 Case History: Spring Failure -- 11.3 Case History: Spline Fretting -- 11.4 Case History: Sheet Metal Vibration Cracking -- 11.5 Case History: Bearing Brinelling and False Brinelling -- 11.6 Case History: Crankshaft Failure -- 11.7 Case History: Brush Holder Wear -- 11.8 Case History: Cracking of a Vibrating Conveyor Structure -- 11.9 Case History: Failure of a Cooling Tower Blade Arm -- 11.10 Case History: Fatigue Failures at High Cyclic Stress Areas -- 11.11 Case History: Fatigue Failure of Shafts -- 11.12 Case History: Failure of a Steam Turbine Blade -- 11.13 Case History: Failure of a Reciprocating Compressor Slipper -- 11.14 Case History: Multiple-Cause Gear Failure -- 11.15 Case History: Loose Bolt Failures -- 11.16 Case History: Piston Failure in a Racing Car -- 11.17 Case History: Stop Holes For Cracks Don't Always Work -- 11.18 Case History: Small Bearing Failure Due To Vibration -- 11.19 Appearance of Fatigue Fracture Surfaces -- References -- 12 Metal Fatigue -- 12.1 Metal Fatigue Defined -- 12.2 Reduction of a Component's Life When Subjected to Excessive Vibration -- 12.3 Case History: Special Case of Fatigue Potential -- 12.4 Metallurgical Examination -- 12.5 Taking Risks and Making High-Level Presentations -- References -- 13 Short History of Vibration -- References -- Index.
Summary: This highly accessible book provides analytical methods and guidelines for solving vibration problems in industrial plants and demonstrates their practical use through case histories from the author's personal experience in the mechanical engineering industry. It takes a simple, analytical approach to the subject, placing emphasis on practical applicability over theory, and covers both fixed and rotating equipment, as well as pressure vessels. It is an ideal guide for readers with diverse experience, ranging from undergraduate students to mechanics and professional engineers.
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Intro -- CASE HISTORIES INVIBRATION ANALYSISAND METAL FATIGUEFOR THE PRACTICINGENGINEER -- CONTENTS -- Preface -- 1 Introduction -- Reference -- 2 Basics of Vibration -- 2.1 Spring-Mass Systems and Resonance -- 2.2 Case History: Combining Springs and Masses in a Steam Turbine Problem -- 2.3 Useful Questions to Ask Before Beginning a Vibration Analysis -- 2.4 Linear Spring Constants and Area Moments of Inertia -- 2.5 Vibrating Flat Plates -- 2.6 Two-Degree Tuned Vibration Absorber -- 2.7 Natural Frequencies of Pipes and Beams -- 2.8 Effect of Clearance on the Natural Frequency -- 2.9 Static Deflection and Pendulum Natural Frequency -- 2.10 Coupled Single-Mass Systems -- References -- 3 Vibration-Measuring Methods and Limits -- 3.1 Important Frequencies -- 3.2 Campbell Diagrams -- 3.3 Case History: Systematic Procedure to Identify a Vibration Source -- 3.4 Vibration-Measuring Terms -- 3.5 Cascade Diagram -- 3.6 Shock Pulse Method -- 3.7 Measuring Transducers -- 3.8 Measurements: Time-Based, Bode, and Orbit Plots -- 4 Simple Analytical Examples -- 4.1 Determining Vibration Amplitude -- 4.2 Resonant and Off-Resonant Amplitudes -- 4.3 Case History: Transmitted Force and Isolation of a Roof Fan -- 4.4 Case History: Seal Failure Due to Misalignment of an Agitator Shaft -- 4.5 Case History: Structural Vibration -- 4.6 Case History: Production-Line Grinding Problem -- 4.7 Case History: Vehicle on Springs -- 4.8 Case History: Vibrating Cantilevered Components -- 4.9 Bump Test -- 4.10 Case History: Vibrating Pump Mounted on a Plate Deck -- 4.11 Case History: Misalignment Force -- 4.12 Case History: Vertical Pump Vibrations and Bearing Survival -- 4.13 Case History: Cause of Mysterious Movement on a Centrifuge Deck -- 4.14 Case History: Engine Vibration Monitoring Device -- 4.15 Case History: Natural Frequency of A Midsupport Vertical Mixer.

4.16 Case History: Valve Float Analysis -- References -- 5 Vibration-Based Problems and Their Sources -- 5.1 Fatigue Cracking -- 5.2 Fretting and Wear -- 5.3 Ball and Roller Bearing Failures -- 5.4 Bolt Loosening -- 5.5 Flow-Induced Vibration -- 5.5.1 Case History: Stack Vibration Induced by Wind -- 5.6 Excessive Noise -- 5.7 Pressure Pulsations -- 5.8 Mechanical Seal Chipping and Damage -- 5.9 Surging of Fans and Other Causes of Vibration -- 5.10 Vibration Due to Beats -- 5.11 The Slip-Stick Problem -- 5.12 Drive Belt Vibration -- References -- 6 Causes of Vibrations and Solutions in Machinery -- 6.1 Rotating Imbalance -- 6.1.1 Case History: Motor Imbalance -- 6.2 Causes of Shaft Misalignment -- 6.2.1 Types of Misalignment -- 6.2.2 Thermal Offset -- 6.2.3 Acceptable Coupling Offset and Angular Misalignment -- 6.3 A Problem in Measuring Vibration on Large Machines -- 6.4 Causes of Pump Vibration -- 6.4.1 NPSH Problems and Cavitation -- 6.4.2 Suction Vortex -- 6.4.3 Off Best Efficiency Point -- 6.4.4 Vertical Pump Vibration -- 6.4.5 Pump Vibration Level Guidelines -- 6.5 Other Causes of Motor Vibration -- 6.5.1 Electrical Causes -- 6.5.2 Mechanical Cause -- 6.5.3 Motor Vibration-Level Guidelines -- 6.6 Causes of Gearbox Vibration -- 6.6.1 Cyclic External Reaction Loads -- 6.6.2 Tooth Breakage -- 6.6.3 Gearbox Vibration-Level Guidelines -- 6.6.4 Causes of Cooling Tower Fan System Vibration -- 6.6.5 Complex Gearbox Vibration Spectra -- 6.7 Types of Couplings for Alignment -- References -- 7 Piping Vibration -- 7.1 Types of Piping Vibration Problems -- 7.2 Vibration Screening Charts and Allowable Limits -- 7.3 Case History: Water Hammer and Piping Impacts -- 7.4 Case History: Heat-Exchanger Tube Vibration -- 7.5 Case History: Useful Equations In Solving a Cracked Nozzle -- 7.6 Support and Constraint Considerations in Vibrating Services.

7.7 Case History: Control Valve Trim Causing Piping Vibration -- 7.8 Vibration Observed and Possible Causes -- 7.9 Acoustical Vibration Problems -- 7.9.1 Case History: Compressor Acoustical Vibration Analysis -- 7.9.2 Case History: Tuning Using a Helmholz Resonator -- 7.9.3 Case History: Tuning Using Surge Volume -- 7.10 Two-Phase Flow and Slug Flow -- 7.11 Case History: U-Tube Heat-Exchanger Vibration -- 7.12 Crack Growth in a Flat Plate -- References -- 8 Torsional Vibration -- 8.1 Torsional Vibration Defined -- 8.2 Case History: Torsional Vibration of a Motor-Generator-Blower -- 8.3 Case History: Engine-Gearbox-Pump -- 8.4 Case History: Internal Combustion Engine-Gearbox-Propeller -- 8.5 Case History: Effect of Changing Firing Order On Crankshaft Stress -- 8.6 Case History: Transient Power Surge Motor-Gearbox-Compressor -- 8.7 Case History: Vibratory Torque on the Gear of a Ship System -- 8.8 Torsional Spring Constants and Mass Moments of Inertia -- 8.9 Three-Mass Natural Frequency Simplification -- 8.10 Case History: Torsional Vibration of a Drill String -- 8.11 Case History: Effect of a Suddenly Applied Torsional Load -- 8.12 Sensitivity Analysis of a Two-Mass Torsional System -- 8.13 Case History: Engine Natural Frequency as a Continuous Shaft -- 8.14 Types of Torsionally Soft Couplings -- 8.15 Torsional Vibration Testing -- 8.16 Case History: Out-of-Synchronization Grid Closure -- 8.17 Operating Through a Large Torsional Amplitude -- 8.18 Case History: Engine Mode Shape as a Continuous Shaft -- 8.19 Holzer Method for Calculating Torsional and Linear Multimass Systems -- 8.20 Experimental Determination of Mass Moment of Inertia J -- References -- 9 Turbomachinery Vibration -- 9.1 Unique Vibration Problems of Turbomachinery -- 9.1.1 The Rotor System -- 9.2 Lateral Vibrations of a Simplified System -- 9.2.1 A Simplified Rotor System.

9.2.2 Compressor with High Stiffness Bearings -- 9.2.3 Critical Speed of a Rotor on Spring Supports -- 9.3 Allowable Shaft Displacement Guidelines -- 9.4 Compressor Surge and Rotor Vibration -- 9.5 Rigid and Flexible Rotor Balancing -- 9.6 Case History: Checking the Critical Speed of a Motor Rotor -- 9.7 Case History: Response of a Missing Blade on a Steam Turbine -- 9.8 Case History: Stepped Shaft Into Equivalent Diameter -- 9.9 Case History: Two-Diameter Rotor System -- 9.10 Hydrodynamic Bearing Stiffness -- 9.11 Rotor Dynamics of Pumps -- References -- 10 Very Low Cycle Vibrations and Other Phenomena -- 10.1 Very Low Cycle Vibration Defined -- 10.2 Vessels In High-Cycle Service -- 10.3 Case History: Cracking of a Rotary Dryer -- 10.4 Phantom Failures: Some Failures are Very Elusive -- 10.5 Case History: Troubleshooting Gear Face Damage -- 10.6 Case History: Thermally Bowed Shaft and Vibration -- 10.7 Case History: Effect of Nonlinear Stiffness -- 10.8 Case History: Effect of Clearance on a Vibrating System -- 10.9 Case History: Fatigue Failure of a Crankshaft -- 10.10 Case History: Understanding Slip-Jerk During Slow Roll -- 10.11 Case History: Predicting the Crack Growth on a Machine -- 10.12 Case History: Bolt Loosening on Counterweight Bolts -- 10.13 Case History: Centrifuge Vibration -- 10.14 Case History: Crack Growth In a Gear Tooth -- 10.15 Case History: Vibration of a Rotor In Its Case -- 10.16 Case History: Gearbox Input Shaft Lockup -- 10.17 Case History: Troubleshooting a Roller Bearing Failure -- 10.18 Case History: Using Imprints to Determine Loads -- 10.19 Case History: Extruder BlowBack -- 10.20 Case History: Vibratory and Rotational Wear -- 10.21 Two-Mass System With Known and Unknown Displacement -- 10.22 Case History: Fiberglass Mixing Tank Flexing Vibration -- References -- 11 Vibration Failures.

11.1 Why Things Fail In Vibration -- 11.2 Case History: Spring Failure -- 11.3 Case History: Spline Fretting -- 11.4 Case History: Sheet Metal Vibration Cracking -- 11.5 Case History: Bearing Brinelling and False Brinelling -- 11.6 Case History: Crankshaft Failure -- 11.7 Case History: Brush Holder Wear -- 11.8 Case History: Cracking of a Vibrating Conveyor Structure -- 11.9 Case History: Failure of a Cooling Tower Blade Arm -- 11.10 Case History: Fatigue Failures at High Cyclic Stress Areas -- 11.11 Case History: Fatigue Failure of Shafts -- 11.12 Case History: Failure of a Steam Turbine Blade -- 11.13 Case History: Failure of a Reciprocating Compressor Slipper -- 11.14 Case History: Multiple-Cause Gear Failure -- 11.15 Case History: Loose Bolt Failures -- 11.16 Case History: Piston Failure in a Racing Car -- 11.17 Case History: Stop Holes For Cracks Don't Always Work -- 11.18 Case History: Small Bearing Failure Due To Vibration -- 11.19 Appearance of Fatigue Fracture Surfaces -- References -- 12 Metal Fatigue -- 12.1 Metal Fatigue Defined -- 12.2 Reduction of a Component's Life When Subjected to Excessive Vibration -- 12.3 Case History: Special Case of Fatigue Potential -- 12.4 Metallurgical Examination -- 12.5 Taking Risks and Making High-Level Presentations -- References -- 13 Short History of Vibration -- References -- Index.

This highly accessible book provides analytical methods and guidelines for solving vibration problems in industrial plants and demonstrates their practical use through case histories from the author's personal experience in the mechanical engineering industry. It takes a simple, analytical approach to the subject, placing emphasis on practical applicability over theory, and covers both fixed and rotating equipment, as well as pressure vessels. It is an ideal guide for readers with diverse experience, ranging from undergraduate students to mechanics and professional engineers.

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Electronic reproduction. Ann Arbor, Michigan : ProQuest Ebook Central, 2018. Available via World Wide Web. Access may be limited to ProQuest Ebook Central affiliated libraries.

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