Rotordynamics Module,

General Introduction
COMSOL Products for Rotordynamics Modeling

• Required modules:
– COMSOL Multiphysics
– Structural Mechanics Module
– Rotordynamics Module

• Possible extensions:
– Nonlinear Structural Materials Module
– Multibody Dynamics Module
– Fatigue Module
Purpose of Rotordynamics Modeling

• Analyze the vibration and stability in

rotating components induced due to
external or self excitation.
• Find the critical speeds and the regions of
stability in a system and optimize
the design.
• Design the rotor and supporting
components so that stresses and
deformations are within
permissible limits. A turboset rotor

• Static and dynamic balancing of rotors.

• Vibration transmission to
connected components.
Design Questions

• How is the system dynamics affected by

changes in properties of supports and
mounted components?
• Is the operating speed of the rotor in a safe
operating range?
• How much of the rotor vibration is
transferred to connected components?
• What are the forces and moments
experienced by supports?
• What are the stresses and deformations in
rotor components?
• Is there a risk of failure of a component due
to large deformations or fatigue?
Vibrations in the flexible shafts of a gear train

• What are the eigenmodes of the

overall system?
Rotordynamics Application Areas

• Automotive
• Aerospace
• Marine
• Machinery
• Vehicle components
• Power transmission
• Pumps and compressors
• Steam and gas turbines Transient simulation of a crankshaft supported on
bearings provides insight into its deformation and
stress
• Home appliances
• Education
Rotordynamics Module Overview

• Solid, beam, and rigid elements

• Bearings (Journal and thrust)
– Lumped models (Journal and thrust)
– Rolling element bearings (Radial)
– Multi-spool bearing
– Active magnetic bearing (Radial)
– Hydrodynamic bearings (Journal and thrust)

• Gears library (Rigid and elastic gear pairs)* Model of a beam rotor supported on
hydrodynamic bearings
– Backlash, Transmission error, Friction

• Time dependent; Eigenfrequency; Frequency

domain; Stationary; Transient with FFT;
Eigenfrequency, prestressed; and Frequency domain,
prestressed analyses
• Nonlinear material models e.g. plasticity and creep**
• Fatigue analysis of stator and rotor components***
• Predefined multiphysics coupling nodes
* Requires Multibody Dynamics Module
** Requires Nonlinear Structural Materials Module
*** Requires Fatigue Module
 Key Features:
Rotordynamics Interfaces
Solid Rotor Interface

• Available under Structural Mechanics->

Rotordynamics in Model Wizard
• Rotor is represented using 3D solid
geometry
• Dependent variables (u, v, w) in
corotating frame
• Space dimensions: 3D
• Material models:
– Linear elastic material (Initial stress and strain,
Thermal expansion, Damping)
– Rigid
– With Nonlinear Structural Material Module:
Plasticity, Viscoelasticity, Creep

• Geared connections
– Available with Multibody Dynamics Module
Beam Rotor Interface

• Available under Structural Mechanics-

>Rotordynamics in Model Wizard
• Abstract model of rotor represented by
a series of line segments
• Timoshenko theory based 3D
beam element
• Dependent variables (u, v, w, thx, thy,
thz) in space fixed frame
• Space dimensions: 3D
• Material models:
– Linear elastic material (Initial stress and
strain, Thermal expansion, Damping)
Solid Rotor vs Beam Rotor

Solid Rotor: Beam Rotor:

• Geometrically linear and • Only geometrically linear formulation
non-linear formulation
• Spin softening is not present
• Spin softening can be taken into
account • Journal and mountings are
assumed rigid
• Deformation of journal and mounting
• Computationally very fast
• Computationally expensive, especially
when performing a sweep over the rpm • Option to suppress axial and
• Splitting of bending, axial, and torsional torsional vibration
vibrations is not possible • Does not need a stationary step
• Requires a stationary step to account
for the geometric stiffness (stress
stiffening)
Hydrodynamic Bearing Interface
• Available under Structural Mechanics->Rotordynamics in
Model Wizard

• 3D Reynolds equation on surface to model the pressure distribution in

the film

• Analysis types:
– Stationary, Parametric
– Time Dependent
– Eigenfrequency
– Frequency Domain
– Transient with FFT

• Journal bearing types:

– Plain, Elliptic, Split halves, Multilobe, Tilted pad, Floating ring, User
defined
– Turbulence effect

• Thrust bearing types:

– Tilted pad, Tapered pad, User defined

• Squeeze film damper

• Cavitation

• Static and dynamic characteristics

Journal Bearing Types

• Plain:
– Uniform film thickness with no preload

• Elliptic:
– An initial wedge is created due to elliptic
profile

• Split halves:
– Always preloaded

• Multilobe:
– Ability to control the geometry of each pad
by adjusting the offset

• Tilted pad:
– Free or spring loaded pads
– Pads automatically respond to pressure
distribution
Floating Ring Bearing

• Features
– Full floating
– Semi floating
– Inner-outer film connection
– Centrifugal force effect in channel

• Used in high speed applications

– Turbocharger
Thrust Bearing Types

• Tapered pad:
– Linear variation of the film thickness in
taper area

• Tilted pad:
– Pads can freely tilt due to the
pressure distribution
– Line Pivot – Tilting allowed only about the
radial direction at the pivot location
– Point Pivot – Pad can tilt about both radial
and circumferential direction at the pivot
location
– Spring loaded – Pads are mounted on
the spring
– Pad inertia can be included

• User defined:
– Film thickness can be entered as a function of
radial and azimuthal coordinates
Multiphysics Interfaces

• Solid Rotor with Hydrodynamic Bearing

– Combines Solid Rotor and Hydrodynamic
Bearing interfaces

• Beam Rotor with Hydrodynamic Bearing

– Combines Beam Rotor and Hydrodynamic
Bearing interfaces

• Rotor Bearing Coupling

– Automatically included in both of the
above multiphysics interfaces
– Pressure and shear stresses in fluid film act
as an external load on rotor
– Motion of journal affects the film
thickness and flow velocity and thus the
pressure distribution in the fluid film
Multiphysics Coupling

• Solid-Bearing Coupling
– Combines Solid Mechanics/Multibody
Dynamics and Hydrodynamic Bearing
interfaces
– Foundation can also be modeled
Rotor Assembly

Rotor
Bearings (Journal and Bearing
Thrust)
Disks (with/without Offset) Bearing
(Inertial forces)
(Forces)

Rotor
(Equations of motion)

External Loads Gear Pairs (Rigid/Elastic) Disks

(Forces) (Connection between rotors)
Rotor Boundary Conditions
• Fixed axial rotation
• Rotor axis (Solid Rotor)
• Bearings (Lumped models)
• Rolling element bearing
• Active magnetic bearing
• Rotor coupling
• Multi-spool bearing
• Misalignment
• Disk
• Loads (Fixed/Corotating frame)
• Gravity
• Change rotor speed
• Added mass
Journal and Thrust Bearings
• Journal bearing (supports lateral motion
of rotors)
– No clearance
– Plain hydrodynamic
– Total spring and damping constants
– Total force and moments
– Force per area (Solid Rotor)

• Thrust bearing (supports axial motion

of rotors)
– No clearance
– Total spring and damping constant
– Total force and moment
– Force per area (Solid Rotor)

• More options:
– Translation-rotation coupling
– Constrain bending rotation (Beam Rotor)
– Constrain axial/lateral motion
– Foundation
Radial Roller Bearing

• Each bearing can have either single row

or double rows of rolling elements
• Rolling elements can be spherical or
cylindrical resulting into point or line
contact, respectively
• A nonlinear contact stiffness is used
between roller and both the races
• Clearance between the rollers and
races can be modeled in a time
dependent analysis
Radial Roller Bearing Types

Deep groove ball Angular contact ball Self aligning ball

bearing bearing bearing

Spherical roller Cylindrical roller bearing Tapered roller

bearing bearing
Roller Bearings

• Radial Roller Bearing

– Deep Groove Ball Bearing
– Angular Contact Ball Bearing
– Self Aligning Ball Bearing
– Spherical Roller Bearing
– Cylindrical Roller Bearing
– Tapered Roller Bearing

• Clearance and Preload

• Geometric and Material Properties are
the inputs to define a roller bearing
• Foundation
Roller Bearing Selection

• Available for both Solid Rotor and Beam Rotor interfaces.

• Selection of the feature in Solid Rotor interface is a cylindrical surface representing
the surface shrunk fit with the inner race of bearing
• A rigid map of the motion of the surface in the Solid Rotor interface is computed to
evaluate the translational and rotational motion of the shaft.
• In Beam Rotor interface the selection of the feature is a point
• The displacement and rotation of this point serves as the translation and rotation of
the shaft in a bearing
Multi-Spool Bearing

• A multi-spool bearing is used to

support a pair of coaxial shafts against
each other
• Connection can be rigid or flexible
• Requires corresponding selections on
both shafts to specify the
connection locations
• Shafts can be rotating at
different speeds
Foundations

• Foundation:
– Fixed
– Moving
– Flexible (stiffness and damping)
– Squeeze film damper
– Attachments
– Translation-rotation coupling in
flexible foundation
Rotor Coupling

• Spline: Connects translational motion

• Torsional: Connects translation and torsional motion
• User defined: A general flexibility between the shafts
Bearing Misalignment

• Misalignment
– Parallel
– Angular
– Mixed
CAD & Meshing Interoperability

For trademark ownership, see Support for implementation of the ODB++ Format was
www.comsol.com/trademarks. provided by Mentor Graphics pursuant to the ODB++
Solutions Development Partnership General Terms and
Conditions (www.odb-sa.com).
Model Tutorials in Application
Library
Geared Rotors
(Automotive and Aerospace)
• A time dependent analysis for an applied external torque is performed
• Presence of gears causes lateral and torsional vibrations in the rotor
• Gear mesh is elastic with constant stiffness

von Mises stress distribution Forces on the bearing

Geared Rotors
(Automotive and Aerospace)

Eigenfrequency variation with rotor speed Self excited frequency response of the rotor
Gearbox Vibration and Noise: Bearing Version
(Automotive and Aerospace)
▪ 5-speed synchromesh gearbox is
modelled
▪ Vibro-acoustics analysis of the
gearbox is performed
▪ A detailed model for the bearing is
considered to connect the shafts
with the housing
▪ Multibody analysis is performed with
elastic gear mesh in the time domain
▪ Acoustics analysis is performed in
the frequency domain after taking
FFT of the normal acceleration on
the housing
 Gearbox Vibration and Noise: Bearing Version
(Automotive and Aerospace)
• Model Methods are used to create sound from pressure data
• Results Parameters are used to define microphone locations

Mic2
(0,0,0.75)

Mic1 (0,-
0.5,0)
Gearbox noise received at the two microphones. von-Mises stresses in the gearbox housing. Pressure wave in the gearbox surrounding.
Reciprocating Engine Rotor
(Automotive and Aerospace)
• A time dependent analysis of a crankshaft is performed to determine:
– steady state motion
– stresses in the crankshaft
– pressure distribution in the bearings

Pressure distribution in bearings Stress distribution in crankshaft Orbits of the journals (rotating frame)
Single Cylinder Reciprocating Engine
(Automotive and Aerospace)
• A single cylinder reciprocating engine supported on hydrodynamic bearings is
studied to determine:
– Stress in the crankshaft and foundation
– Pressure in the bearings
– Bearing force

Pressure and stress Bearing reaction to the piston load Journal eccentricity
Turbocharger Stability Analysis
(Automotive and Aerospace)
▪ An eigenfrequency analysis of a turbocharger rotor is performed to study the effect
of the cross-coupled stiffness of the bearings
▪ Logarithmic decrements are compared with and without the cross-coupled stiffness
of the bearing to determine the stability of the system

Mode
shape

Campbell plot in fixed frame

Turbocharger Stability Analysis
(Automotive and Aerospace)

A negative
logarithmic
decrement
implies instability

Logarithmic decrement without cross-coupled stiffness Logarithmic decrement with cross-coupled stiffness
Turbocharger Stability Analysis
(Automotive and Aerospace)
• Frequency response of the turbocharger rotor excited due to the turbine and
compressor eccentricity

Waterfall plot without cross-coupled Waterfall plot with cross-coupled

stiffness stiffness
Turbocharger Transient Analysis
(Automotive and Aerospace)
• A time dependent analysis of a turbocharger during its run-up is performed
to determine:
– Ring speed in steady state
– Stresses in the shaft
– Pressure distribution in the bearings
– Flow through channels

Pressure and stress Ring Flow rate in channel 1

speed
Coupled Rotors
(Verification)
• Two rotors are coupled through a spline coupling
• Variation of the natural frequency and eigenmodes of system are calculated as
function of the angular speed of the rotor

Rotor geometry Rotor whirl Campbell diagram

Dual Rotors
(Verification)
• A dual rotor system is interconnected by a multi-spool bearing on the right end
• On the left end both the rotors are supported on external bearings
• Critical speeds for both the rotors is calculated and compared with the values
reported in the literature

Whirl Plot with rotor geometry Campbell

plot
Journal Bearing Dynamic Coefficients
(Verification)
• Stiffness
𝑘𝑦𝑦 𝐶 4 16𝜖 2 + 𝜋 2 2 − 𝜖 2
𝑘ത 𝑦𝑦 = =
𝑊 𝑄
𝑘𝑦𝑧 𝐶 𝜋(𝜋 1 − 𝜖 2 2 − 16𝜖 4 )
2
𝑘ത 𝑦𝑧 = =
𝑊 𝜖 1 − 𝜖2 𝑄
𝑘𝑧𝑦 𝐶 𝜋(𝜋 2 1 − 2𝜖 2 1 − 𝜖 2 + 32𝜖 2 1 + 𝜖 2 )
𝑘ത 𝑧𝑦 = =−
𝑊 𝜖 1 − 𝜖2 𝑄
𝑘𝑧𝑧 𝐶 4(𝜋 2 1 + 2𝜖 2 1 − 𝜖 2 + 32𝜖 2 1 + 𝜖 2 )
𝑘ത 𝑧𝑧 = =
𝑊 1 − 𝜖2 𝑄
• Damping coefficient
𝑐𝑦𝑦 𝐶Ω 2𝜋√(1 − 𝜖 2 )(𝜋 2 (1 + 2𝜖 2 ) − 16𝜖 2 )
𝑐𝑦𝑦
ҧ = =
𝑊 𝜖𝑄
𝑐𝑧𝑦 𝐶Ω 8(16𝜖 − 𝜋 2 1 + 2𝜖 2 )
2
𝑐𝑦𝑧
ҧ = 𝑐𝑧𝑦ҧ = =
𝑊 𝑄
𝑐𝑧𝑧 𝐶Ω 2𝜋(48𝜖 + 𝜋 1 − 𝜖 2 2 )
2 2
𝑐𝑧𝑧
ҧ = =
𝑊 𝜖 1 − 𝜖2 𝑄
3ൗ
𝑄 = 𝜋 2 + 16 − 𝜋 2 𝜖 2 2
Squeeze Film Damper Damping Coefficients
(Verification)
𝜇𝑅𝐿3 𝜋 1 + 2𝜖 2
𝐶𝑟𝑟 =
𝐶 3 2 1 − 𝜖 2 5ൗ2
𝜇𝑅𝐿3 𝜋 1
𝐶𝑡𝑡 = 3
𝐶 2 1 − 𝜖 2 3ൗ2
𝜇𝑅𝐿3 2𝜖
𝐶𝑟𝑡 = 𝐶𝑡𝑟 = 3
𝐶 1 − 𝜖2 2
𝐶𝑦𝑦 = 𝐶𝑟𝑟 sin2 𝜙 + 𝐶𝑡𝑡 cos 2 𝜙 + 2𝐶𝑟𝑡 sin 𝜙 cos 𝜙
𝐶𝑧𝑧 = 𝐶𝑟𝑟 cos 2 𝜙 + 𝐶𝑡𝑡 sin2 𝜙 − 2𝐶𝑟𝑡 cos 𝜙 sin 𝜙
𝐶𝑦𝑧 = 𝐶𝑡𝑡 − 𝐶𝑟𝑟 cos 𝜙 sin 𝜙 + 𝐶𝑟𝑡 (sin2 𝜙 − cos2 𝜙)
𝐶𝑧𝑦 = 𝐶𝑦𝑧
Gear Rattle with Bearing Misalignment
(Tutorial)
• A time dependent analysis of a pair of shafts connected through gears is performed to capture the vibration due
to gear rattling and misalignment in the bearing

• Angular velocity of the driven shaft has a sinusoidal variation

• When the driven shaft is unloaded, rattle vibrations are observed

• Vibration response is compared for two cases, one, all bearings aligned, and two, one of the bearings misaligned

Bearing force and stress in the shafts Axial vibration in aligned and Gear mesh contact force
misaligned cases
Hydrodynamic Bearings Comparison
(Tutorial)
• Compares the locus of the journal equilibrium position for different types of bearings
as the load increases
• Maximum and minimum clearance values are kept the same for all bearing types

Pressure profile Journal position as function of load

Misaligned Rotor
(Tutorial)
• A shaft is supported by two hydrodynamic bearings
• The rotor is initially concentric with the bearing and falls under gravity
• One of the bearing is misaligned with the rotor

Rotor whirl and bearing pressure. Right bearing orbit

Nonsynchronous Vibration in Rotor with the Roller Bearing
(Tutorial Example)
• A rotor supported by two end roller bearings has a centrally mounted eccentric disk
• A time dependent analysis is performed for different bearing clearances

Shaft

Bearing Disk
Nonsynchronous Vibration in Rotor with the Roller Bearing
(Tutorial)
• For smaller clearances the synchronous vibration is dominant but for larger
clearances participation of the nonsynchronous vibration increases

synchronous

Orbit of bearing and disk at Frequency spectrum of the z-displacement at the

C=2e-5m bearing
Nonsynchronous Vibration in Rotor with the Roller Bearing
(Tutorial)
• Bearing reaction forces and moments on the shaft are intermittent and large for
large clearances
Rotor Thermal Stress
(Tutorial)
• Viscous heat dissipated in the bearing is modeled as a heat source
• Heat in the bearing is conducted to the rotor and bearing housing
• Finally, heat is convected to the atmosphere from the rotor and bearing housing
• Change in the temperature profile causes the thermal stress and deformation

Temperature and stress in the rotor Pressure and heat dissipation in

assembly bearings
Rotor Whirl
(Tutorial)
• A beam rotor is supported on hydrodynamic bearings at both ends
• The rotor is initially concentric with the bearing and falls under gravity
• Gyroscopic moment in the rotor due to its bending causes the whirling motion
• Rotor eventually performs steady state orbit

Orbit of the journal

Frequency spectrum of lateral acceleration

Simply Supported Rotor
(Tutorial)
• A rotor with three disks
– An eigenfrequency analysis is performed to obtain the Campbell plot
– Bearings are modelled through equivalent dynamic coefficients

• A rotor with a single disk

– A time dependent analysis is performed to determine the vibration response due to the disk eccentricity
– An analytical value of the bearing dynamic coefficients for a short plain journal bearing is used

Waterfall diagram: z-displacement at disk Orbit: bearing 1 Campbell diagram

2
Step Thrust Bearing
(Tutorial)
• Stationary analysis of a step thrust bearing to obtain the pressure distribution on
the pads.

Bearing pressure Pressure distribution (radial)

Vibration Control with AMB
(Tutorial)
• Vibrations in a motor driven rotor assembly is studied due to imbalances in the rotor
• Second analysis is performed by introducing an Active Magnetic Bearing (AMB) and
switching it on just before the resonanse occurs
• Vibration levels are compared in both the cases

Stress in the rotor assembly without AMB Stress in the rotor assembly with AMB Comparison of the vertical displacement
Demo Application
Rotor Bearing System Simulator

• This application performs an eigenfrequency analysis of a generic rotor bearing

system to find the variation of the natural frequency of the system with its angular
speed
• The App creates the Campbell plot and computes critical speeds.
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