Investigations on the modal vibration caused by bolted joint interface contact in the rotor-AMBs systems: modelling and experimentation

Rotor-active magnetic bearings (rotor-AMBs) systems nowadays have been widely used in fluid machinery and the impeller and the shaft are commonly connected by bolted joint. However, when a certain pre-tightening force is applied to the bolted joint and the interface contact between the shaft and the impeller is formed, causing flexible modal vibrations when rotor is levitated. The mechanism of this modal vibration needs to be revealed to ensure stable operation of the machine. In traditional modelling, the effect of the interface contact is equated to an additional stiffness matrix by massless spring units, whose certain contact stiffness is uniformly distributed over the interface. Particularly, the calculation of contact stiffness and the effect of AMBs are neglected, resulting in the inaccurate response compared to experiments. Based on traditional modelling, we consider that there is partial separation in the contact interface due to the AMBs supporting and a novel additional stiffness matrix related to contact status is proposed by calculating the real-time contact area. The contact stiffness is calculated by microscopic contact model based on fractal theory and surface topography measurement. Finally, numerical simulation shows that the interface contact influences the system robustness and the unstable mode is excited. The increase of pre-tightening torque and contact radius both will increase the steady vibration amplitude, with the former being the major contributor. Moreover, the influence and order of the vibration are quantitatively validated by the experiments.