Reliable crack detection in a rotor system with uncertainties via advanced simulation models based on kriging and Polynomial Chaos Expansion

In this study the authors propose to take into account the nonlinear effects induced by the presence of a transverse crack to carry out vibratory monitoring and detect transverse cracks in rotating systems subject to model uncertainties. More precisely, we focus more particularly on the global complexity of the nonlinear dynamic behaviour of cracked rotors and the evolution of their harmonic components as a function of the parameters of a transverse breathing crack (its position and depth) when numerous uncertainties are considered. These random uncertainties correspond to random geometric imperfections (two disc thicknesses), random material properties (Young modulus and material density) and boundary conditions uncertainty (two bearing stiffnesses). The objective of the present work is to identify robust indicators capable of determining the presence of a crack and its status even though numerous uncertainties are present. To conduct such a study, an advanced surrogate modelling technique based on kriging and Polynomial Chaos Expansion (PCE) is proposed for the prediction of both the critical speeds and the harmonic components n× during passage through sub-critical resonances. An extensive study to ensure the validation of the surrogate models and a relevant choice of both the parametric and random Design of Experiments (i.e. kriging DoE and PCE DoE) is proposed. The proposed methodology is applied on a flexible rotor with a transverse breathing crack and subjected to random geometric imperfections and fluctuations in material properties of the rotor system.