PRE-STRESS MODAL ANALYSIS OF A CENTRIFUGAL PUMP IMPELLER FOR
DIFFERENT BLADE THICKNESSES
S. SENDILVELAN1 AND M. PRABHAHAR2
1
Department of Mechanical Engineering, Dr. M.G.R Educational and Research Institute, University, Chennai-
600 095, India, Email: [Link]@[Link]
2
Department of Mechanical Engineering, Aarupadai Veedu Institute of Technology, Chennai-603104, India,
Email: mprabhahar@[Link]
ABSTRACT
Centrifugal pump impellers are high speed rotating components vulnerable to vibration resulting in the
failure of the system pump eventually. While rotating, stresses are created due to the inertial forces. The model
characteristics change due to the stress created and hence it is important to measure the model characteristics
with consideration to the prestresses. Therefore, in this paper, the prestressed modal analysis of the impeller
with blade thicknesses ranging from 3mm to 5mm with increments of 0.5mm, are analyzed by the numerical
method, FEA for a rotational velocity of 3600rpm. The experimental modal testing of the impellers is then done
using electro-dynamic shaker, to validate the FEA results.
KEYWORDS: Pre-stress modal analysis, impeller, mode shape, natural frequency, von-mises stress, blade
thickness
INTRODUCTION
Modal analysis plays an important role in the design and optimization of dynamic structures. Modal
analysis is the method of determining the natural frequency and mode shapes of a component that it may have
when it is subjected to resonance conditions. Modal characters are inherent of the component. Centrifugal pump
impellers are high speed rotating components that have a high chance of rotor failure by attaining resonance
frequencies. While rotating, stresses are created in the impeller due to its inertial effects which may change the
inherent character of the impeller namely the natural frequencies and mode shapes. Therefore, the modal testing
may be done considering the prestresses for accurate results. A parametric study of a centrifugal pump impeller,
by changing the outlet blade angle using the numerical method of computational fluid dynamics [1,2],
discretized three-dimensional, incompressible Navier-Stokes equations over an unstructured grid was
accomplished, with a commercial computational fluid dynamics finite-volume code. For each impeller, the flow
pattern and the pressure distribution in the blade passages were calculated, and finally, the head-capacity curves
were compared and discussed [3,4].
Transverse vibration characteristics of a thin spinning disc under free and forced vibrating conditions,
using the numerical method found that the natural frequencies of the thin spinning plate attached to a rigid core
increased significantly, with an increase in the speed [5,6]. The modal properties of the fluid-structure system by
an experimental modal analysis with the impeller suspended in air and inside a water reservoir can be analysed
.
[7,8]. The impeller was excited with an instrumented hammer, and the response measured by means of
miniature accelerometers. The Frequency Response Functions (FRFs) have been obtained from a large number
of impacting positions, in order to ensure the identification of the main mode shapes. As a result, the main
modes of vibration have been well characterized both in air and in water, in terms of natural frequency, damping
ratio and mode shape.
Numerical simulation carried out to analyse modal behavior of a reduced scale pump-turbine impeller.
The simulation has been done using the numerical method, in air and in water [9]. The same boundary
conditions in the experiment were considered: free body in air and free body submerged in a reservoir of water.
The stress distribution and concentration of a single blade in the impeller, under the different pressure fields of
the blade structure surface, and also studied the fatigue failure of the blades [10]. A method developed for the
performance computation of an expandable-impeller pump and validated it [11,12]. Numerical method was used
to estimate the total radial load on the impeller of two test pumps as a function of flow rate. The predictions
were validated with the experimental data of global characteristics, and unsteady pressure distribution round the
impeller. Structural stress analysis and modal analysis carried out by the researchers, on an impeller by One-way
Fluid Structure Interaction technique in the numerical method [13,14]. The study showed that the maximum
equivalent stress occurs at the liner near the blade pressure surface of the impeller. The experimental modal
analysis of a fan by using the hammer-hitting pulse-inspirit method revealed that the natural frequencies of the
fan vibration.
Dynamics analysis of the pump and turbine of hydrodynamic coupling, the modal vibration analysis
data of pump and turbine could be obtained by the numerical method, and its natural frequencies at different
rotational speeds are calculated [15]. All the above survey has not considered the exact impeller geometry
shape, i.e. all the earlier researchers assumed uniform blade thickness, like disk. This work addresses the exact
impeller geometry shape with different thicknesses, and is concerned with the numerical method and modal
testing of an industrial impeller. The objective is to determine and verify the vibration characteristics of the
impeller, using both the numerical and experimental methods.
STATIC STRUCTURAL ANALYSIS
The 3D model for the finite element analysis is generated, using the Bladegen feature in the ANSYS-
Workbench. The impeller is a shrouded one, designed for a radial type centrifugal pump. The assumptions and
the impeller parameters are given in Table 1. Figure 1 shows that the three-dimensional model of the impeller,
using the Bladegen feature in the ANSYS Workbench. The finite element model of the impeller is prepared and
then analysed, using the ANSYS Workbench. The impeller is composed of a complex geometric structure, and
hence, for better results tetrahedral elements are used. Impellers are high speed rotating components that may
have considerable inertial effects on the modal behavior of the impeller. Therefore, the modal analysis may be
done considering the stress effects due to rotation. A rotating velocity of 3600 rpm is given to the impeller in the
clockwise direction. The static structural analysis is conducted by applying the rotational velocity on the
impeller. The stresses acting on the impeller due to the inertial forces created due to rotation are determined.
The stress values obtained from the stress analysis are used as pre-stress values for the modal analysis.
Table 1: Impeller Parameters
Type Radial, Closed impeller
Fluid Water
Flow rate 60 m3/hr
Head 51m
Number of blades 6
Blade inlet angle 35 degrees
Blade exit angle 26 degrees
Suction diameter 85mm
Impeller diameter 215mm
Material Cast Iron
Rotating velocity 3600rpm
MODAL ANALYSIS USING FEM
The modal analysis is done on five impellers with different blade thicknesses, ranging from 3.0 mm to
5.0 mm, with increments of 0.5mm. Six modes were extracted for each impeller. The natural frequencies of the
extracted modes range from 450 to 2200 Hz. Figures 3 to 8 show the mode shapes of the impeller obtained from
the modal analysis for an impeller, with the blade thickness of 4.0 mm. In modes 1 and 2, the nodal diameter is
found to be one. Zero nodal diameters are exhibited by the impeller in modes 3 and 4. Modes 5 and 6 exhibited
nodal diameters of two. Though the natural frequencies of the impeller are found to change considerably with
the blade thickness of the impeller, the mode shapes did not show a notable change with the change in the blade
thicknesses
Figure 1. Three-dimensional geometric model for thickness t = 3.0 mm
The points, which remain stationary in the vibration cycle, form a diametric line called nodal diameter.
Natural frequency is the frequency at which an object vibrates when excited by force. At this frequency, the
structure offers the least resistance to a force, and if left uncontrolled, failure can occur. The mode shape is a
deflection of an object at a given natural frequency. The eigenvalue (natural frequency) and the accompanying
eigenvector (mode shape) are calculated to define the dynamics of a structure. The term nodal diameter is
derived from the appearance of a circular geometry, like a disk, vibrating in certain mode.
Figure 2. Finite element model of the impeller with tetrahedral elements
Figure 3. Mode shape 1 for the impeller with blade thickness t=4.0 mm
Figures 3 to 8 show the various mode shapes for the extracted modes. It is noted that even though the
natural frequencies of the impeller change considerably as the thickness changes, there was not much change in
the mode shapes of the impellers. These mode shapes obtained for the impeller analysed, show congruence with
the results obtained by Ziaei Rad [16].
Figure 4. Mode shape 2 for the impeller with blade thickness t=4.0 mm
Figure 5. Mode shape 3 for the impeller with blade thickness t=4.0 mm
Figure 6. Mode shape 4 for the impeller with blade thickness t=4.0 mm
Figure 7. Mode shape 5 for the impeller with blade thickness t=4.0 mm
Figure 8. Mode shape 6 for the impeller with blade thickness t=4.0 mm
Figure 9. Natural frequency from modal analysis Vs Blade thickness
It is also noted that the natural frequencies exhibited by the impeller in modes 1 and 2 are almost the
same as those with similar mode shapes, with nodal diameter one and no node circles formed. While the natural
frequency increased with respect to the blade thickness, the natural frequency showed a gradual drop with an
increase in the blade thickness for mode 3. Modes 3 and 4 have a nodal circle. Modes 5 and 6 also have the
same frequency values, without any notable differences in the frequency values, as well as the mode shapes with
nodal diameter two. It is found that, as the thickness of the impeller increases the natural frequency also
increases. Figure 9 shows the plot between the natural frequency and the blade thicknesses of the impeller for
different modes. The values of mode 1 and mode 2 are very close to each other, and the values of mode 5 and 6
are close to each other, as shown in the above-mentioned figures.
EXPERIMENTAL PRESTRESS MODAL ANALYSIS TESTING
The natural frequencies obtained from the finite element analysis are validated by the experimental
modal testing. For the testing, the impeller was fabricated by casting. The modal testing was done for impellers
of different thicknesses. The impeller is constrained at the center. An electric motor is used to excited the
structure. The transducer attached to the shaker measures the input load that is given. The output response is
measured using an accelerometer attached to the impeller. The input impulse and output response signals are fed
into a signal conditioner. The signals are then processed by an FFT analyzer, which in turn, is connected to a
computer system, which acquires and processes the digital frequency domain data into frequency response
functions. The natural frequencies are then obtained from the FRF data.
Figure 10. Mode Vs Natural frequency comparison of the experimental prestress modal value and FEA values
for blade thickness t=3.0 mm
VALIDATION OF THE FEA PRESTRESS MODAL ANALYSIS VALUES WITH THE
EXPERIMENTAL PRESTRESS MODAL ANALYSIS VALUES
The values obtained in the testing are very close to the FEA results. Figures 10 to 14 are the natural
frequency values obtained from the experimental modal testing and the FEA plotted against the modes. It can be
noticed that the natural frequency values obtained from the experiment and the FEA are very close, thus
validating the results obtained.
Figure 11. Mode Vs Natural frequency comparison of the experimental prestress modal value and FEA values
for blade thickness t=3.5 mm
Figure 12. Mode Vs Natural frequency comparison of the experimental prestress modal value and FEA values
for blade thickness t=4.0 mm
Figure 13. Mode Vs Natural frequency comparison of the experimental prestress modal value and FEA values
for blade thickness t=4.5 mm
Figure 14. Mode Vs Natural frequency comparison of the experimental prestress modal value and FEA values
for blade thickness t=5.0 mm
The prestress modal analysis of the impellers ranging from 3.0 mm to 5.0 mm is done by the Finite
Element Analysis at a rotational velocity of [Link] natural frequencies and the mode shapes of the
impellers are extracted. It is found that the natural frequency of the impeller increased considerably, as the
thickness of the impeller blades increased. This increase in the natural frequency can be attributed to the
increase in the stiffness of the structure overcoming the effect of the addition of mass. Even though the thickness
has a considerable effect on the natural frequencies, the mode shapes of the impeller at resonance are not
affected due to the increase in thickness. The results obtained from the FEA were validated by conducting the
experimental modal testing on the impellers, by the shaker testing method.
CONCLUSIONS
The prestressed modal analysis of the impellers ranging from 3.0mm to 5.0mm was done by the Finite
Element Analysis at a rotational velocity of 3600rpm. The natural frequencies and the mode shapes of the
impellers were extracted. It was found that the natural frequency of the impeller increased considerable as the
thickness of the impellers blades increases. This increase in natural frequency can be attributed to the increase in
the stiffness of the structure overcoming the effect of the addition of mass. Even though the thickness had a
considerable effect on the natural frequencies, the mode shapes of the impeller at resonance were not affected
due to the increase in thickness. The results obtained from the FFA were validated by conducting the
experimental model testing on the impellers, by the shaker testing method.
ACKNOWLEDGEMENTS
Authors are greatful to Dr. M.G.R. Educational and Research Institute and Aarupadai Veedu Institute
of Technology, Chennai, for providing support to carried out this research work.
REFERENCES
1. Bacharoudis, E., Vrachopoulos, M. G., Koukou, M. K., Margaris, D., Filios, A. E., & Mavrommatis, S.
A. (2007). Study of the natural convection phenomena inside a wall solar chimney with one wall
adiabatic and one wall under a heat flux. Applied Thermal Engineering, 27(13), 2266–2275.
2. Barrio, R., Fernndez, J., Blanco, E., & Parrondo, J. (2011). Estimation of radial load in centrifugal
pumps using computational fluid dynamics. European Journal of Mechanics, B/Fluids, 30(3), 316–
324.
3. Campbell, R. L., & Paterson, E. G. (2011). Fluid-structure interaction analysis of flexible
turbomachinery. Journal of Fluids and Structures, 27(8), 1376–1391.
4. Cui, B., Zhu, Z., Zhang, J., & Chen, Y. (2006). Flow simulation and experimental study of low-
specific-speed high-speed complex centrifugal impellers. Chinese Journal of Chemical Engineering,
14(4), 435–441.
5. Djerroud, M., Dituba Ngoma, G., & Ghie, W. (2011). Numerical Identification of Key Design
Parameters Enhancing the Centrifugal Pump Performance: Impeller, Impeller-Volute, and Impeller-
Diffuser. ISRN Mechanical Engineering, 2011, 1–16.
6. Escaler, X., Liang, Q. W., Valero, C., & Egusquiza, E. (2008). Experimental Modal Analysis of a
Francis Model Runner. 24th IAHR Symposium on Hydraulic Machinery and Systems. (pp. 27-31).
7. Gu, L., Chen, L., Hong, P., Pan, Y., Zhang, T., Putti Srinivasa, R., … Shouhuan, Z. (2015). Modal and
Harmonic Analysis of Leaf Spring Using Composite Materials. International Journal of Novel
Research in Electrical and Mechanical Engineering, 5(3), 323–327.
8. Keshava Kumar, S., Cinefra, M., Carrera, E., Ganguli, R., & Harursampath, D. (2014). Finite element
analysis of free vibration of the delaminated composite plate with variable kinematic multilayered plate
elements. Composites Part B: Engineering, 66, 453–465.
9. Presas, A., Valero, C., Huang, X., Egusquiza, E., Farhat, M., & Avellan, F. (2012). Analysis of the
dynamic response of pump-turbine runners-Part I: Experiment. IOP Conference Series: Earth and
Environmental Science, 15(5), 52015.
10. Ranjan, V., & Ghosh, M. K. (2005). Forced vibration response of thin plate with attached discrete
dynamic absorbers. Thin-Walled Structures, 43(10), 1513–1533.
11. Shojaeefard, M. H., Tahani, M., Khalkhali, A., Ehghaghi, M. B., Fallah, H., & Beglari, M. (2012). A
parametric study for improving the centrifugal pump impeller for use in viscous fluid pumping. Heat
and Mass Transfer, 49(2), 197–206.
12. Sirový, M., Peroutka, Z., Molnár, J., Michalík, J., & Byrtus, M. (2011). Sophisticated software for
design and optimization of variable speed drives for high-power pumps: Hydrodynamic coupling
versus frequency converter. In IECON Proceedings (Industrial Electronics Conference) (pp. 955–960).
13. Subramaniam, L., & Sendilvelan, S. (2012). Modal Analysis of a Centrifugal Pump Impeller. European
Journal of Scientific Research, 79(1). 5-14.
14. Wu, L. Y., & Wang, Y. L. (2011). Finite Element Analysis on the Blade Structure of Centrifugal
Pump. In Materials Processing Technologies, Pts 1 and 2 (Vol. 154–155, pp. 1748–1751).
15. Yang, S.-S., Kong, F.-Y., Chen, H., & Su, X.-H. (2012). Effects of Blade Wrap Angle Influencing a
Pump as Turbine. Journal of Fluids Engineering, 134(6), 61102.
16. Ziaei Rad, S. Finite element, Modal testing and modal analysis of centrifugal pump impeller. Iranian
Journal of Science and Technology, 29(B2), 157-169.