Theoretical and experimental study for identification of crack in cantilever beam by measurement of natural frequencies

Most of the rotating machines used in process industries or in manufacturing plant need maintenance and repair. However, failure of just one of these machines can disturb an entire process with losses in terms of production, manpower, and equipment repair or replacement. Also failure of a single machine component in process industries like petrochemicals or power stations can result in the loss of millions of rupees per down time hour. These facts together with higher costs for new equipment have placed increased demand on plant maintenance to keep existing equipment operating efficiently with higher availability. A number of non-destructive crack detection techniques have been developed, such as ultrasonic testing, X-ray technique, magnetic particle method etc. Every method has some advantages and disadvantages. In recent years, ultrasonic testing has gained greater attention for monitoring the cracks in structures and machine components. Most of these methods are very laborious and time consuming, in the case of larger components like bridges, long pipe lines, railway tracks etc. These inconveniences can be avoided by the use of vibration monitoring technique such as model analysis. Therefore the development of vibration monitoring techniques has received increasing attention in recent years. Damage in structure alters its dynamic characteristics. The change is characterized by a change in model parameters i.e. model frequencies, model damping values and mode shapes associated with each model frequencies. Changes also occur in some of the structural parameters like mass, damping, stiffness and flexibility matrices of structure. Thus a vibration technique can be suitably used as a nondestructive test for crack detection of components to be tested. In this paper, theoretical and experimental analysis of a vibrating cantilever beam with a crack is carried out. This method is used to address the inverse problem of assessing the crack location and crack size in various beam structure. The method is based on measurement of natural frequencies, which are global parameter and can be easily measured from any point on the structure. In theoretical analysis the crack is simulated by an equivalent spring, connecting the two segments of the beam. Analysis of this approximate model results in algebraic equation, which relates the natural frequencies of the beam, and crack location. Also the relationship between the natural frequencies, crack location and crack size has also been developed. For identification of crack location and crack size, it was shown that data on the variation of the first two natural frequencies are sufficient. The computation of natural frequencies of uncracked and cracked beam is facilitated by a finite element method package. This database is to be utilized in an analytical method to address the inverse problem to identify the crack location and crack size.