Numerical Simulation and Experimental Validation of Failure Caused by Vibration of a Fan

This paper presents the root cause analysis of an unexpected fracture occurred on the blades of a motor fan used in a natural gas reciprocating compressor unit. A finite element model was established to investigate the natural frequencies and modal shapes of the fan, and a modal test was performed to verify the numerical results. It was indicated that the numerical results agreed well with experimental data. The third order natural frequency was close to the six times excitation frequency, and the corresponding modal shape was the combination of bending and torsional vibration, which consequently contributed to low-order resonance and fracture failure of the fan. The torsional moment obtained by a torsional vibration analysis of the compressor shaft system was exerted on the numerical model of the fan to evaluate the dynamic stress response of the fan. The results showed that the stress concentration regions on the numerical model were consistent with the location of fractures on the fan. Based on the numerical simulation and experimental validation, some recommendations were given to improve the reliability of the motor fan.