A new approach for expanding incomplete experimental mode shapes is presented which considers the modelling errors in the analytical model and the uncertainties in the vibration modal data measurements. The proposed approach adopts the perturbed force vector that includes the effect of the discrepancy in mass and stiffness between the finite element model and the actual tested dynamic system. From the developed formulations, the perturbed force vector can be obtained from measured modal data and is then used for predicting the unmeasured components of the expanded experimental mode shapes. A special case that does not require the experimental natural frequency in the mode shape expansion process is also discussed. A regularization algorithm based on the Tikhonov solution incorporating the generalized cross-validation method is employed to filter out the influence of noise in measured modal data on the predictions of unmeasured mode components. The accuracy and robustness of the proposed approach is verified with respect to the size of measured data set, sensor location, model deficiency and measurement uncertainty. The results from two numerical examples, a plane frame structure and a thin plate structure, show that the proposed approach has the best performance compared with the commonly used existing expansion methods, and can reliably produce the predictions of mode shape expansion, even in the cases with limited modal data measurements, large modelling errors and severe measurement noise.
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