Assembly accuracy analysis and phase optimization of aero-engine multistage rotors considering surface morphology and non-uniform contact deformation
The assembly accuracy of multistage rotors is crucial to guarantee the quality and performance of aero engines. However, traditional assembly accuracy analysis methods usually oversimplify geometric deviations as the degrees of freedom (DOF) variations relative to the ideal position, ignoring real s...
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Published in | Precision engineering Vol. 88; pp. 595 - 610 |
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Main Authors | , , , , |
Format | Journal Article |
Language | English |
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Elsevier Inc
01.06.2024
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Abstract | The assembly accuracy of multistage rotors is crucial to guarantee the quality and performance of aero engines. However, traditional assembly accuracy analysis methods usually oversimplify geometric deviations as the degrees of freedom (DOF) variations relative to the ideal position, ignoring real surface morphology and the resulting non-uniform contact deformation. Therefore, this paper proposes an assembly accuracy analysis method that integrates the effects of surface morphology and non-uniform contact deformation on error propagation process, and further adopts a phase optimization method to improve the assembly accuracy of multistage rotors. Specifically, the surface morphology of rotor end faces is generated using the random midpoint displacement method. The Conjugate Gradient-Fast Fourier Transform (CG-FFT) algorithm is employed to calculate the non-uniform contact deformation. According to the simulation results, a fitting deformation surface (FDS) is constructed to determine the assembly position and orientation. On this basis, a novel error propagation model is established and the mounting phase of each stage rotor is optimized by a genetic algorithm (GA). A case study of a specific rotor system is carried out to verify the proposed error propagation model and give the optimized assembly combination with the objective of minimum coaxiality. This research effectively improves the prediction and actual assembly accuracy of aero-engine multistage rotors and provide a theoretical basis for the precision assembly of multistage rotors in aero-engine applications.
•A novel assembly accuracy analysis method considering real surface morphology and non-uniform contact deformation is proposed.•Rough surface morphology of rotor end face is generated by the random midpoint displacement method.•Non-uniform contact deformation is calculated by an improved CG-FFT method.•The phase optimization algorithm reduces coaxiality by 60.2% compared to random assembly in the given case study. |
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AbstractList | The assembly accuracy of multistage rotors is crucial to guarantee the quality and performance of aero engines. However, traditional assembly accuracy analysis methods usually oversimplify geometric deviations as the degrees of freedom (DOF) variations relative to the ideal position, ignoring real surface morphology and the resulting non-uniform contact deformation. Therefore, this paper proposes an assembly accuracy analysis method that integrates the effects of surface morphology and non-uniform contact deformation on error propagation process, and further adopts a phase optimization method to improve the assembly accuracy of multistage rotors. Specifically, the surface morphology of rotor end faces is generated using the random midpoint displacement method. The Conjugate Gradient-Fast Fourier Transform (CG-FFT) algorithm is employed to calculate the non-uniform contact deformation. According to the simulation results, a fitting deformation surface (FDS) is constructed to determine the assembly position and orientation. On this basis, a novel error propagation model is established and the mounting phase of each stage rotor is optimized by a genetic algorithm (GA). A case study of a specific rotor system is carried out to verify the proposed error propagation model and give the optimized assembly combination with the objective of minimum coaxiality. This research effectively improves the prediction and actual assembly accuracy of aero-engine multistage rotors and provide a theoretical basis for the precision assembly of multistage rotors in aero-engine applications.
•A novel assembly accuracy analysis method considering real surface morphology and non-uniform contact deformation is proposed.•Rough surface morphology of rotor end face is generated by the random midpoint displacement method.•Non-uniform contact deformation is calculated by an improved CG-FFT method.•The phase optimization algorithm reduces coaxiality by 60.2% compared to random assembly in the given case study. |
Author | Gong, Hao Shao, Nan Anwer, Nabil Liu, Jianhua Shi, Song |
Author_xml | – sequence: 1 givenname: Song surname: Shi fullname: Shi, Song organization: Beijing Institute of Technology, School of Mechanical Engineering, 5 South Zhongguancun Street, Haidian District, 100081, Beijing, China – sequence: 2 givenname: Jianhua surname: Liu fullname: Liu, Jianhua organization: Beijing Institute of Technology, School of Mechanical Engineering, 5 South Zhongguancun Street, Haidian District, 100081, Beijing, China – sequence: 3 givenname: Hao surname: Gong fullname: Gong, Hao organization: Beijing Institute of Technology, School of Mechanical Engineering, 5 South Zhongguancun Street, Haidian District, 100081, Beijing, China – sequence: 4 givenname: Nan surname: Shao fullname: Shao, Nan email: nan.shao@bit.edu.cn organization: Beijing Institute of Technology, School of Mechanical Engineering, 5 South Zhongguancun Street, Haidian District, 100081, Beijing, China – sequence: 5 givenname: Nabil surname: Anwer fullname: Anwer, Nabil organization: Université Paris-Saclay, ENS Paris-Saclay, LURPA, 4 Avenue des Sciences, 91190, Gif-sur-Yvette, France |
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Keywords | Non-uniform contact deformation Phase optimization Assembly accuracy analysis Aero-engine multistage rotors Surface morphology |
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SubjectTerms | Aero-engine multistage rotors Assembly accuracy analysis Non-uniform contact deformation Phase optimization Surface morphology |
Title | Assembly accuracy analysis and phase optimization of aero-engine multistage rotors considering surface morphology and non-uniform contact deformation |
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