| Citation: | ZHOU T Y，HU L，ZHAO S，et al. Prediction of aeroengine rotor unbalance considering multi-source errors in assembly process[J]. Journal of Beijing University of Aeronautics and Astronautics，2025，51（9）：3001-3010 （in Chinese） doi: 10.13700/j.bh.1001-5965.2023.0438
|
To address the difficulty in predicting the unbalance of aeroengine rotors assembled by complex assembly system, this paper proposed a numerical simulation method for unbalance considering multi-source errors, aiming to achieve the reliable traceability design of the accuracy of workpiece group and its assembly system. Firstly, the transmission principle among process parameters, multi-source errors, relative pose, and unbalance during the rotor assembly process was clarified. Quantitative characterization models were established for typical rotor part manufacturing errors, flange and spigot pose measurement errors, and multi-degree-of-freedom installation mechanism motion errors. Then, a Monte Carlo simulation algorithm for rotor unbalance was designed based on the above models. It realized unbalance prediction under different assembly conditions. For the analysis case of a low-pressure turbine rotor simulator, the accuracy of its assembly system was optimized inversely through comprehensive sensitivity analysis. The qualified rate of corresponding simulated unbalance reaches 99.8%. The proposed simulation method provides reliable accuracy design reference. Finally, assembly verification experiments were carried out. The results show that the deviation rates between the averages of the experimental unbalance and the predicted unbalance are all less than 10%. Thus, the proposed prediction method has high accuracy.
| [1] |
陈予恕, 张华彪. 航空发动机整机动力学研究进展与展望[J]. 航空学报, 2011, 32(8): 1371-1391.
CHEN Y S, ZHANG H B. Review and prospect on the research of dynamics of complete aero-engine systems[J]. Acta Aeronautica et Astronautica Sinica, 2011, 32(8): 1371-1391(in Chinese).
|
| [2] |
陈果, 李兴阳. 航空发动机整机振动中的不平衡-不对中-碰摩耦合故障研究[J]. 航空动力学报, 2009, 24(10): 2277-2284.
CHEN G, LI X Y. Study on imbalance-misalignment-rubbing coupling faults in aero-engine vibration[J]. Journal of Aerospace Power, 2009, 24(10): 2277-2284(in Chinese).
|
| [3] |
EWINS D J. Control of vibration and resonance in aero engines and rotating machinery-an overview[J]. International Journal of Pressure Vessels and Piping, 2010, 87(9): 504-510. doi: 10.1016/j.ijpvp.2010.07.001
|
| [4] |
陈立芳, 王维民, 高金吉. 航空发动机自动平衡技术发展综述[J]. 航空动力学报, 2019, 34(7): 1530-1541.
CHEN L F, WANG W M, GAO J J. Summary on the development of auto-balancing technology of aero-engine[J]. Journal of Aerospace Power, 2019, 34(7): 1530-1541(in Chinese).
|
| [5] |
张渝, 李琳, 陈津, 等. 航空发动机重要装配工艺分析及研发展望[J]. 航空制造技术, 2019, 62(15): 14-21.
ZHANG Y, LI L, CHEN J, et al. Research current status and prospect on aero-engine assembly process technology[J]. Aeronautical Manufacturing Technology, 2019, 62(15): 14-21(in Chinese).
|
| [6] |
石宏. 航空发动机装配工艺技术[M]. 北京: 北京亚洲成人在线一二三四五六区出版社, 2015.
SHI H. Aeroengine assembly technology[M]. Beijing: Beijing University of Aeronautics & Astronautics Press, 2015(in Chinese).
|
| [7] |
SUN C Z, LIU Z W, LIU Y M, et al. An adjustment method of geometry and mass centers for precision rotors assembly[J]. IEEE Access, 2019, 7: 169992-170002. doi: 10.1109/ACCESS.2019.2955124
|
| [8] |
SUN Q C, ZHAO B B, LIU X, et al. Assembling deviation estimation based on the real mating status of assembly[J]. Computer-Aided Design, 2019, 115: 244-255. doi: 10.1016/j.cad.2019.06.001
|
| [9] |
YU L, ZHANG Y L, BI Q Z, et al. Research on surface normal measurement and adjustment in aircraft assembly[J]. Precision Engineering, 2017, 50: 482-493. doi: 10.1016/j.precisioneng.2017.07.004
|
| [10] |
ZHANG M W, LIU Y M, SUN C Z, et al. Precision measurement and evaluation of flatness error for the aero-engine rotor connection surface based on convex hull theory and an improved PSO algorithm[J]. Measurement Science and Technology, 2020, 31(8): 085006. doi: 10.1088/1361-6501/ab8170
|
| [11] |
何晓煦, 田威, 曾远帆, 等. 面向飞机装配的机器人定位误差和残差补偿[J]. 航空学报, 2017, 38(4): 420538.
HE X X, TIAN W, ZENG Y F, et al. Robot positioning error and residual error compensation for aircraft assembly[J]. Acta Aeronautica et Astronautica Sinica, 2017, 38(4): 420538(in Chinese).
|
| [12] |
LI Z H, TIAN W, WANG M, et al. Positioning error compensation of a flexible track hybrid robot for aircraft assembly based on response surface methodology and experimental study[J]. The International Journal of Advanced Manufacturing Technology, 2022, 119(1): 1313-1330.
|
| [13] |
ZHU Y G, HUANG X, FANG W, et al. Trajectory planning algorithm based on quaternion for 6-DOF aircraft wing automatic position and pose adjustment method[J]. Chinese Journal of Aeronautics, 2010, 23(6): 707-714. doi: 10.1016/S1000-9361(09)60273-9
|
| [14] |
WHITNEY D E, GILBERT O L, JASTRZEBSKI M. Representation of geometric variations using matrix transforms for statistical tolerance analysis in assemblies[J]. Research in Engineering Design, 1994, 6(4): 191-210. doi: 10.1007/BF01608399
|
| [15] |
DING S Y, HE Y H, ZHENG X H. A probabilistic approach for three-dimensional variation analysis in aero-engine rotors assembly[J]. International Journal of Aeronautical and Space Sciences, 2021, 22(5): 1092-1105. doi: 10.1007/s42405-021-00384-w
|
| [16] |
ZHOU Z L, LIU W, WU Q, et al. A combined measurement method for large-size aerospace components[J]. Sensors, 2020, 20(17): 4843. doi: 10.3390/s20174843
|
| [17] |
孙汕民, 孙传智, 冯硕, 等. 1种高精度大型阶梯轴圆柱轮廓测量模型[J]. 航空发动机, 2020, 46(2): 61-65.
SUN S M, SUN C Z, FENG S, et al. One kind of high accuracy measurement model of large stepped shaft cylinder profile[J]. Aeroengine, 2020, 46(2): 61-65(in Chinese).
|
| [18] |
YANG J X, DING H. A new position independent geometric errors identification model of five-axis serial machine tools based on differential motion matrices[J]. International Journal of Machine Tools and Manufacture, 2016, 104: 68-77. doi: 10.1016/j.ijmachtools.2016.02.001
|
| [19] |
ZHOU W Y, CHEN W Y, LIU H D, et al. A new forward kinematic algorithm for a general Stewart platform[J]. Mechanism and Machine Theory, 2015, 87: 177-190. doi: 10.1016/j.mechmachtheory.2015.01.002
|
| [20] |
HUSSAIN T, MCWILLIAM S, POPOV A A, et al. Geometric error reduction in the assembly of axi-symmetric rigid components: a two-dimensional case study[J]. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2012, 226(7): 1259-1274. doi: 10.1177/0954405412443471
|
| [21] |
MEMON M, HUSSAIN T, MEMON Z A. Minimizing assembly errors by selecting optimum assembly sequence in the assembly of a rigid circular structure[J]. Mehran University Research Journal of Engineering and Technology. 2012, 31(4): 743-754.
|
| [22] |
BOLOTOV M A, PECHENIN V A, YU PECHENINA E, et al. Digital model to optimize the rotor assembly for aircraft engine compressor models[J]. Journal of Physics: Conference Series, 2021, 1745(1): 012033. doi: 10.1088/1742-6596/1745/1/012033
|
| [23] |
QURESHI A J, DANTAN J Y, SABRI V, et al. A statistical tolerance analysis approach for over-constrained mechanism based on optimization and Monte Carlo simulation[J]. Computer-Aided Design, 2012, 44(2): 132-142. doi: 10.1016/j.cad.2011.10.004
|
| [24] |
LEE N K S, YU G, JONEJA A, et al. The modeling and analysis of a butting assembly in the presence of workpiece surface roughness and part dimensional error[J]. The International Journal of Advanced Manufacturing Technology, 2006, 31(5): 528-538.
|
| [25] |
胡明. 面向质量特性优化的航空发动机转子堆叠装配方法[D]. 哈尔滨: 哈尔滨工业大学, 2019.
HU M. Stacked assembly method of aero-engine rotor oriented to optimization of quality characteristics[D]. Harbin: Harbin Institute of Technology, 2019(in Chinese).
|
Figures(7) / Tables(3)
Copyright © Journal of Beijing University of Aeronautics and Astronautics
Address: Editorial Department of Journal of Beijing University of Aeronautics and Astronautics, 37 Xueyuan Road, Haidian District, Beijing Post Code: 100191 Email: jbuaa@cqjj8.com
Supported by:
Beijing Renhe Information Technology Co., Ltd.
DownLoad:
