A Novel Method for Stacking Optimization of Aeroengine Multi-stage Rotors Based on 3D Deviation Prediction Model

Abstract

The assembly precision of high pressure compressor (HPC) multi-stage rotors is critical to the healthy and high-performance operation of aeroengine. The traditional trial assembly method usually requires multiple disassembly and assembly of rotors to ensure assembly precision, which is cumbersome and may cause damage to parts. It is important to predict and optimize the stacking precision of multi-stage rotors to improve the assembly quality and reduce aeroengine operational failure. This paper proposes a novel method for stacking optimization of aeroengine multi-stage rotors based on 3D deviation prediction model. First, the three-dimensional deviation propagation and accumulation process in the stacking process of a four-stage rotor is deduced using the coordinate transformation method, and the 3D deviation prediction model is established to derive the concentricity and perpendicularity of rotors under different bolt hole phase combinations; Second, the Gaussian distribution is used to simulate the radial and axial runout data of the upper end surface of each stage of rotor, and the center and unit normal vector of the upper end surface of rotors are obtained by the least squares method, then the predicted values of concentricity and perpendicularity of rotors under different bolt hole phase combinations are calculated through the 3D deviation prediction model; Third, a dual-objective integer optimization function is established, and the optimal installation phase and the corresponding predicted values of concentricity and perpendicularity of rotors are obtained. The proposed method can predict the concentricity and perpendicularity of rotors and optimize the stacking phase accurately, so as to achieve the target stacking precision requirements through a single assembly, which can provide theoretical guidance for the actual stacking process of aeroengine multi-stage rotors.