Search Results (82)

Aiming to improve the accuracy of the aero-engine’s multi-stage rotor’s mating surface classification and initial unbalance prediction, a new intelligent approach for the unbalance prediction of the aero-engine’s multi-stage rotor is proposed in this paper. Numerical simulations of the proposed scheme were conducted on actual assembly datasets of actual aero-engine rotors, and assembly experiments implementing actual aero-engine’s multi-stage rotors were carried out to validate the effectiveness of the proposed method. Results of numerical simulation and experimental validation revealed that the proposed hybrid network method was not only capable of efficiently recognizing different types of rotors’ mating surfaces with a satisfactory accuracy of more than 98% in the training process and 93.3% in experiments, but also proved to accurately predict after-assembly initial unbalance with an acceptable error of less than 5% in both simulated and experimental scenarios. Therefore, the method proposed in this paper can not only be used for rotor surface classification, but also can be used to guide the assembly of aero-engine multi-stage rotors. Full article

The rotor is a crucial component in rotating machinery, where its stability directly impacts performance and safety. Imbalance-induced vibrations can cause severe component wear, resonance instability, and even catastrophic failures, especially in high-speed systems like aero-engines. While the squeeze film damper (SFD) is widely used for vibration suppression, the effects of imbalance (manifested as SFD eccentricity) on its dynamic performance are not well understood. Additionally, the combined impact of imbalance and acceleration on rotor–SFD system stability has not been systematically investigated. This study uses numerical simulations to explore the influence of SFD eccentricity, caused by imbalance, on its dynamic characteristics. Experimental tests are conducted to examine the effects of imbalance and acceleration on rotor–SFD dynamics. Results show that increasing imbalance raises SFD eccentricity, reducing the effective oil film bearing area. This results in a rapid increase in the oil film’s stiffness and slower growth in damping, enhancing nonlinearity and reducing stability. Under small imbalance conditions, increasing acceleration improves stability by facilitating critical speed crossing and reducing vibration amplitude. However, excessive imbalance renders acceleration control ineffective, exacerbating system instability. This study provides valuable insights into the interaction between imbalance, acceleration, and SFD performance, offering guidance for optimizing rotor–SFD system parameters and ensuring stable operation. Full article

The air turbine starter (ATS) of an aero-engine incorporates a high-speed, high-energy rotor. An uncontained failure of the ATS could lead to catastrophic consequences, making containment capability research critically important. This study proposes a comprehensive evaluation methodology for ATS containment. A full-scale finite element model of the whole structure of an ATS was established to analyze containment characteristics and structural deformation patterns. Furthermore, an experimental method for ATS containment testing was designed to investigate the containment process and critical structural damage. By integrating simulation and experimental results, the load transfer paths and structural dynamic response of the ATS were systematically analyzed. The results demonstrate that sudden high-energy loads primarily follow two distinct transfer paths, each causing completely different structural damage behaviors. After the turbine wheel is broken, the resulting unbalanced load causes turbine shaft oscillation, which, in turn, compresses the bearings and damages their inner and outer rings. This research provides valuable guidance for the structural design of air turbine starters. Full article

Future aero engine designs must address environmental challenges and meet noise and emissions regulations. To increase efficiency and reduce size, axial compressors require higher pressure ratios and a more compact design, leading to necessary modifications in the variable stator vanes, especially in the stator hub region. This study examines the impact of a variable cantilevered stator on the performance and aerodynamics of a 1.5-stage transonic compressor, representative of a high-pressure compressor front stage. Experimental tests at the transonic compressor test rig at Technical University of Darmstadt involved two variable stators with identical airfoil designs but different hub configurations, using the same inlet guide vane and rotor. Detailed aerodynamic analysis was conducted using steady and unsteady instrumentation. The cantilevered stator achieved a 2% increase in efficiency and a 1% increase in total pressure ratio, due to higher aerodynamic loading and reduced pressure losses. The primary performance gain comes from the reduction of the hub blockage area. The cantilevered stator also performed well at near stall conditions, unlike the shrouded stator. Time-resolved measurements indicated that loss mechanisms are closely linked to the rotor wake phase. Overall, variable cantilevered stators outperformed shrouded stators in this compressor stage. Full article

Bearing clearance, prevalent in multi-supports rotor systems of aero engines, exerts a significant influence on the dynamics of rotor systems, actuators, and aero engines. The essence of it lies in the complex mechanical effects between the bearing and support. These effects become more complicated when significant relative angular deflections between the bearing and support exist, which is rarely considered in previous studies. In this paper, a model of support structure with bearing clearance considering angular deflections is proposed, and a mechanical model of the multi-supports rotor system with bearing clearance is developed. The dynamic response of the multi-supports rotor system with bearing clearance is investigated by numerical calculation and experimental verification. The results indicate that, in addition to the rotational frequency, remarkable harmonic frequency components occur in the response, which are generated by the relative movement and periodical collision between the bearing and support, and the relative angular deflections between the bearing and support have a significant impact on the amplitude of them; reducing the bearing clearance or increasing the misalignment both leads to a notable increase in the amplitudes of the harmonic frequency components. Full article

Modern advanced aero-engine bearing systems typically exhibit structural and loading characteristics with high DN values. The harsh thermal environment and multi-physics loads under operating conditions render the reliability of bearing structural systems particularly sensitive to lubrication efficiency and bearing chamber temperature. This study performs simulation analyses of oil return processes and their influencing factors in an aero-engine main bearing chamber with complex structural features. The results show two primary causes of reduced scavenging performance. On the one hand, the local low-speed region at the inlet of the scavenge pipe causes some oil to fail to enter the scavenge pipe normally. On the other hand, the air in the bearing chamber is disturbed by the rotation of the rotor, which makes oil enter the oil sump with a tendency to return to the oil collection annulus, thereby causing poor oil return. Furthermore, two structural improvements of the oil sump are proposed. These improvements avoid the disruptive effects of circumferential fluid motion in the oil collection annulus on the pressure and velocity distribution within the bearing chamber, thereby improving scavenging performance. Full article

The inter-shaft bearing is an important component of aero-engine rotor systems. It works between a high-pressure rotor and a low-pressure rotor. Effective fault diagnosis of it is significant for an aero-engine. The casing vibration signals can promptly and intuitively reflect changes in the operational health status of an aero-engine’s support system. However, affected by a complex vibration transmission path and vibration of the dual-rotor, the intrinsic vibration information of the inter-shaft bearing is faced with strong noise and a dual-frequency excitation problem. This excitation is caused by the wide span of vibration source frequency distribution that results from the quite different rotational speeds of the high-pressure rotor and low-pressure rotor. Consequently, most existing fault diagnosis methods cannot effectively extract inter-shaft bearing characteristic frequency information from the casing signal. To solve this problem, this paper proposed the denoised improved envelope spectrum (DIES) method. First, an improved envelope spectrum generated by a spectrum subtraction method is proposed. This method is applied to solve the multi-source interference with wide-band distribution problem under dual-frequency excitation. Then, an improved adaptive-thresholding approach is subsequently applied to the resultant subtracted spectrum, so as to eliminate the influence of random noise in the spectrum. An experiment on a public run-to-failure bearing dataset validates that the proposed method can effectively extract an incipient bearing fault characteristic frequency (FCF) from strong background noise. Furthermore, the experiment on the inter-shaft bearing of an aero-engine test platform validates the effectiveness and superiority of the proposed DIES method. The experimental results demonstrate that this proposed method can clearly extract fault-related information from dual-frequency excitation interference. Even amid strong background noise, it precisely reveals the inter-shaft bearing’s fault-related spectral components. Full article

To analyze the wear performance induced by rotor–stator rubbing in an aero-engine sealing structure under authentic operating conditions, a transonic rotor system with double bearing is constructed. This system incorporates the disk, shaft, blades, joint bolts, and auxiliary support structure. The system was evaluated in terms of its critical speed, vibration characteristics, component strength under operational conditions, and response characteristics in abnormal extreme scenarios. A ball screw-type feeding system is employed to achieve precise rotor–stator rubbing during rotation by controlling the coating feed. Additionally, a quartz lamp heating system is used to apply thermal loads to coating specimens, and the appropriate heat insulation and cooling measures are implemented. Furthermore, a high-frequency rubbing force test platform is developed to capture the key characteristics caused by rubbing. The test rig can conduct response tests of the system with rotor–stator rubbing and abrasion tests with tip speeds reaching 425 m/s, feed rates ranging from 2 to 2000 μm/s, and heating temperatures up to 1200 °C. Test debugging has confirmed these specifications and successfully executed rubbing tests, which demonstrate stability throughout the process and provide reliable rubbing force test results. This designed test rig and analysis methodology offers valuable insights for developing high-speed rotating machinery. Full article

This study examines the labyrinth seal disc of an aero-engine, specifically analysing the radial deformation caused by centrifugal force and heat stress during operation. This distortion may lead to discrepancies in the performance attributes of the labyrinth seal and could potentially result in contact between the labyrinth seal tip and neighbouring components. A numerical analytical model incorporating the rotor and stator cavities, along with the labyrinth seal disc structure, has been established. The sealing integrity of a standard labyrinth seal disc’s flow channel is evaluated and studied at different clearances utilising the fluid–solid-thermal coupling method. The findings demonstrate that, after considering radial deformation, a cold gap of 0.5 mm in the conventional labyrinth structure leads to stabilisation of the final hot gap and flow rate, with no occurrence of tooth tip rubbing; however, both the gap value and flow rate show considerable variation relative to the cold state. When the cold gap is 0.3 mm, the labyrinth plate makes contact with the stator wall. To resolve the problem of tooth tip abrasion in the conventional design with a 0.3 mm cold gap, two improved configurations are proposed, and a stability study for each configuration is performed independently. The leakage and temperature rise attributes of the two upgraded configurations are markedly inferior to those of the classic configuration at a cold gap of 0.5 mm. At a cold gap of 0.3 mm, the two improved designs demonstrate no instances of tooth tip rubbing. Full article

Elastic rings are extensively utilized in aero-engine rotor systems owing to their compact size and ease of assembly, where they play a critical role in vibration suppression during engine operation. The dynamic behavior of elastic rings is governed by their structural parameters, with stiffness being a pivotal factor influencing the rotor system’s performance. This study employs finite element methods to investigate the effects of elastic ring structural parameters, particularly the geometric features of bosses and internal/external assembly clearances, on stiffness nonlinearity, with a focus on its mechanisms and contributing factors. The results reveal that stiffness nonlinearity emerges when the whirling radius exceeds a critical threshold. Specifically, increasing the boss width, reducing the boss height, or augmenting the number of bosses all attenuate stiffness nonlinearity under identical whirling radii. Furthermore, external clearances exhibit a stronger capability to suppress stiffness nonlinearity compared to internal clearances. Engineering insights suggest that maintaining a small clearance fit during assembly effectively mitigates stiffness nonlinearity, thereby enhancing the rotor’s dynamic performance. This study elucidates the stiffness nonlinearity behavior of elastic rings in practical applications and provides actionable guidance for their design and operational optimization in rotor systems. Full article

We introduce the solver ARES: Axial-flow pump Radial Equilibrium through Streamlines. The code implements a meanline method, enforcing the conservation of flow momentum and continuity across a set of discrete streamlines in the axial-flow pump’s meridional channel. Real flow effects are modeled with empirical correlations, including off-design deviation and losses due to profile shape, secondary flows, tip leakage, and the end-wall boundary layer (EWBL). Inspired by aeronautical fan and compressor methods, this implementation is specifically tailored for the analysis of the Outboard Dynamic-inlet Waterjet (ODW), the latest aero-engine-derived innovation in marine engineering. To ensure the reliable application of ARES for the systematic designs of ODW pumps, the present investigation focuses on prediction accuracy. Global and local statistics are compared between numerical estimates and available measurements of three test cases: two single rotors and a rotor–stator waterjet configuration. At mass flow rates near the design point, hydraulic efficiency is predicted within $1\%$ discrepancy to tests. Differently, as the flow coefficient increases, the loss prediction accuracy degrades, incrementing the error for off-design estimates. Spanwise velocity and pressure distributions exhibit good alignment with experiments near midspan, especially at the rotor exit, while end-wall boundary layer complex dynamics are hardly recovered by the present implementation. Full article

Taking the cantilever rotor of a turbine engine as the research object, a dynamic and finite-element model of the cantilever rotor is established, and the effectiveness of the model is verified by the rotor test platform. The transfer function method is used to balance the rotor system under unbalanced excitation, and the experiments prove that the method adopted in this paper has a good balancing effect and effectively reduces the vibration of the unbalanced rotor. On this basis, the experimental tests and simulation analyses of the rotor vibration response under different unbalanced phases and difference combinations are carried out, and the influence of the unbalanced phase’s difference combinations on unbalance and dynamic balance is analyzed. The results show that the vibration response of the system decreases with the increase in the unbalanced phase difference combinations, and the amplitude of the vibration induced by the unbalance of the reverse combination is smaller than that of the in-phase combination. The work in this paper can provide a theoretical basis for the dynamic balance and vibration control of the flexible rotor of an aero-engine. Full article

The health monitoring system has been the main technological approach to extending the life of gas turbine engines and reducing maintenance costs resulting from performance degradation caused by asymmetric factors like carbon deposition, damage, or deformation. One of the most critical techniques within the health monitoring system is performance degradation prediction. At present, most research on degradation prediction is carried out using NASA’s open dataset, C-MAPSS, without considering that monitoring measurements are not always available, as in the ideal dataset. This limitation makes fault diagnosis algorithms and remaining useful life prediction methods difficult to apply to real gas turbine engines. Therefore, to solve the problem of performance degradation prediction in light-duty gas turbine engines, a prediction diagram is proposed based on Long Short-Term Memory (LSTM). Various types of onboard signals are taken into consideration among the experimental data. Only accumulated usage time, total temperature and total pressure before the inlet, low-pressure rotor speed, high-pressure rotor speed, fuel flow rate, exhaust temperature, and thrust are used in the training process, which is indispensable for an aero-engine. A genetic algorithm (GA) is introduced into the training process to optimize the hyperparameters of LSTM. The performance degradation prediction modeled with the GA-LSTM method is validated using experimental data. The maximum prediction error of thrust is 70 daN, and the mean absolute percentage error (MAPE) is less than 0.04. This study provides a practical approach to implementing performance degradation prediction in health monitoring systems to improve gas turbine engine reliability, economy, and environmental performance. Full article

A comprehensive investigation into the aero-thermodynamic impacts of UAV-generated airflow on the rice microclimate is essential to elucidate the complex relationships between wind speed, temperature, and temporal dynamics during the critical growth stages of rice. Focusing on the vulnerable stages of rice such as heading, panicle, and flowering, this research aims to advance the understanding of microclimatic influences on rice crops, thereby informing the development of UAV-based strategies to enhance crop resilience and optimize yields. By utilizing UAV rotor downwash, the research examines wind temperature and speed at three key diurnal intervals: 9:00 a.m., 12:00 p.m., and 3:00 p.m. At 9:00 a.m., UAV-induced airflow creates a stable microclimate with favourable temperatures (27.45–28.45 °C) and optimal wind speeds (0.0700–2.050 m/s), which promote and support pollen transfer and grain setting. By 12:00 p.m., wind speeds peak at 2.370 m/s, inducing evaporative cooling while maintaining temperature stability, yet leading to some moisture loss. At 3:00 p.m., wind temperatures reach 28.48 °C, with a 72% decrease in wind speed from midday, effectively conserving moisture during critical growth phases. The results reveal that UAV airflow positively influences panicle and flowering stages, where carefully moderated wind speeds (up to 3 m/s) and temperatures reduce pollen sterility, enhance fertilization, and optimize reproductive development. This highlights the potential of UAV-engineered microclimate management to mitigate stress factors and improve yield through targeted airflow regulation. Key agronomic parameters showed significant improvements, including stem diameter, canopy temperature regulation, grain filling duration, productive tillers (increasing by 30.77%), total tillers, flag leaf area, grains per panicle (rising by 46.55%), biological yield, grain yield (surging by 70.75%), and harvest index. Conclusively, optimal aero-thermodynamic effects were observed with 9:00 a.m. rotor airflow applications during flowering, outperforming midday and late-afternoon treatments. Additionally, 12:00 p.m. airflow during flowering significantly increased the yield. The interaction between rotor airflow timing and growth stage (RRS × GS) exhibited low to moderate effects, underscoring the importance of precise timing in maximizing rice productivity. Full article

In a supersonic state, the aero-engine operates under harsh circumstances of elevated temperature, high pressure, and rapid rotor speed. This work provides an innovative high-stability control technique for engines with fixed-geometry inlets, addressing stability control issues at the aero-propulsion system level. The discussion begins with the importance of an integrated model for the intake and the aero-engine, introducing two stability indices (surge margin and buzz margin) to characterize inlet stability. A novel predictive model for engine air mass flow is developed to address the indeterminate issue of engine air mass flow. The integration of input parameters in the predictive model is refined using the least squares support vector regression (LSSVR) algorithm, and historical input data is used to enhance predictive performance, as validated by numerical simulation results. A data-driven adaptive augmented linear quadratic regulator (d-ALQR) control technique is suggested to adaptively modify the control parameters of the augmented linear quadratic regulator. A highly stable control strategy is finally proposed, integrating the predictive model with the d-ALQR controller. The simulation results conducted during maneuvering flight operations demonstrate that the developed high-stability controller can maintain the inlet in an efficient and safe condition, ensuring optimal compatibility between the engine and the inlet. Full article