Search Results (105)

To resolve the fatigue fracture occurring at the tip trailing edge of thin-walled single-crystal turbine rotor blades for a specific aero-engine, this paper derives the relationship between the single-crystal constitutive stiffness matrix and crystal orientation, and clarifies the influence mechanism of crystal orientation on blade-vibration characteristics. The influence rules and degrees of uncertain parameters on the vibration characteristics of thin-walled and thickened-profile blades are comparatively investigated. The results reveal that blade dynamic frequency is strongly affected by both blade profile thickness and crystal orientation, and blade profile optimization can effectively weaken the effects of crystal orientation and blade thickness on the dynamic frequency of critical modes. Based on the above results, the hazardous resonance overlooked in conventional engineering approaches is detected using uncertainty-based vibration analysis. The corresponding failure mechanism is illustrated, the resonant speed range is determined, and the risk of bending–torsion coupled flutter is detected. The outcomes provide valuable guidance for the frequency tuning design of turbine blades. Full article

The bolted rotor system functions as a critical component in aero-engines and gas turbines. Additionally, the misalignment fault is a typical and common fault in bolted rotor systems. Nevertheless, current research on bolted rotor systems has not covered misalignment faults. Therefore, a mathematical model of bolted rotor systems incorporating misalignment faults is established in this work. The nonlinear dynamics of bolted rotor systems involving misalignment are investigated by the comparison of the frequency amplitude responses, waterfall diagrams, rotor orbits and time-varying stiffness. Moreover, an in-depth analysis is conducted on the variations in vibration behaviors of rotor systems under different misalignment degrees. Finally, the proposed model is examined using rotor-rig tests conducted under aligned and misaligned conditions. A consistent observation from the numerical and test results is that the 2× frequency resonance speed does not equate precisely to 0.5 times the critical speed. In addition, the 2× component undergoes a sudden change as the misalignment level rises. Full article

Rub-impact is a critical failure mode in high-speed rotor systems that heavily complicates fault diagnosis. While traditionally studied in aero-engines due to its severe risks of blade damage and thermal-induced rotor instability, rub-impact has increasingly emerged as a crucial concern in modern electric vehicle (EV) traction motors characterized by high speeds, slender shafts, and ultra-narrow rotor–stator air gaps. Since rub-impact rarely occurs in isolation, this study establishes a dynamic model of an EV motor rotor system experiencing compound rub-impact and bearing faults based on Jeffcott rotor theory and the lumped-mass method. The influences of key fault parameters on system dynamics are comprehensively investigated through analyses of time histories, phase trajectories, Poincaré sections, frequency spectra, and envelope spectra. The results show that increasing the rub-impact stiffness (from 1.0 × 10¹⁰ N/m to 3.0 × 10¹⁰ N/m) significantly enhances the non-linear impulsive behavior of the system while reducing the rotor unbalance vibration amplitude by 20.0%. Under compound fault conditions with a local bearing defect width of 3 mm, the disk response is mainly governed by global rub-impact behavior, whereas the bearing-end response is more sensitive to local bearing defects. Under compound fault conditions, although widening the localized bearing defect (from 1 mm to 3 mm) significantly exacerbates the local fault severity at the bearing end, the disk’s phase trajectories, Poincaré maps, and spectra remain virtually uninfluenced. This is attributed to the fact that the relative signature intensity of the bearing fault characteristic frequency $f_i$ attenuates by more than 99% during structural transmission, causing the global non-linear dynamics of the rotor disk to be exclusively governed by global rub-impact behavior and completely insensitive to the localized defect propagation. These quantitative findings provide a precise theoretical basis for the diagnosis and identification of compound faults in rotor systems. Full article

To address flow instability induced by tip leakage vortex breakdown in high thrust-to-weight ratio aero-engine compressors, this study conducts numerical investigations into the DTR transonic compressor rotor. The unsteady evolution of the tip leakage vortex and the corresponding stall inception mechanism under near-stall conditions are revealed. Active flow control using single-slot and dual-slot endwall synthetic jets is further explored. Results show that an optimized single synthetic jet slot improves the compressor stability margin by 11.24% and design-point efficiency by 0.57%. To address the flow instability on this, synergistic excitation using two slots positioned at 25% and 50% axial chord length further suppresses leakage vortex breakdown and passage blockage, raising the stability margin by an additional 13.68% and efficiency by 0.72% compared to the optimal single-slot configuration. For the baseline compressor under near-stall conditions, tip leakage vortex breakdown occurs near 25% axial chord, causing severe flow deterioration. With synthetic jet actuation, low-energy fluid at the tip is blown away or sucked out, delaying vortex breakdown and reducing flow losses, thereby enhancing stability without compromising aerodynamic efficiency. The underlying mechanism is that, during the blowing phase, the jet splits the large-scale leakage vortex and removes the low-energy blockage region; during the suction phase, it extracts the fluid trapped in the tip clearance, preventing re-accumulation of low-energy fluid. These findings provide theoretical guidance for stall suppression and high-performance design of transonic compressors. Full article

Rotor blades in aero-engines operating in sand-laden environments are highly susceptible to particle-induced erosion. Conventional sand ingestion experiments primarily rely on post-test disassembly, which lacks the capability for real-time surface shape analysis. To overcome this limitation, this study proposes a high-precision three-dimensional (3D) shape measurement method for ultrafast dynamic scenarios, based on pulsed laser illumination and stroboscopic structured light. In the proposed approach, a pulsed laser is employed to illuminate a physical grating, generating stroboscopic structured fringe patterns that are projected onto high-speed rotating blades. The deformed fringe images are synchronously captured by a high-speed camera and processed using Fourier transform profilometry (FTP) to reconstruct fine surface features with high accuracy. Compared with conventional LED-based stroboscopic systems, the pulsed-laser-based scheme effectively suppresses motion blur and significantly improves image intensity under ultra-short exposure conditions. Experimental results demonstrate that stable and high-quality fringe acquisition can be achieved at high rotational speeds. The method enables precise quantification of micro-scale defects, such as scratches and pits, providing a reliable solution for in situ monitoring and performance evaluation in aero-engine sand ingestion tests. Full article

Forced resonance induced by rotor–stator interaction (RSI) is a primary driver of high-cycle fatigue (HCF) failure in aero-engine blisks. To overcome the inability of traditional non-contact excitation methods to replicate authentic three-dimensional aerodynamic forces and the predictive biases of pure numerical approaches regarding complex flow excitation energy, this study investigates the forced resonance characteristics of a rotating blisk using a novel aerodynamic excitation system through integrated numerical and experimental approaches. First, a one-way fluid–structure interaction (FSI) framework, coupling the Nonlinear Harmonic (NLH) method with Finite Element Analysis (FEA), was established to efficiently reconstruct the unsteady aerodynamic loads on blade surfaces. The analysis reveals an excitation mechanism dominated by the upstream propagation of the downstream potential field, based on which the numerical resonance response was predicted. In addition, investigating rotor–stator axial clearance as a key variable indicates that there is a strictly monotonically decreasing dependence of the aerodynamic excitation magnitude on the rotor–stator axial clearance. However, the spatial patterns of the primary first-order harmonic excitation remain relatively insensitive to changes in the rotor–stator axial clearance. Finally, by leveraging these excitation characteristics, broadband aero-resonance of the first three modes was successfully induced within the 2600 Hz frequency range under experimental conditions. This validates both the effectiveness of the experimental apparatus and the fidelity of the numerical model. This research not only clarifies the excitation mechanism under vortex generator-induced RSI but also provides a novel testing platform and theoretical framework for rotating modal analysis in advanced propulsion systems. Full article

Accurate prediction and optimization of assembly accuracy are critical to ensuring assembly quality and efficiency for multistage connected aero-engine rotors. To mitigate the effects of residual alignment errors induced by repeated component measurements and to avoid the formation of bowed rotors caused by conventional stacking strategies that only minimize parallel misalignment, a harmonic decomposition-based registration method is proposed to unify inconsistent measurement datums among multiple setups. Meanwhile, key assembly process parameters are considered simultaneously, including front-and-rear support concentricity, front-and-rear bearing mounting face end-face runout, rotor blade-tip runout, and rotor unbalance. Taking the discrete assembly phase angles of each rotor stage as independent variables, a multi-objective genetic algorithm is adopted to realize the assembly accuracy prediction and optimization of multistage flange-bolted rotors. The proposed method is validated using a four-stage simulated rotor assembly. Experimental results show that the harmonic decomposition-based registration method improves the average geometric prediction accuracy of rotor assembly by 1.2 percentage points, with the prediction error of geometric assembly parameters for each stage not exceeding 8.4% and the unbalance prediction error not exceeding 29.0%. Compared with random assembly, four-objective comprehensive optimization achieves significant reductions in all objectives: front-and-rear support concentricity is reduced by 66.2%, front-and-rear support shoulder end-face runout by 63.9%, blade-tip runout by 16.7%, and unbalance by 33.8%. The residual alignment error compensation method and stacking optimization strategy proposed in this study provide valuable engineering guidance for improving rotor assembly prediction accuracy and enhancing assembly reliability. Full article

The service environment of the turbine blade–disk dovetail joint structure in aero-engines is complex. Uncertainties in material properties and geometry, as well as the failure correlations among multiple locations or components, make reliability assessment challenging. First, a probabilistic life modeling method based on linear heteroscedastic regression is proposed, and the Manson–Coffin probabilistic life models of DD6 and FGH96 alloys at 650 °C are established. Then, the Copula function is introduced to characterize the failure dependence structure, and the effectiveness of the method is verified through numerical examples. Fatigue-critical locations of the dovetail are identified, and a Kriging surrogate model is established to obtain the probabilistic stress distribution at the critical locations. Subsequently, the Copula method is employed to conduct reliability analysis of dovetail structures. The results show that the reliability of multiple dovetails considering correlation lies between that of a single dovetail and that under the assumption of complete independence. Moreover, the life of the entire disk dovetail structure is significantly influenced by the number of dovetails and the required reliability level. Finally, the study is extended to the blade–disk dovetail multi-component system. The results indicate that when correlation is considered, the reliability of both components decreases, and the overall structural life is dominated by the dovetail component with the lower life. The analytical method proposed in this paper provides theoretical support and engineering reference for the reliability design and life assessment of aero-engine rotor structures. Full article

This study investigates the stiffness characteristics of elastic ring supports and the dynamic response of aero-engine rotor systems. First, comparative analysis demonstrates that the finite element model provides higher accuracy in predicting the stiffness of the elastic ring compared to traditional analytical methods, with the experimental error controlled within 5%. Grid independence verification further reveals that the mesh density in the boss region is a critical factor determining the accuracy of stiffness calculations. On this basis, the influence mechanism of contact states on stiffness characteristics was deeply explored; it was found that the transition between frictional and bonded contact states can lead to a stiffness deviation of up to 46.8%. Furthermore, quantitative analysis of manufacturing tolerances indicates that the thickness deviation of the boss should be strictly controlled within 0.02 mm to ensure the stability of support performance. Finally, a dynamic model of the rotor system developed using two-dimensional beam elements was fully validated against experimental data, with a calculation error of only 2%. The results of this study provide an important reference for the precise design and stiffness evaluation of elastic ring supports, as well as the engineering testing of rotor system dynamic characteristics. Full article

Excessive vibration during critical speed traversal remains a primary challenge in assembling multi-stage rotors of aero-engines. Conventional assembly optimization methods, which target static geometric and mass eccentricity errors or vibration at a fixed operating speed, are inadequate to ensure smooth passage through multiple critical speeds. To address this gap, we propose a novel, vibration-suppression-oriented assembly optimization model. A normalized objective function is formulated to minimize the overall vibration response across multiple rotor nodes specifically at the first and second critical speeds. This function integrates an assembly error propagation model with a rotor dynamic model that considers flexible dynamic deflection. The optimal assembly angle sequence is solved using a genetic algorithm. Experimental validation on a four-stage rotor demonstrates that the proposed method reduces the maximum vibration displacement amplitude at the first and second critical speeds by 74.7% and 11.9%, respectively, significantly outperforming conventional objectives based on geometric error, unbalanced mass, or single-speed vibration. This work provides a practical and effective strategy to enhance rotor dynamic safety by ensuring low-vibration operation across the critical speeds encountered before reaching the operating speed through optimal assembly. Full article

Integrated blisk–shaft rotors represent a critical advancement in aero-engine design, offering enhanced structural integrity and weight reduction. However, their complex dynamic behavior under inherent material uncertainties poses significant challenges for reliable vibration prediction. This study presents a novel stochastic uncertainty analysis framework combining reduced-order finite element modeling and artificial neural networks (ANNs) to efficiently and accurately quantify the modal variability of integrated blisk–shaft rotors. A high-fidelity finite element model is first developed, followed by the construction and validation of a reduced-order model (ROM) to substantially decrease computational costs while preserving modal accuracy. Material parameter uncertainties are introduced, and corresponding natural frequencies are computed using the ROM. Subsequently, an ANN surrogate model is trained to capture the nonlinear mapping between uncertain input parameters and modal frequencies, enabling rapid prediction across the stochastic parameter space. The proposed approach is employed to perform comprehensive uncertainty propagation and global sensitivity analyses, identifying the dominant parameters influencing each modal frequency. Results demonstrate that the combined ROM-ANN methodology achieves high predictive accuracy with significantly reduced computational effort, offering an effective tool for uncertainty-aware dynamic analysis and design optimization of integrated blisk–shaft rotors. This work advances the integration of machine learning techniques with classical structural dynamics for robust aero-engine rotor design under uncertainty. Full article

In complex mechanical systems involving multiple parts and contact interfaces, failure modes are not only statistically correlated but may also interact through underlying physical mechanisms. These interactions, often neglected in current reliability analysis, can lead to significant deviations in failure predictions, especially in rotor systems and actuators. Taking aeroengine turbine rotor assemblies as an example, multiple failure modes, such as wear, fatigue and slip at contact interfaces, affect key mechanical property parameters including assembly preload, cylindrical interference fit and cooling performance. These variations lead to evolving stress/strain and temperature fields with increasing load cycles, thereby inducing physical interactions among different failure modes. This study systematically analyzes the interaction mechanisms among multiple failure modes within a turbine rotor assembly. A mechanics model is established to quantify these interactions and their effects on failure evolution. Furthermore, a time-dependent reliability evaluation method is proposed based on Monte Carlo simulation and the Probability Network Evaluation Technique. A case study illustrates that both continuous-type and trigger-type interactions significantly affect the failure probabilities of wear and low-cycle fatigue. The results emphasize the necessity of accounting for interaction of multi-failure modes to improve the accuracy of failure prediction and enhance the design reliability of turbine rotor assemblies. Full article

With the increase in thrust–weight ratio of advanced aeroengines, the rotor and stator often exhibit comparable stiffness characteristics, leading to significant vibration coupling which harms the safety and reliability of operations. However, an effective vibration coupling evaluation method for complex rotor–stator systems is still lacking. This paper proposes the Vibration Coupling Evaluation Factor (VCEF) to quantitatively evaluate the interaction between the rotor and stator within the framework of the linear system. Then a new evaluation procedure is established for the structural optimization during the early design phase and the fault source localization in troubleshooting scenarios in the high-speed rotating machinery. In this paper, two typical rotor–stator systems are studied with the VCEF method: a simplified rotor–stator system is studied numerically to reveal the influence pattern of different parameters, and a complex rotor–stator system is studied numerically and experimentally to examine the validity of the evaluation method. The results show that VCEF can effectively capture rotor–stator vibration coupling. The VCEF curve with rotational speed shows a significant stepped decrease, indicating a significant strengthening of the rotor–stator vibration coupling, which aligns closely with experimental data. This evaluation method quantitatively assesses the degree of rotor–stator vibration coupling by comparing the differences in modal characteristics between the rotor system and the rotor–stator system under the gyroscopic effect. Optimizing rotor–stator stiffness and mass distribution based on VCEF mitigates operational risks in high-speed regimes. This methodology provides engineers with a systematic, quantitative tool to determine when integrated rotor–stator analysis is essential for accurate dynamic prediction and offers broad applicability to aeroengine design and other high-speed rotating machinery. Full article

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 high-performance aeroengine operates under extreme loads. In engineering practice, the vibration problems caused by stator vibrations have become increasingly prominent, with impacts on the rotor dynamic behavior. This paper takes the rotor–stator system of aeroengines as the analysis object and studies the influence of stator modal vibration on the rotor dynamic behavior. The dynamic model of the rotor–stator system has been established, and the influence of the contact state of cylindrical roller bearings (CRBs) has been analyzed by considering bearing clearance. To precisely capture the transient contact state within the CRBs, a numerical method combining the Newmark-β method with the Event Function has been developed. The numerical calculation results show that the collision effect introduced by the bearing clearance will excite a localized stator mode at the supercritical state, which fundamentally alters the rotor dynamic behavior: generating prominent combination frequencies $f_M\pm f_r$ due to modulation between the rotor rotation $f_r$ and the stator vibration $f_M$. Moreover, good consistency between the experimental and calculated results has been obtained. This study demonstrates that the stator modal vibration can critically modify rotor dynamic behavior in supercritical operation, leading to potentially hazardous non-synchronous whirl. The integrated model and numerical method provide a robust framework for analyzing complex rotor–stator interactions, offering significant insights for vibration control and fault diagnosis in high-speed rotating machinery. Full article