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Robust tolerance design for rotor dynamics based on possibilistic concepts

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Abstract

Tolerance is one of major sources of uncertainty and it significantly contributes to the variation of dynamic responses of mechanical structures/products. In this paper, a robust tolerance design method based on possibilistic concepts is presented in order to reduce dynamic response variation of a rotor system due to uncertainties of design variables and assembly process. The robust design model is constructed with the objective of minimizing both the variation of system performance and manufacturing cost. The full factorial numerical integration (FFNI) method instead of the direct Monte Carlo simulation (MCS) is used to calculate the variance (standard deviation) of stochastic responses. The approach is performed by four steps: (1) construct a parameterized model including design and assembly process parameters, (2) analyze the uncertainty propagation of design and assembly process parameters with the statistical tolerance analysis performed by the full factorial numerical integration (FFNI) method instead of the MCS, (3) determine initial space for tolerance design and set up multi-objective optimization functions, and (4) obtain the Pareto front using the evolutionary algorithm NSGA-II and the robust tolerance design results. A rotor of low-pressure turbine compressor with initial unbalanced discs assembly is taken as an example and the robust tolerance design to reduce vibration responses and their variations is undertaken to demonstrate the capability and effectiveness of the proposed approach. The results show that vibration responses of the rotor of low-pressure turbine compressor can be significantly decreased and the qualified rate of maximum vibration responses of the low-pressure turbine compressor rotor system can be increased from 53.29% to over 99.87% if the initial unbalance amplitudes and phase angles of the discs are considered and optimum matching of each disc assembly is determined. The effectiveness of the proposed approach is validated with the Monte Carlo simulation analysis. It indicates the practical potential in industrial applications.

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Acknowledgements

The authors gratefully appreciate the financial support for this work provided by the National Natural Science Foundation of China (No. 12072146). The support of the Jiangsu Province Key Laboratory of Aerospace Power System, the Key Laboratory of Aero-engine Thermal Environment and Structure, and the Ministry of Industry and Information Technology are also gratefully acknowledged.

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Authors and Affiliations

  1. Aero-Engine Thermal Environment and Structure Key Laboratory of Ministry of Industry and Information Technology, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Bensheng Xu, Chaoping Zang & Genbei Zhang

  2. School of Mechanical Engineering, Guilin University of Aerospace Technology, Guilin, 541004, China

    Bensheng Xu

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  1. Bensheng Xu
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  2. Chaoping Zang
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  3. Genbei Zhang
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Correspondence to Chaoping Zang.

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Xu, B., Zang, C. & Zhang, G. Robust tolerance design for rotor dynamics based on possibilistic concepts. Arch Appl Mech 92, 755–770 (2022). https://doi.org/10.1007/s00419-021-02070-5

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