基于数字孪生的航空发动机配合界面装配分析

doi:10.7527/S1000-6893.2024.29800

Abstract

Abstract:

With the improvement of machining accuracy and quality stability of aero-engine parts， assembly accuracy has gradually become the critical factor affecting product accuracy. To predict the influence of form and position deviation of mating surfaces on the product final assembly deviation， assembly error analysis methods based on mathematical models have been developed. However， these methods are constrained by modeling limitations， leading to a simplified approximation of the geometric and physical information for the mating interfaces. While the convenience of computational analysis is enhanced， the accurate representation of surface morphology deviations is hindered， thereby， resulting in the inability to precisely analyze their influence on the assembly process. Especially for precision mechanical products， such as aero-engine， small deviations could have an important impact on product quality and stability under large load conditions. Therefore， an assembly deviation analysis method based on digital twin is proposed. This solution leverages the digital twin technology as the framework， utilizes the skin model shapes as the modeling method of the mating surface， and combines the data-driven multi-factor simulation model to realize the comprehensive analysis of influence of the assembly mating surface deviation on the assembly accuracy. A set of engine assembly interface test work pieces are performed， and the effectiveness of the proposed digital twin method is verified by comparing the experiment with simulation results.

Key words: aero-engine, mating interface, digital twin, assembly analysis, surface measurement, digital simulation

CLC Number:

V263.2

Jinyue LI, Pengfei ZHANG, Yuecheng GUO, Maocheng XU, Gang ZHAO. Assembly analysis of aero-engine mating interface based on digital twin[J]. Acta Aeronautica et Astronautica Sinica, 2024, 45(21): 629800.

Figures/Tables 19

Fig.1

Fig.2

Fig.3

Fig.4

Fig.5

Fig.6

Fig.7

Fig.8

Fig.9

Fig.10

Fig.11

Fig.12

Fig.13

Fig.14

Fig.15

Fig.16

Fig.17

Table 1

Fig.18

References 48

1	ZHU W H， HAN H， FANG M L， et al. Studies on visual scene process system of aircraft assembly［J］. Journal of Manufacturing Systems， 2013， 32（4）： 580-597.
2	郭德伦，韩野，张媛. 航空发动机的发展对制造技术的需求［J］. 航空制造技术， 2015， 22： 68-72.
	GUO D L， HAN Y， ZHANG Y. Demand of aeroengine development for manufacturing technology［J］. Aeronautical Manufacturing Technology， 2015， 22： 68-72 （in Chinese）.
3	刘检华，孙清超，程晖，等. 产品装配技术的研究现状、技术内涵及发展趋势［J］. 机械工程学报， 2018， 54（11）： 1-28.
	LIU J H， SUN Q C， CHENG H， et al. The state-of-the-art， connotation and developing trends of the products assembly technology［J］. Journal of Mechanical Engineering， 2018， 54（11）： 1-28 （in Chinese）.
4	赵罡，李瑾岳，徐茂程，等. 航空发动机关键装配技术综述与展望［J］. 航空学报， 2022， 43（10）： 527484.
	ZHAO G， LI J Y， XU M C， et al. Research status and prospect of key aero-engine assembly technology［J］. Acta Aeronautica et Astronautica Sinica， 2022， 43（10）： 527484 （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	陈爽. 螺栓-止口连接的安装边制造误差对装配性能的影响研究［D］. 大连：大连理工大学， 2021.
	CHEN S. Research on the influence of manufacturing error of installation edge of bolt-stop connection on assembly performance［D］.Dalian： Dalian University of Technology， 2021 （in Chinese）.
7	刘亮. 基于机器学习的航发转子装配精度预测与优化［D］. 大连：大连理工大学， 2021.
	LIU L. Prediction and optimization of assembly accuracy of aeroengine rotor based on machine learning［D］. Dalian： Dalian University of Technology， 2021 （in Chinese）.
8	ZHENG B， YU H D， LAI X M. Assembly deformation prediction of riveted panels by using equivalent mechanical model of riveting process［J］. The International Journal of Advanced Manufacturing Technology， 2017， 92（5）： 1955-1966.
9	孙汕民，周烁，高鸽，等. 航空发动机装配仿真的关键技术问题［J］. 航空制造技术， 2018， 61（22）： 98-103.
	SUN S M， ZHOU S， GAO G， et al. Key technical issues on aero-engine assembly simulation［J］. Aeronautical Manufacturing Technology， 2018， 61（22）： 98-103 （in Chinese）.
10	陶飞，张贺，戚庆林，等. 数字孪生十问：分析与思考［J］. 计算机集成制造系统， 2020， 26（1）： 1-17.
	TAO F， ZHANG H， QI Q L， et al. Ten questions towards digital twin： Analysis and thinking［J］. Computer Integrated Manufacturing Systems， 2020， 26（1）： 1-17 （in Chinese）.
11	GRIEVES M. Virtually perfect： Driving innovative and lean products through product lifecycle management［M］. Merritt Island： Space Coast Press， 2011.
12	LIU S M， BAO J S， LU Y Q， et al. Digital twin modeling method based on biomimicry for machining aerospace components［J］. Journal of Manufacturing Systems， 2021， 58： 180-195.
13	陶飞，刘蔚然，刘检华，等. 数字孪生及其应用探索［J］. 计算机集成制造系统， 2018， 24（1）： 1-18.
	TAO F， LIU W R， LIU J H， et al. Digital twin and its potential application exploration［J］. Computer Integrated Manufacturing Systems， 2018， 24（1）： 1-18 （in Chinese）.
14	戴晟，赵罡，于勇，等. 数字化产品定义发展趋势：从样机到孪生［J］. 计算机辅助设计与图形学学报， 2018， 30（8）： 1554-1562.
	DAI S， ZHAO G， YU Y， et al. Trend of digital product definition： From mock-up to twin［J］. Journal of Computer-Aided Design & Computer Graphics， 2018， 30（8）： 1554-1562 （in Chinese）.
15	刘永泉，黎旭，任文成，等. 数字孪生助力航空发动机跨越发展［J］. 航空动力， 2021（2）： 24-29.
	LIU Y Q， LI X， REN W C， et al. Digital Twin boosting leap-forward development of aero engine［J］. Aerospace Power， 2021（2）： 24-29 （in Chinese）.
16	孙惠斌，颜建兴，魏小红，等. 数字孪生驱动的航空发动机装配技术［J］. 中国机械工程， 2020， 31（7）： 833-841.
	SUN H B， YAN J X， WEI X H， et al. Digital twin-driven aero-engine assembly technology［J］. China Mechanical Engineering， 2020， 31（7）： 833-841 （in Chinese）.
17	BAO Q W， ZHAO G， YU Y， et al. Ontology-based modeling of part digital twin oriented to assembly［J］. Proceedings of the Institution of Mechanical Engineers， Part B： Journal of Engineering Manufacture， 2022， 236（1-2）： 16-28.
18	汪祥，王友涛，唐彬，等. 力矩-转角拧紧工艺在改进发动机机匣装配质量的应用研究［J］. 装备制造技术， 2021（3）： 116-118， 142.
	WANG X， WANG Y T， TANG B， et al. Improvement of torque angle tightening process the application research of the assembly quality of engine gearbox［J］. Equipment Manufacturing Technology， 2021（3）： 116-118， 142 （in Chinese）.
19	王方，甘甜，王煜栋，等. 航空发动机燃烧室数字孪生体系关键技术［J］. 航空动力学报， 2023， 38（7）： 1546-1560.
	WANG F， GAN T， WANG Y D， et al. Key technology of digital twin system for aero-engine combustors［J］. Journal of Aerospace Power， 2023， 38（7）： 1546-1560 （in Chinese）.
20	刘美. 航空发动机气路系统数字孪生技术研究与开发［D］. 哈尔滨：哈尔滨工业大学， 2020： 13-21.
	LIU M. Research and development of digital twin technology for aero engine gas path system［D］. Harbin： Harbin Institute of Technology， 2020： 13-21 （in Chinese）.
21	郭钢毅. 航发转子螺栓-止口连接界面均匀性分析及工艺调控研究［D］. 大连：大连理工大学， 2022： 1-6.
	GUO G Y. Research on the contact uniformity and process control of bolt-spigot connection structure of aero-engine rotor［D］.Dalian： Dalian University of Technology， 2022： 1-6 （in Chinese）.
22	颜诚，王昱景，董世煌，等. 考虑接触状态和力学特性差异的圆弧端齿连接安装角度优化方法［J］. 航空动力学报， 2024， doi： 10.13224/j.cnki.jasp.20220971 .
	YAN C， WANG Y J， DONG S H， et al. Assembly angle optimization of curvic couplings considering contact status and mechanical characteristics［J］. Journal of Aerospace Power， 2024， doi： 10.13224/j.cnki.jasp.20220971 （in Chinese）.
23	李伦绪，陈果，杨默晗. 航空发动机套齿连接结构刚度特性仿真分析及试验研究［J］. 中国机械工程， 2022， 33（18）： 2249-2257.
	LI L X， CHEN G， YANG M H. Simulation analysis and experimental study of stiffness characteristics of aero-engine spline couplings［J］. China Mechanical Engineering， 2022， 33（18）： 2249-2257 （in Chinese）.
24	张譍之，孙惠斌，颜诚，等. 短精密螺栓连接结构组合偏心预测及安装相位优化［J］. 航空动力学报， 2024， doi：10.13224/j.cnki.jasp.20220421 .
	ZHANG Y Z， SUN H B， YAN C， et al. Prediction of assembly eccentricity and optimization of installation phase for short precision bolted structures［J］. Journal of Aerospace Power， 2024， doi： 10.13224/j.cnki.jasp.20220421 （in Chinese）.
25	ZHOU T Y， HU L， JIN X X， et al. Measuring point planning and fitting optimization of the flange and spigot structures of aeroengine rotors［J］. Machines， 2023， 11（8）： 786.
26	ZHANG D Y， YANG C， HE T， et al. Modelling and stress analysis for double-row curvic couplings［J］. Proceedings of the Institution of Mechanical Engineers， Part C： Journal of Mechanical Engineering Science， 2021， 235（19）： 4231-4243.
27	QURESHI W， CURA F， MURA A. Prediction of fretting wear in aero-engine spline couplings made of 42CrMo₄ ［J］. Proceedings of the Institution of Mechanical Engineers， Part C： Journal of Mechanical Engineering Science， 2017， 231（24）： 4684-4692.
28	王中宇，孟浩，付继华. 表面综合形貌误差的灰色分离方法［J］. 仪器仪表学报， 2008， 29（9）： 1810-1815.
	WANG Z Y， MENG H， FU J H. Separation method for surface comprehensive topography based on grey theory［J］. Chinese Journal of Scientific Instrument， 2008， 29（9）： 1810-1815 （in Chinese）.
29	ZHANG H， LIU Q， CHEN X， et al. A digital twin-based approach for designing and multi-objective optimization of hollow glass production line［J］. IEEE Access， 2017， 5： 26901-26911.
30	庄存波，刘检华，熊辉，等. 产品数字孪生体的内涵、体系结构及其发展趋势［J］. 计算机集成制造系统， 2017， 23（4）： 753-768.
	ZHUANG C B， LIU J H， XIONG H， et al. Connotation， architecture and trends of product digital twin［J］. Computer Integrated Manufacturing Systems， 2017， 23（4）： 753-768 （in Chinese）.
31	GRIEVES M W. Product lifecycle management： The new paradigm for enterprises［J］. International Journal of Product Development， 2005， 2（1-2）： 71.
32	陶飞，刘蔚然，张萌，等. 数字孪生五维模型及十大领域应用［J］. 计算机集成制造系统， 2019， 25（1）： 1-18.
	TAO F， LIU W Y， R， ZHANG M， et al. Five-dimension digital twin model and its ten applications［J］. Computer Integrated Manufacturing Systems， 2019， 25（1）： 1-18 （in Chinese）.
33	SCHLEICH B， ANWER N， MATHIEU L， et al. Skin Model Shapes： A new paradigm shift for geometric variations modelling in mechanical engineering［J］. Computer-Aided Design， 2014， 50： 1-15.
34	刘婷. 基于肤面模型的装配误差分析方法研究［D］. 杭州：浙江大学， 2019： 131.
	LIU T. Study on the methods of assembly error analysis based on skin model［D］. Hangzhou： Zhejiang University， 2019： 131 （in Chinese）.
35	国家质量监督检验检疫总局，中国国家标准化管理委员会. 产品几何技术规范（GPS）光滑工件尺寸的检验：［S］. 北京：中国标准出版社， 2009.
	General Administration of Quality Supervision， Inspection and Quarantine of the People’s Republic of China， Standardization Administration of the People’s Republic of China. Geometrical Product Specifications （GPS）—Inspection of plain workpiece sizes：［S］. Beijing： Standards Press of China， 2009 （in Chinese）.
36	国家质量监督检验检疫总局，中国国家标准化管理委员会. 产品几何技术规范（GPS）表面结构轮廓法表面波纹度词汇：［S］. 北京：中国标准出版社， 2009.
	General Administration of Quality Supervision， Inspection and Quarantine of the People’s Republic of China， Standardization Administration of the People’s Republic of China. Geometrical product specification （GPS）—Surface texture： Profile method—Surface waviness terms：［S］. Beijing： Standards Press of China， 2009 （in Chinese）.
37	宋寿鹏，邵勇华，堵莹. 采样方法研究综述［J］. 数据采集与处理， 2016， 31（3）： 452-463.
	SONG S P， SHAO Y H， DU Y. Survey of sampling methods［J］. Journal of Data Acquisition and Processing， 2016， 31（3）： 452-463 （in Chinese）.
38	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.
39	MA S H， HU T L， XIONG Z Q. Precision assembly simulation of skin model shapes accounting for contact deformation and geometric deviations for statistical tolerance analysis method［J］. International Journal of Precision Engineering and Manufacturing， 2021， 22（6）： 975-989.
40	DESROCHERS A. A CAD/CAM representation model applied to tolerance transfer methods［J］. Journal of Mechanical Design， 2003， 125（1）： 14-22.
41	DESROCHERS A， RIVIÈRE A. A matrix approach to the representation of tolerance zones and clearances［J］. The International Journal of Advanced Manufacturing Technology， 1997， 13（9）： 630-636.
42	GAO J S， CHASE K W， MAGLEBY S P. Generalized 3-D tolerance analysis of mechanical assemblies with small kinematic adjustments［J］. IIE Transactions， 1998， 30（4）： 367-377.
43	DING S Y， JIN S， LI Z M， et al. Multistage rotational optimization using unified Jacobian-Torsor model in aero-engine assembly［J］. Proceedings of the Institution of Mechanical Engineers， Part B： Journal of Engineering Manufacture， 2019， 233（1）： 251-266.
44	黄智，李超，李凯，等. 航空叶片型面三坐标检测技术现状及发展趋势［J］. 航空制造技术， 2017， 21： 73-79.
	HUANG Z， LI C， LI K， et al. Status and prospect of detection technology of coordinate measuring machine for blade surface of aeroengine［J］. Aeronautical Manufacturing Technology， 2017， 21： 73-79 （in Chinese）.
45	孙贵青，吕玉红. 航空发动机先进装配工艺检测技术［C］∥2015年第二届中国航空科学技术大会. 北京：中国航空学会， 2015： 7.
	SUN G Q， LV Y H. The advanced detection methods of aero-engine assembly technology［C］∥The 2nd China Aeronautical Science and Technology Conference. Beijing： Chinese Society of Aeronautics and Astronautics， 2015： 7 （in Chinese）.
46	Model EAS 1000G Genspect system［EB/OL］. ［2024-01-31］. .
47	Aerospect SPS stack prediction ［EB/OL］. ［2024-01-31］..
48	Integrated turbine rotor measurement and assembly platforms［EB/OL］. ［2024-01-31］. .

项目	方法	零件1	零件2	零件3
安装相位角/（°）	现有设备预测	0	176	237
安装相位角/（°）	数字孪生方法预测	0	180	236
同心度/mm	实测数据	0.010 7	0.037 6	0.027 5
	现有设备预测	0.004 7	0.026 6	0.023 9
	数字孪生方法预测	0.004 8	0.026 4	0.023 7

[1]	Guanwei YAO, Gaowen LIU, Yan CHEN, Xiaozhi KONG, Aqiang LIN. Forward design of high-performance turbine low-radius pre-swirl system [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(7): 130832-130832.
[2]	Yaling HE, Tao JIANG, Shen DU, Guoqiang XU. Research progress on performance boundary of air heat exchanger within flight envelope [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(5): 531745-531745.
[3]	Xianzhao YANG, Gaowen LIU, Lingying GUO, Jiale MA, Aqiang LIN. Design of turbine high radius pre-swirl system with high temperature drop [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(2): 130672-130672.
[4]	Yiwei HUANG, Yibin GENG, Tianhe GAO, Xuanwei HU, Yuan WANG, Hongyan MA, Kuo TIAN. Digital twin driven high precision reconstruction method for full-field deformation of structure [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 530967-530967.
[5]	Dingqiang DAI, Xuan ZHOU, Leiting DONG, Xiasheng SUN. Research progress and prospects of digital engineering and digital twin in field of aeronautical fatigue and structural integrity [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 531022-531022.
[6]	Shangyu LI, Hang FENG, Junquan CHEN, Bin CHEN, Dan MEI. A design architecture and conceptual modeling approach for digital twins [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 531118-531118.
[7]	Junqi LEI, Yuehua CHENG, Bin JIANG, Cheng XU, Guili XU, Tianyu SUN. Digital-twin’s modelling and dynamic adjustment mechanism of rudder-loop-system under fault conditions [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 531273-531273.
[8]	Liang CHEN, Lei HUANG, Yuxuan GU, Cong GUO, Kexin LIN, Yu GUAN, Jian SONG. Twinning technology of key part load based on flight parameters [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 531292-531292.
[9]	Yuxuan GU, Cong GUO, Lei HUANG, Yifei DONG, Hongda DONG, Zhilun DENG. Refined management of fleet life driven by digital twins [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 531290-531290.
[10]	Yinxuan ZHANG, Qi ZHANG, Zhenyong XU, Linshu MENG. Predicting method of aircraft mechanical response based on residual neural networks [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 531295-531295.
[11]	Ruoyao XIAO, Lianyu ZHENG, Jian ZHOU, Siru ZHAO, Jieru ZHANG, Yuwu CHEN. Online optimization method for positioning accuracy in cylindrical components aligning based on digital twins [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 531978-531978.
[12]	Jialiang HU, Jiangpeng WU, Sixu HUO, Yidi GAO, Hua ZHENG. Modal parameter estimation based on reconstruction of digital twin sweep data in flutter flight test [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 531602-531602.
[13]	Pengfei WANG, Lifang ZENG, Xueming SHAO, Jun LI. Multi-source data fusion modeling method for aerodynamic load of aircraft wing based on pre-training and fine-tuning [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 532297-532297.
[14]	Yifei WANG, Geyong CAO, Yang CAO, Xiaojun WANG. Uncertainty technologies in aircraft digital strength twins [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 532408-532408.
[15]	Liang CHEN, Fanxing MENG, Chengbo WANG, Yinxuan ZHANG, Linshu MENG. Development and application of digital twins technology in aircraft strength design [J]. Acta Aeronautica et Astronautica Sinica, 2025, 46(19): 532252-532252.

Assembly analysis of aero-engine mating interface based on digital twin

RichHTML

PDF (PC)

Knowledge

Abstract

Cite this article

share this article

Figures/Tables 19

References 48

Related Articles 15

Recommended Articles

Metrics

Comments