Optimizing circumferential assembly angle of rotor parts connected by curvic couplings based on acquired tooth surface error data

Abstract

Due to the excellent self-centering and load-carrying capability, curvic couplings have been widely used in advanced aero-engine rotors. However, curvic tooth surface errors lead to poor assembly precision. Traditional physical-master-gauge-based indirect tooth surface error measurement and circumferential assembly angle optimization methods have the disadvantages of high cost and weak generality. The unknown tooth surface fitting mechanism is a big barrier to assembly precision prediction and improvement. Therefore, this work puts forward a data-driven assembly simulation and optimization approach for aero-engine rotors connected by curvic couplings. The origin of curvic tooth surface error is deeply investigated. Using 5-axis sweep scan method, a large amount of high-precision curvic tooth surface data are acquired efficiently. Based on geometric models of parts, the fitting mechanism of curvic couplings is uncovered for assembly precision simulation and prediction. A circumferential assembly angle optimization model is developed to decrease axial and radial assembly runouts. Experimental results show that the assembly precision can be predicted accurately and improved dramatically. By uncovering the essential principle of the assembly precision formation and proposing circumferential assembly angle optimization model, this work is meaningful for assembly quality, efficiency and economy improvement of multistage aero-engine rotors connected by curvic couplings.