Abstract
As a critical component of reusable rocket engines (RRE), the cyclic life of the turbine rotor blisk often varies due to uncertainties such as machining errors and other factors. However, considering the difficulty of structural reconstruction and the large number of parameters related to the blade configuration, few studies have considered the blade configuration variation due to machining errors in the reliability analysis process. To investigate the influence of factors in reliability analysis, a reliability analysis framework is established by combining parametric modelling methods with finite element analysis methods under fluid-thermal-solid sequential coupling. The influence of blade lattice changes due to machining errors on the reliability of turbine rotor blisks in reusable rocket engines (RRE) is investigated. The effects of machining errors, material, and load variability on the cyclic life reliability of rotor blisks are effectively quantified. With the suggested method, a reliability analysis is conducted for an RRE turbine rotor blisk, and the effect of the machining error range on the analysis results is investigated. It is found that the tolerance level to meet the high reliability requirements is at least medium for the basic cyclic life requirements of the model. In terms of cyclic life reliability, the more influential random factors are blade axial chord, low-cycle fatigue plasticity coefficient, and low-cycle fatigue ductility coefficient, with sensitivity factors of 29.09%, 24.4% and 22.13%, respectively. This study provides an efficient and reliable modelling method for the reliability analysis of reusable turbine rotor blisks based on machining errors, investigates the influence of the range of machining errors, quantifies the ability of the random factors to influence, and provides valuable insights and recommendations for the reliability design and optimization of reusable turbine blisks.
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