A finite element (FE) model of the rotor tester of an aero-engine, having a thin-walled casing structure, mounted with the way of an actual engine, is developed to simulate the intrinsic vibration characteristics under actual engine-mounting condition. First, a modal experiment of the rotor tester for the whole aero-engine is conducted, and the FE model is modified and validated based on the modal experimental results. Second, the first three orders of natural frequencies and the modal shapes are evaluated using the modified FE model under three different types of mounting stiffness, namely, a fixed mounting boundary, a free mounting boundary, and a flexible mounting boundary. Subsequently, the influences of the mounting stiffness on the coupling vibration of the rotor and stator are studied via a new rotor–stator coupling factor, which is proposed in this study. The results show that the higher the rotor–stator coupling degree of the modal shape, the greater the influence of the mounting condition on the modal shape. Moreover, the influence of the mounting stiffness on the rotor–stator coupling degree is nonlinear. The coupling phenomena of the rotor and stator exist in many modal shapes of actual large turbofan engines, and the effect of mounting stiffness on the rotor–stator coupling cannot be ignored. Hence, the mounting stiffness needs to be considered carefully while modeling the whole aero-engine and simulating the dynamic characteristics of the whole aero-engine.
This paper investigates the whole aero-engine coupling vibration, as a rotor tester to be the research object. The rotor tester system is composed of two mountings, stator system, support structures and the rotor system. The modal experiment of the whole tester under the condition of mounting in the test room is carried out. The finite element (FE) model of the rotor tester is built, and the model was modified and validated according to the modal test results. A rotor-stator coupling factor and a section rotor-stator rubbing risk coefficient are proposed, the influence of the support stiffness values on the engine vibration characteristics, such as natural frequencies, modal shapes, rotor-stator coupling degree, and stator-rotor rubbing risk degree at compressor and turbine section is quantitative studied. Results show that the support stiffness contributes to the rigid body modal shapes greatly and to the rotor bending ones slightly. The factor and coefficient defined in this study are both reasonable, and they can reflect the corresponding characteristics exactly. Moreover, the effect of the supports stiffness values on the rotor-stator coupling degree and the rotor-stator rubbing risk degree is nonlinear. The rotor-stator coupling factor and the section stator-rotor rubbing risk coefficient proposed in this study provide a new way to quantitatively research the whole engine coupling vibration.
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