Novel Optimization Technique for Variation Propagation Control in An Aero-Engine Assembly

Abstract

This paper presents a novel optimization technique in straight-build assembly to control variation propagation. The optimization technique is developed by minimizing the eccentricity stage by stage in the assembly. The straight-build assembly model is derived from connective assembly models, easily expressing the part-to-part relationships. Any measurement error or process error in the assembly can be easily incorporated in the model. This approach can be also used to predict the final assembly quality while the design is still at the conceptual stage. The straight-build assembly is validated by using statistical analysis through two case studies: a simple identical cylindrical-component assembly and a practical non-identical cylindrical-component assembly. The variation propagation can be reduced significantly for the straight-build assembly, compared to the direct-build assembly without optimization. The results show how the variation propagation control is related to process noise and measurement accuracy. The simulation results also show that minimal variation can be achieved at reduced cost by properly selecting the accuracy of measurement, according to process procedures. The information obtained provides a practical and useful approach for design engineers. The potential applications of the straight-build assembly are also illustrated.

Virtual Robustness Evaluation of Turbine Structure Assemblies Using 3D Scanner Data

“…Robust design practices have been applied to FEM [17] and CFD [18] , as well as for variation propagation control in aero-engine assembly [19]. In this paper, the connection between these fields of science is investigated in one coupled, multidisciplinary problem.…”

Assembly research of aero-engine casing involving bolted connection based on rigid-compliant coupling assembly deviation modeling

“…Liu et al 17 proposed a method to analyze the eccentricity of the aircraft engine rotors assembly, and obtained the optimal assembly angle. Yang et al 18 presented a method to minimize the assembly deviation of the aero-engine and analyzed assembly deviation with different measurement accuracies. The result showed a good suitability with the manufacturing process.…”

“…However, the relevant tolerance investigations about aero-engine mainly focus on the rotor of the aero-engine, 17,18,22 and considered assembly quality without any compliant deformation. The existing researches involved in the aircraft engine casing were almost about the vibrational and mechanical behaviors.…”

Location optimization of interchangeable parts in sheet metal assembly

“…Yang presented an optimization technique in straight-build assembly to control variation propagation in an aero-engine assembly. 18 Liao proposed an algorithm of clamp shimming optimization for minimizing sheet metal assembly deformation. 19 This article is running on this line for dealing with reducing the assembly variation of stiffener panel, which is widely used in aviation manufacturing.…”