Design method of simulation rotor with curvic couplings-rod based on similarity of pretension state and dynamic characteristics
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摘要:
针对圆弧端齿-拉杆转子系统相似设计问题，从转子支承约束、几何构形、质量分布、圆弧端齿结构、装配预紧特性等方面，提出了结构力学特性相似设计原则及相应设计参数，着重考虑了转子压紧状态相似性，并形成了相似设计流程。基于实际燃气发生器转子进行了相似设计，通过仿真分析与动力特性试验，验证了模拟转子与燃气发生器转子结构力学特性的相似性。结果表明：模拟转子各结构特征相对设计参数与实际转子误差在5%以内，最大转速下拉杆预紧力变化百分比与实际转子一致，临界转速分布误差在5%以内，模拟转子试验与仿真得到的临界转速误差小于5%，模拟转子与实际转子有较好的相似性，验证了所提方法的有效性。
Abstract:In view of the similarity design problem of curvic couplings-rod rotor system, the structural mechanics’ characteristic similarity design principles and corresponding design parameters were proposed from the aspects of support constraint, rotor geometry configuration, curvic couplings, mass distribution, and assembly pre-tightening, etc. The similarity of rotor pretension states was emphasized, and a design process was formed. A design case was studied based on the actual gas generator rotor, and the similarity of the mechanical characteristics between the simulation rotor and the gas generator rotor structure was verified through simulation analysis and dynamic characteristic experiment. The results showed that the relative design parameters of various structural features of the simulation rotor had an error of less than 5% compared with the actual rotor. The percentage change in the pretension force of the rod at the maximum speed was consistent with the actual rotor, and the critical speed distribution error was within 5%. The critical speed error obtained from experiments and simulations was less than 5%. The simulation rotor had a good similarity with the actual rotor, which verified the effectiveness of this method.
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图 1 典型燃气发生器转子及圆弧端齿结构特征
Figure 1. Structural feature of typical gas generator rotor and curvic couplings
图 2 圆弧端齿-拉杆模拟转子系统相似设计流程
Figure 2. Similarity design process for curvic couplings-rod simulation rotor system
图 3 模拟转子支承约束相似设计示意图
Figure 3. Schematic diagram of support similarity design for simulation rotor
图 4 模拟转子几何构形相似设计示意图
Figure 4. Schematic diagram of geometrical configuration similarity design for simulation rotor
图 5 模拟转子与燃发转子几何构形相对参数对比
Figure 5. Comparison of geometrical relative parameters between simulation rotor and gas generator rotor
图 7 模拟转子与燃发转子质量相对参数对比
Figure 7. Comparison of mass relative parameters between simulation rotor and gas generator rotor
图 9 模拟转子第3级圆弧端齿结构（凸齿）
Figure 9. Third stage curvic coupling of simulation rotor （convex teeth）
图 10 转子中心拉杆预紧力传递路线
Figure 10. Transmission route of pretension force of rotor center pull rod
图 11 拉杆-转子结构轴向刚度仿真分析模型
Figure 11. Simulation analysis model for axial stiffness of rod-rotor structure
图 13 拉杆预紧力变化仿真分析模型
Figure 13. Simulation analysis model for changes in pretension force of rod
图 14 模拟转子最大转速下拉杆预紧力松弛因子
Figure 14. Pretension force relaxation factor of rod at maximum speed of simulation rotor
图 15 模拟转子动力特性仿真分析模型
Figure 15. Dynamic characteristic simulation analysis model of simulation rotor
图 18 转子系统临界转速应变能分布因子
Figure 18. Strain energy distribution factor at critical speed of rotor system
图 19 模拟转子结构及动力特性试验系统
Figure 19. Simulation rotor structure and dynamic characteristics experiment system
图 20 模拟转子动力特性试验幅频曲线
Figure 20. Amplitude-frequency curves of simulation rotor dynamic characteristic test
图 21 燃发转子动力特性仿真幅频曲线
Figure 21. Amplitude-frequency curves of gas generator rotor dynamic characteristic simulation
表 1 燃发转子质量相对参数
Table 1. Mass relative parameters of gas generator rotor
部件名称 相对质量Mri 转动惯量比Jri 第1级压气机 0.07 1.77 第2级压气机 0.05 1.68 第3级压气机 0.05 1.67 离心压气机 0.25 1.74 第1级涡轮 0.26 1.61 第2级涡轮 0.21 1.83 
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表 2 模拟转子与燃发转子圆弧端齿相对位置参数对比
Table 2. Comparison of curvic couplings relative location parameters between simulation rotor and gas generator rotor
端齿名称 轴向相对位置$ {L}_{\text{rcc}i} $ 径向相对
尺寸$ {R}_{\text{rcc}i} $燃发转子-第1级 0.17 1.15 燃发转子-第2级 0.46 1.62 燃发转子-第3级 0.67 1.00 模拟转子-第1级 0.17 1.12 模拟转子-第2级 0.46 1.45 模拟转子-第3级 0.63 1.00
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表 3 模拟转子与燃发转子圆弧端齿相对模数对比
Table 3. Comparison of curvic couplings relative modulus between simulation rotor and gas generator rotor
端齿名称 实际模数 相对模数 燃发转子-第1级 0.89 燃发转子-第2级 1.00 燃发转子-第3级 0.95 模拟转子-第1级 2.67 0.89 模拟转子-第2级 3.00 1.00 模拟转子-第3级 2.75 0.92
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表 4 转子临界转速分布系数
Table 4. Distribution factor of rotor critical speeds
临界转速
阶次燃发转子临界
转速分布因子模拟转子临界
转速分布因子相对
误差/%第1阶 0.31 0.31 0 第2阶 0.63 0.65 3.1 第3阶 1.78 1.79 0.6
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表 5 模拟转子临界转速结果对比
Table 5. Results comparison of simulation rotor critical speeds
临界转速 阶次 第1阶 第2阶 仿真结果/（r/min） 3072 6557 试验结果/（r/min） 3029 6747 相对误差/% 1.4 −2.8
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