航空发动机套齿结构内摩擦动力学特征研究

王彤; 王俨剀; 王掩刚; 王得龙

doi:10.13224/j.cnki.jasp.20250112

航空发动机套齿结构内摩擦动力学特征研究

doi: 10.13224/j.cnki.jasp.20250112

王彤^1,,
王俨剀^{2, 3,*, ,},
王掩刚^{1, 2, 3},
王得龙²

1.
西北工业大学无人系统技术研究院，西安 710129
2.
西北工业大学动力与能源学院，西安 710129
3.
中国航发四川燃气涡轮研究院高空模拟技术重点实验室，四川绵阳 621000

基金项目: 国家自然科学基金（52372432）

详细信息

作者简介:
王彤（1996-），男，博士生，主要从事转子系统非线性动力学研究。E-mail：wang_tong@mail.nwpu.edu.cn

通讯作者:
王俨剀（1978-），男，副教授，博士，主要从事航空发动机健康管理技术研究。E-mail：ykwang@nwpu.edu.cn

中图分类号: V231.9
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- 被引次数: 0
出版历程
- 收稿日期: 2025-03-07
- 网络出版日期: 2025-09-10

Internal friction dynamic characteristics of aero-engine spline coupling

WANG Tong^1
,,
WANG Yankai^{2, 3,*
, ,},
WANG Yangang^{1, 2, 3},
WANG Delong²

1.
Unmanned Systems Technology Institute，Northwestern Polytechnical University，Xi’an 710129，China
2.
School of Power and Energy，Northwestern Polytechnical University，Xi’an 710129，China
3.
Science and Technology on Altitude Simulation Laboratory，Sichuan Gas Turbine Establishment，Aero Engine Corporation of China，Mianyang Sichuan 621000，China

摘要

摘要:
套齿结构因具有高可靠性和扭矩传递补偿能力，广泛应用于航空发动机传动系统，但其内摩擦失稳问题易引发转子振动突增，威胁飞行安全。针对某型直升机涡轴发动机套齿结构内摩擦故障，通过理论建模、数值仿真与试验研究相结合的方法，系统揭示了内摩擦失稳的动力学特征与稳定边界。基于运动分析建立了带套齿转子的非线性动力学模型，推导了跳跃门槛与失稳门槛的解析表达式，理论揭示了失稳振动幅值突降/突增及次谐波成分的产生机理。采用有限元仿真分析了跳跃特征与失稳特征的幅频响应规律，发现表面粗糙度增大可提高跳跃门槛转速，而定位面间隙增大会显著降低失稳门槛转速。设计并搭建了套齿内摩擦失稳故障模拟试验器，通过更换不同参数的内花键试验件，验证了理论模型与仿真结果。试验表明：失稳发生时，时域振动幅值呈现“突降-突增”的跳跃现象，频域伴随1阶临界转速的次谐波成分；定位面间隙对跳跃门槛转速无影响，但增大会使失稳门槛转速降低5%～8%；表面粗糙度从0.8 μm增至3.2 μm，跳跃门槛转速提升2.4%，失稳门槛转速降低10%。研究结果为航空发动机套齿结构的设计优化与失稳故障预防提供了理论依据，建议采用过盈配合定位面以抑制内摩擦故障。
- 内摩擦故障 /
- 非线性动力学 /
- 失稳门槛 /
- 失稳特征 /
- 跳跃特征
Abstract:
Spline coupling structures are widely used in aero-engine transmission systems due to their high reliability and torque transmission compensation capability. However, internal friction instability can easily trigger sudden rotor vibration increase, posing a threat to flight safety. The internal friction instability in a turboshaft engine spline coupling structure of a helicopter was investigated, and the dynamic characteristics and stability boundaries were systematically revealed through theoretical modeling, numerical simulation, and experimental research. A nonlinear dynamic model of a rotor with spline coupling was established based on kinematic analysis. Analytical expressions for the instability transition threshold and instability threshold were derived, theoretically explaining the mechanisms behind the sudden amplitude drop/rise and the generation of subharmonic components during instability. Finite element simulations were conducted to analyze the amplitude-frequency response patterns of jump and instability characteristics. Results indicated that increased surface roughness elevated the jump threshold speed, while larger positioning surface gaps significantly reduced the instability threshold speed. A dedicated test rig was designed and constructed to simulate the spline internal friction instability. By testing spline components with varying parameters, the theoretical and simulation results were validated. Experimental findings demonstrated that during instability, the vibration amplitude in the time domain exhibited a “sudden drop-sudden rise” jump phenomenon, accompanied by subharmonic components at the first critical speed in the frequency domain. While the positioning surface gap had no impact on the jump threshold speed, its increase reduced the instability threshold speed by 5%—8%. Increasing surface roughness from 0.8 μm to 3.2 μm raised the jump threshold speed by 2.4% and lowered the instability threshold speed by 10%. These results could provide theoretical guidance for optimizing spline coupling design and preventing instability in aero-engines. Interference-fit positioning surfaces were suggested to suppress the internal friction faults. Notably, this novel work experimentally reproduced the instability transition state, bridging the gap between theoretical predictions and engineering validation.
- internal friction fault /
- nonlinear dynamic /
- instability threshold /
- instability characteristics /
- jump characteristics.

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图 1 涡轴发动机传动轴系结构示意图

Figure 1. Schematic diagram of the turboshaft engine transmission shaft system

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图 2 带套齿转子内摩擦模型

Figure 2. Internal friction model of a spline-coupled rotor

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图 3 带套齿转子有限元模型

Figure 3. Finite element model of a spline-coupled rotor

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图 4 试验器转子Campbell图

Figure 4. Test rotor Campbell diagram

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图 5 跳跃特征仿真

Figure 5. Jump characteristic simulation

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图 6 失稳特征仿真

Figure 6. Simulation of instability characteristics

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图 7 门槛转速仿真

Figure 7. Threshold speed simulation

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图 8 试验器总体结构图

Figure 8. Structure of the tester

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图 9 套齿连接结构示意图

Figure 9. Schematic diagram of spline-coupling

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图 10 外花键转子

Figure 10. External spline rotor

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图 11 内花键转子

Figure 11. Internal spline rotor

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图 12 测试方案

Figure 12. Test plan

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图 13 增速过程响应曲线

Figure 13. Response curve of acceleration process

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图 14 失稳时域特征图

Figure 14. Time domain characteristics of instability

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图 15 失稳色谱图

Figure 15. Instability chromatogram

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图 16 失稳频谱图

Figure 16. Instability spectrum diagram

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图 17 基频及次谐波幅值随转速变化图

Figure 17. Variation of fundamental frequency and sub-harmonic amplitude with rotational speed

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图 18 表面粗糙度对门槛转速的影响

Figure 18. Influence of surface roughness on threshold speed

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图 19 定位面间隙对门槛转速的影响

Figure 19. Influence of positioning surface gap on threshold speed

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表 2 套齿参数

Table 2. Spline parameters

套齿段节点编号	外轴外径/mm	外轴内径/mm	内轴外径/mm
8～9	37	32	26

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表 1 刚性盘参数

Table 1. Rigid disk parameters

参数	数值
盘节点编号	1
质量/kg	45
极转动惯量/（kg·m²）	0.97
径转动惯量/（kg·m²）	0.5

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表 3 支承参数

Table 3. Bearing parameters

支承节点编号	支承编号	刚度/10⁶ （N/m）	阻尼/（N·s²/m）
6	1	3.3	100
10	2	1000	100
36	3	3.01	100

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表 4 套齿连接结构尺寸参数

Table 4. Dimensional parameters of spline-coupling

序号	参数	数值
1	齿数	15
2	模数/mm	1.5
3	压力角/（°）	30
4	大径/mm	24.75±0.2
5	小径/mm	21.23±0.2
6	齿宽/mm	30 mm
7	定位面1直径/mm	16±0.4
8	定位面2直径/mm	25±0.4
9	定位间距/mm	95
10	定位面1宽度/mm	6
11	定位面2宽度/mm	7
12	外径/mm	50

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表 5 内花键影响参数水平

Table 5. Influence parameters level of internal spline

组号	定位面间隙/mm	表面粗糙度/μm	序号
基准	−0.01（过盈配合）	0.8	0
第1组	0.01（间隙配合）	0.8	1
		1.6	2
		3.2	3
第2组	0.02（间隙配合）	0.8	4
		1.6	5
		3.2	6
第3组	0.03（间隙配合）	0.8	7
		1.6	8
		3.2	9

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表 6 测点参数

Table 6. Measurement point parameters

序号	位置	信号类型	量程	分辨率
1	模拟盘竖直	位移	500 μm	0.1 μm
2	模拟盘水平	位移	500 μm	0.1 μm
3	模拟轴	光电脉冲	6 V	0.01 V

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表 7 门槛转速仿真与试验结果对比

Table 7. Comparison of threshold speed simulation and experimental results

门槛类型	转速/（r/min）		误差/%
门槛类型	仿真	试验	误差/%
跳跃门槛	4278	4134	3.53
失稳门槛	4911	4952	0.83

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表 8 表面粗糙度对门槛转速的影响（定位面间隙为0.01 mm）

Table 8. Influence of surface roughness on threshold speed （positioning surface gap of 0.01 mm）

序号	表面粗糙度/μm	跳跃门槛转速/（r/min）	变化率/%
1	0.8	4179	0
2	1.6	4229	1.2
3	3.2	4331	2.4

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表 9 定位面间隙对门槛转速的影响（表面粗糙度为1.6 μm）

Table 9. Influence of positioning surface gap on threshold speed （surface roughness of 1.6 μm）

序号	定位面间隙/mm	跳跃门槛转速/（r/min）	变化率/%
1	0.01	4229	0
2	0.02	4227	−0.8
3	0.03	4232	0.7

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