| Citation: | WANG Tong, WANG Yankai, WANG Yangang, et al. Internal friction dynamic characteristics of aero-engine spline coupling[J]. Journal of Aerospace Power, 2026, 41（4）：20250112 doi: 10.13224/j.cnki.jasp.20250112
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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.
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