Precision Regulation in Multistage Aero-Engine Rotors With Curvic Couplings Using Line-Structured Light Array Scanning and Virtual Assembly

As the “heart” of the aviation industry, high-performance aero-engines have always been a stumbling block restricting rapid development. Curvic couplings are widely used in the assembly of multistage aero-engine rotors. The coaxiality of the assembly significantly influences the performance and life of the aero-engine, so it is necessary to predict and optimize the assembly coaxiality. Aiming at three key problems, we propose an assembly coaxiality optimization and prediction approach. In this approach, we measure 3-D point clouds by a line-structured light array scanning measurement system and come up with a weighted iterative closest point (ICP) algorithm to perform a virtual assembly of the point cloud model to regulate the assembly precision. Ultimately, rotors with curvic couplings are used to experimentally validate the coaxiality prediction and optimization approach. According to the experimental findings, the two-/ three-stage rotors assemblies’ maximum coaxiality prediction errors under eight distinct assembly phases are 4.8 and
$7.7~\mu $
m, respectively. The two-/three-stage rotors optimization assemblies’ coaxiality errors are decreased by 11.9 and
$31.8~\mu $
m, respectively, compared with the direct assembly without optimization. The three-stage rotors’ assembly accuracy is improved by 12.09%. The results show the effectiveness of the proposed method.