Application of Small Sample Analysis in Life Estimation of Aeroengine Components

The samples of fatigue life tests for aeroengine components are usually less than 5,so the evaluation of these samples belongs to small sample analysis. The Weibull distribution is known to describe the life data accurately,and the Weibayes method （developed from Bayesian method） expands on the experiential data in the small sample analysis of fatigue life in aeroengine. Based on the Weibull analysis,a program was developed to improve the efficiency of the reliability analysis for aeroengine compgnents. This program has complete functions and offers highly accurate results. A particular turbine disk＇s low cycle fatigue life was evaluated by this program. From the results,the following conclusions were drawn：（a） that this program could be used for the engineering applications,and （b） while a lack of former test data lowered the validity of evaluation results,the Weibayes method ensured the results of small sample analysis did not deviate from the truth.

Prediction Approach to Life on Wing for Civil Aeroengine

To reduce engine maintenance cost and support safe operation, a prediction method of engine life on wing was proposed. This method is a kind of regression model which is a function of the condition monitoring and failure data. Key causes of engine removals were analyzed, and the life limit due to performance deterioration was predicted by proportional hazards model. Then the scheduled removal causes were considered as constraints of engine life to predicte the finai life on wing. Application of the proposed prediction method to the case of CF6-80C2A5 engine fleet in an airline proved its effectiveness.

Aeroengine Nonlinear Sliding Mode Control Based on Artificial Bee Colony Algorithm

For a class of aeroengine nonlinear systems,a novel nonlinear sliding mode controller(SMC)design method based on artificial bee colony(ABC)algorithm is proposed.In view of the strong nonlinearity and uncertainty of aeroengines,sliding mode control strategy is adopted to design controller for the aeroengine.On basis of exact linearization approach,the nonlinear sliding mode controller is obtained conveniently.By using ABC algorithm,the parameters in the designed controller can be tuned to achieve optimal performance,resulting in a closedloop system with satisfactory dynamic performance and high steady accuracy.Simulation on an aeroengine verifies the effectiveness of the presented method.

Fault diagnosis method for an Aeroengine Based on Independent Component Analysis and the Discrete Hidden Markov Model

The vibration signals of an aeroengine are a very important information source for fault diagnosis and condition monitoring. Considering the nonstationarity and low repeatability of the vibration signals, it is necessary to find a corresponding method for feature extraction and fault recognition. In this paper, based on Independent Component Analysis （ICA） and the Discrete Hidden Markov Model （DHMM）, a new fault diagnosis approach named ICA-DHMM is proposed. In this method, ICA separates the source signals from the mixed vibration signals and then extracts features from them, DHMM works as a classifier to recognize the conditions of the aeroengine. Compared with the DHMM, which use the amplitude spectrum of mixed signals as feature parameters, experimental results show this method has higher diagnosis accuracy.

Application study on plasma ignition in aeroengine strut–cavity–injector integrated afterburner

To increase the thrust-weight ratio in next-generation military aeroengines,a new integrated afterburner was designed in this study.The integrated structure of a combined strut–cavity–injector was applied to the afterburner.To improve ignition characteristics in the afterburner,a new method using a plasma jet igniter was developed and optimized for application in the integrated afterburner.The effects of traditional spark igniters and plasma jet igniters on ignition processes and ignition characteristics of afterburners were studied and compared with the proposed design.The experimental results show that the strut–cavity–injector combination can achieve stable combustion,and plasma ignition can improve ignition characteristics.Compared with conventional spark ignition,plasma ignition reduced the ignition delay time by 67 ms.Additionally,the ignition delay time was reduced by increasing the inlet velocity and reducing the excess air coefficient.This investigation provides an effective and feasible method to apply plasma ignition in aeroengine afterburners and has potential engineering applications.

Extrapolation for Aeroengine Gas Path Faults with SVM Bases on Genetic Algorithm

Mining aeroengine operational data and developing fault diagnosis models for aeroengines are to avoid running aeroengines under undesired conditions.Because of the complexity of working environment and faults of aeroengines,it is unavoidable that the monitored parameters vary widely and possess larger noise levels.This paper reports the extrapolation of a diagnosis model for 20 gas path faults of a double-spool turbofan civil aeroengine.By applying support vector machine(SVM)algorithm together with genetic algorithm(GA),the fault diagnosis model is obtained from the training set that was based on the deviations of the monitored parameters superimposed with the noise level of 10%.The SVM model(C=24.7034;γ=179.835)was extrapolated for the samples whose noise levels were larger than 10%.The accuracies of extrapolation for samples with the noise levels of 20%and 30%are 97%and 94%,respectively.Compared with the models reported on the same faults,the extrapolation results of the GASVM model are accurate.

Application of Interval Multi-attribute Decision-Making Method to Aeroengine Performance Ranking

In view of the uncertainty of the monitored performance parameters of aeroengines, the fluctuating scope of the monitored infurmation during a period is taken as interval numbers, and the interval multi-attribute decision-making method is employed to predict the performance of aeroengine, The synthetic weights of interval numbers are obtained by calculating deviation degree and possibility degree. As an example of application, 5 performance parameters monitored on 10 CF6 aeroengines of China Eastern Airlines Co., Ltd are adopted as decision attributes to verify the algorithm. The obtained synthetic ranking result shows the effectiveness and rationality of the proposed method in reflecting the performance stares of aeroengins.

Research on Time-Synchronization-Based Test and Control System of Aeroengine

This paper presents a method of NTP-based time synchronization and a strategy of master-slave server structured time synchronization to ensure the test and control system of aeroengine to be time-synchronized. Based on time synchronization, the hierarchy and the integration of the measurement and control system of aeroengine are investigated. In result, our method is successfully applied for multiple front-end tests in a simulative altitude test facility of aeroengine.

Knowledge and data jointly driven aeroengine gas path performance assessment method

Aeroengines,as the sole power source for aircraft,play a vital role in ensuring flight safety.The gas path,which represents the fundamental pathway for airflow within an aeroengine,directly impacts the aeroengine's performance,fuel efficiency,and safety.Therefore,timely and accurate evaluation of gas path performance is of paramount importance.This paper proposes a knowledge and data jointly driven aeroengine gas path performance assessment method,combining Fingerprint and gas path parameter deviation values.Firstly,Fingerprint is used to correct gas path parameter deviation values,eliminating parameter shifts caused by non-component performance degradation.Secondly,coarse errors are removed using the Romanovsky criterion for short-term data divided by an equal-length overlapping sliding window.Thirdly,an Ensemble Empirical Mode Decomposition and Non-Local Means(EEMD-NLM)filtering method is designed to“clean”data noise,completing the preprocessing for gas path parameter deviation values.Afterward,based on the characteristics of gas path parameter deviation values,a Dynamic Temporary Blended Network(DTBN)model is built to extract its temporal features,cascaded with Multi-Layer Perceptron(MLP),and combined with Fingerprint to construct a Dynamic Temporary Blended AutoEncoder(DTB-AutoEncoder).Eventually,by training this improved autoencoder,the aeroengine gas path multi-component performance assessment model is formed,which can sufficiently decouple the nonlinear mapping relationship between aeroengine gas path multi-component performance degradation and gas path parameter deviation values,thereby achieving the performance assessment of engine gas path components.Through practical application cases,the effectiveness of this model in assessing the aeroengine gas path multi-component performance is verified.

Pneumatic pressure control based on improved NMPC and its application to aeroengine surge simulation

In the semi-physical simulation of aeroengines,using the pneumatic pressure servo control technology to provide realistic pneumatic excitation to the sensors and electronic controller can improve the confidence of the simulation and reduce the test cost and risk.However,the existing methods could not satisfy the precise simulation of large-amplitude and high-frequency pulsating pressure during aeroengine surge.In this paper,a pneumatic pressure control system with asymmetric groups of the High-Speed on–off Valve(HSV)is designed,and an Improved Nonlinear Model Predictive Control(INMPC)method is proposed.First,the volumetric flow characteristics of HSV are tested and analyzed with Pulse Width Modulation(PWM)signal input.Then,a simplified HSV model with the volume flow characteristic correction is developed.Based on these,an integrated model for the whole system is further established and used as the prediction model in INMPC.To improve the computational speed of the rolling optimization process,the mapping scheme from control signal to PWM duty cycle of HSVs and the objective function with exterior penalty function are designed.Finally,the random step,sinusoidal and real engine surge data are set as the reference pressure in multiple comparative experiments to verify the effectiveness of the pressure tracking system.

A 5-DOF Model for Aeroengine Spindle Dual-rotor System Analysis

This paper develops a five degrees of freedom（5-DOF） model for aeroengine spindle dual-rotor system dynamic analysis.In this system,the dual rotors are supported on two angular contact ball bearings and two deep groove ball bearings,one of the latter-mentioned bearings works as the inter-shaft bearing.Driven by respective motors,the dual rotors have different co-rotating speeds.The proposed model mathematically formulates the nonlinear displacements,elastic deflections and contact forces of bearings with consideration of 5-DOF and coupling of dual rotors.The nonlinear equations of motions of dual rotors with 5-DOF are solved using Runge-Kutta-Fehlberg algorithm.In order to investigate the effect of the introduced 5-DOF and nonlinear dy-namic bearing model,we compare the proposed model with two models：the 3-DOF model of this system only considering three translational degrees of freedom（Gupta,1993,rotational freedom is neglected）;the 5-DOF model where the deep groove ball bearings are simplified as linear elastic spring（Guskov,2007）.The simulation results verify Gupta＇s prediction（1993） and show that the rotational freedom of rotors and nonlinear dynamic model of bearings have great effect on the system dynamic simula-tion.The quantitative results are given as well.

An extrapolation approach for aeroengine's transient control law design

Transient control law ensures that the aeroengine transits to the command operating state rapidly and reliably. Most of the existing approaches for transient control law design have complicated principle and arithmetic. As a result, those approaches are not convenient for application. This paper proposes an extrapolation approach based on the set-point parameters to construct the transient control law, which has a good practicability. In this approach, the transient main fuel control law for acceleration and deceleration process is designed based on the main fuel flow on steady operating state. In order to analyze the designing feature of the extrapolation approach, the simulation results of several different transient control laws designed by the same approach are compared together. The analysis indicates that the aeroengine has a good performance in the transient process and the designing feature of the extrapolation approach conforms to the elements of the turbofan aeroengine.

Dynamic parametric modeling-based model updating strategy of aeroengine casings

For accurate Finite Element(FE)modeling for the structural dynamics of aeroengine casings,Parametric Modeling-based Model Updating Strategy(PM-MUS)is proposed based on efficient FE parametric modeling and model updating techniques regarding uncorrelated/correlated mode shapes.Casings structure is parametrically modeled by simplifying initial structural FE model and equivalently simulating mechanical characteristics.Uncorrelated modes between FE model and experiment are reasonably handled by adopting an objective function to recognize correct correlated modes pairs.The parametrized FE model is updated to effectively describe structural dynamic characteristics in respect of testing data.The model updating technology is firstly validated by the detailed FE model updating of one fixed–fixed beam structure in light of correlated/uncorrelated mode shapes and measured mode data.The PM-MUS is applied to the FE parametrized model updating of an aeroengine stator system(casings)which is constructed by the proposed parametric modeling approach.As revealed in this study,(A)the updated models by the proposed updating strategy and dynamic test data is accurate,and(B)the uncorrelated modes like close modes can be effectively handled and precisely identify the FE model mode associated the corresponding experimental mode,and(C)parametric modeling can enhance the dynamic modeling updating of complex structure in the accuracy of mode matching.The efforts of this study provide an efficient dynamic model updating strategy(PM-MUS)for aeroengine casings by parametric modeling and experimental test data regarding uncorrelated modes.

Transfer element method with application to acoustic design of aeroengine nacelle

In the present survey, various methods for the acoustic design of aeroengine nacelle are first briefly introduced along with the comments on their advantages and disadvantages for practi- cal application, and then detailed analysis and discussion focus on a kind of new method which is called ＂transfer element method＂ （TEM） with emphasis on its application in the following three problems： turbomachinery noise generations, sound transmission in ducts and radiation from the inlet and outlet of ducts, as well as the interaction between them. In the theoretical frame of the TEM, the solution of acoustic field in an infinite duct with stator sound source or liner is extended to that in a finite domain with all knows and unknowns on the interface plane, and the relevant acoustic field is solved by setting up matching equation. In addition, based on combining the TEM with the boundary element method （BEM） by establishing the pressure and its derivative con- tinuum conditions on the inlet and outlet surface, the sound radiation from the inlet and outlet of ducts can also be investigated. Finally, the effects of various interactions between the sound source and acoustic treatment have been discussed in this survey. The numerical examples indicate that it is quite important to consider the effect of such interactions on sound attenuation during the acoustic design of aeroengine nacelle.

Error modeling and compensating of a novel 6-DOF aeroengine rotor docking equipment

In the docking process of aeroengine rotor parts,docking accuracy that indicates the gaps between the end faces is strictly required.A key issue is improving docking accuracy using automated docking equipment.In this paper,a systematic study is carried out on the error modeling and compensation of a novel six-degrees-of-freedom(6-DOF)docking equipment for aeroengine rotors.First,a new model for indicating the main indexes of docking accuracy is proposed.Then,the error model of a specially designed 6-DOF docking equipment is established based on a modified Denavit Hartenberg method with five parameters.Subsequently,two error compensation methods are proposed.Based on the above models,a docking accuracy simulation algorithm is proposed using the Monte Carlo method.Finally,verification experiments are conducted.The results show that,for the maximum values and standard deviations of the gaps between the rotor end-faces in the actual and target positions and attitudes,i.e.,main indexes that represent docking accuracy,the deviation rates between the simulation and experimental results are less than20%.The modeling methods have referential significance.The decline rates of these values are 50–65%when using the two proposed compensation methods.The compensation methods significantly improve the docking accuracy.

Design and experiments of plasma jet igniter for aeroengine

A plasma jet ignition technology was studied for aeroengine combustor.The advantages of compact stnucture and advanced performance of air-cooled plasma jet igniter had been tested and verified in the opening test.The plasma jet igniter could produce a continuous plasma jet,stable and reliable ignition.The influence factors of plasma jet ignition aerodynamic and structure were studied in the opening test.Continuous plasma jet was closely related to inlet pressure and flow,simultaneously to the igniter nozzle geometry and throat size.Based on the stable continuous plasma jet,some methods were explored in order to reduce plasma output power,optimize the structure design,and improve the thermal protective.The plasma jet igniter applied to aeroengine combustor was identified initially.For combustion chamber with the igniter,altitude ignition performance were experimented for the inlet pressure of plasma ignition from 10 kPa to 50 kPa,the flow of plasma jet not more than 0.20 g/s,and energy output of ignition from 800 W to 1500 W.The test results were compared with that of conventional aeroengine high energy ignition system.The results show that the plasma jet igniter is better than the conventional one.

An experimental method to obtain the hard alpha anomaly distribution for titanium alloy aeroengine disks

A probability-based damage tolerance methodology has been proposed to improve the recognition of material anomalies, especially hard alpha(TiN) anomalies for aeroengine rotor disks. A key input to this method is hard alpha anomaly distribution, which reflects the occurrence rate and size of anomalies present in the finished part material of titanium rotors. Since anomalies rarely occur naturally, an experimental method is proposed to obtain the anomaly distribution for titanium alloy aeroengine disks to reflect and equivalently replace the manufacturing development in titanium industry. In general, the anomaly distribution information can be divided into two parts: the Probability of Detection(POD) curve and the detected anomaly distribution, which contains the size and frequency data of the detected anomalies. The distribution can be established based on several appropriate assumptions and derivation steps with different confidence levels of POD curves and detected anomaly distributions. In this case, the distribution can be obtained in a relatively short time as a key input to the probability-based damage tolerance methodology. Then the Probability of Failure(POF) can be calculated, and the value is found to vary with different confidence levels. On this basis, the conservative estimated POF can be obtained in conjunction with confidence levels.

A novel low pressure-difference fluctuation electro-hydraulic large flowrate control valve for fuel flowrate control of aeroengine afterburner system

To address the control accuracy of large fuel flowrate during pressure fluctuation,a novel electro-hydraulic fuel metering unit(FMU)is constructed for afterburner fuel system of military aeroengine.Different from the previous FMU,the proposed FMU can achieve the higher precision opening control by a new metering valve with double control chambers(MVDCC),and realize the lower pressure difference fluctuation regulating by a novel two-stage constant pressure difference compensated valve(CPDCV)with dynamic damping orifice and damping piston.The experimental and AMESim simulation results verify the validity and superiority of the novel FMU.Since the temperature-induced variation in fuel properties and device capabilities may degrade or even impair the properties of novel FMU,the discharge flowrate is analyzed by global sensitivity analysis to research the effect proportion of each factor,the temperature effect is explored to ensure the working reliability in long-span temperature variation.Finally,the optimization of structure parameters for novel CPDCV can further reduce pressure difference fluctuation during pressure regulation,and the overshoot,adjust time and the integral of time multiplied by absolute value of error(ITAE)can be reduced by 24%,30%and 26%,respectively.This paper provides a reference for improving the stability of large flowrate during pressure fluctuation.

Two-sided ultrasonic surface rolling process of aeroengine blades based on on-machine noncontact measurement

As crucial parts of an aeroengine,blades are vulnerable to damage from long-term operation in harsh environments.The ultrasonic surface rolling process(USRP)is a novel surface treatment technique that can highly improve the mechanical behavior of blades.During secondary machining,the nominal blade model cannot be used for secondary machining path generation due to the deviation between the actual and nominal blades.The clamping error of the blade also affects the precision of secondary machining.This study presents a two-sided USRP(TS-USRP)machining for aeroengine blades on the basis of on-machine noncontact measurement.First,a TS-USRP machining system for blade is developed.Second,a 3D scanning system is used to obtain the point cloud of the blade,and a series of point cloud processing steps is performed.A local point cloud automatic extraction algorithm is introduced to extract the point cloud of the strengthened region of the blade.Then,the tool path is designed on the basis of the extracted point cloud.Finally,an experiment is conducted on an actual blade,with results showing that the proposed method is effective and efficient.

An Exploration of Surface Integrity Remanufacturing for Aeroengine Components

Surface integrity is the major factor impacting on the operation quality, service life and reliability of the aeroengine components. The surface integrity of aeroengine component is damaged by the failures such as crack,deformation, oxidation, corrosion, erosion, and microstructural degeneration. It adopts advanced remanufacturing technologies to restore or improve the surface integrity and regenerate these high value parts. This paper firstly puts forward the concept, namely surface integrity remanufacturing for aeroengine components, and its connotation. The key remanufacturing technologies have been developed to repair the components with surface damages. Ultimately, some application examples of surface integrity remanufacturing technologies as well as their effects in aeroengine maintenance are introduced. The discarded components have been reused and their service lives have been extended and their reliability has been increased by implementing surface integrity remanufacturing. It has realized "The Repaired Components Outpacing the New Ones", material saving, energy saving, and emission reduction.