Research On Key Technologies Of Rotor Lcf Test Facility

The fatigue reliability problem of disk at a condition of high speed and temperature has been the focus in the field of aviation engine development. A large number of experiments are required to obtain the accurate design parameters. And the rotor LCF test facility is the most important facility for completing the disk LCF test. At present, many of the domestic facilities in the service are introduced from the European and American countries, however the price is very expensive and the maintenance of the facilities is inconvenience. Therefore, the development of the rotor LCF test facility with independent intellectual property is of great significance.On the basis of sufficient investigation and research, the design parameters of ZUST6D type tester are given and detailed research work is carried out. The main work completed is as follows:(1) The design of a concise and efficient two-stage gear increaser system is completed. The maximum output speed of the flexible cantilever rotor reached to60000r/min by the means of high-speed flat and gearbox. Reasonable gear processing technology and modified high-speed tooth relief technique are applied to improve the carrying capacity and the stability of the gear box, and reduce the gear transmission noise.(2) The design of high-speed flexible cantilever rotor system is finished, and a way to avoid critical rotational speed is found by adjusting the tooling. Elastomer O-rings Damper is applied to improve the ability of resisting unbalance response of the rotor system and the smoothness of operation.(3) Preliminary study of health online monitoring method of the disk is fulfilled. The system detects the existence of dangerous cracks in turbine engine disks by measuring the vibration response of the flexible rotor and drawing the real-time trend of the vibration amplitude graph with cycle number.(4) A set of high temperature resistance furnace is designed, which has realized the high temperature heating of the spinning test pieces.(5) The automatic control system for the ZUST6D type rotor LCF test facility is completed. Touch screen is used for Human Machine Interface, and PLC is used as the control master station, and IPC is responsible for data display and storage. Third-party component is utilized to realize serial communication of IPC and PLC. Testing results show that stability and reliability of the control system is well, which meet the design requirements.The test facility and automatic control system is verified by tests. The test facility has completed LCF test of a turbine disk and all of the test data is recorded. Test results show that the stability and reliability of the tester and the control system is well, which fully meet the design requirements.