Error propagation analysis models for aero-engine rotor assembly: A systematic review

Accurate rotor installation is essential in order to ensure the performance, reliability, and safety of aero-engines. However, manufacturing errors introduced during the assembly process have the potential to propagate and drive the entire assembly out of their desired specifications. According to the reviewed studies, advanced mathematical models show notable improvements in rotor assembly precision. Reported outcomes include reduction of maximum coaxiality errors from 48.8 <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" display="inline" overflow="scroll"> <mml:mrow> <mml:mspace width="0.25em"/> <mml:mi>μ</mml:mi> </mml:mrow> </mml:math> m to 17.9 <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" display="inline" overflow="scroll"> <mml:mrow> <mml:mspace width="0.25em"/> <mml:mi>μ</mml:mi> </mml:mrow> </mml:math> m, reduced fitting-axis offsets from 21.3 <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" display="inline" overflow="scroll"> <mml:mrow> <mml:mspace width="0.25em"/> <mml:mi>μ</mml:mi> </mml:mrow> </mml:math> m to 8.5 <mml:math xmlns:mml="http://www.w3.org/1998/Math/MathML" display="inline" overflow="scroll"> <mml:mrow> <mml:mi>μ</mml:mi> </mml:mrow> </mml:math> m, docking error reductions of 50%–65%, and prediction deviations maintained below 14%. Additional findings show 22.5% reduction in vibration amplitude, 44.1% reduction in unbalance, and error reduction rates reaching 86% using intelligent optimization approaches. This review provides a systematic and comprehensive analysis of the state-of-the-art mathematical models employed for the error propagation analysis in aero-engine rotor assembly. These models are effectively used for evaluating and mitigating errors from the conceptual design to the final assembly. The primary objective of this review study is to identify the most widely adopted mathematical model used for error propagation analysis in aero-engine rotor assembly. Forty-five scholarly research papers, including journal articles, patents, and a conference paper have been thoroughly reviewed to provide key insights pertaining to error propagation rotor assembly. The findings of this study underscore the growing importance of mathematical models in improving aero-engine rotor assembly precision, particularly HMT based models thus paving the way for more efficient and robust aero-engine manufacturing processes. This review serves as a valuable source of knowledge for researchers and engineers, guiding them in selecting the most appropriate model to improve assembly accuracy and ensure the safe functioning of aero-engines.