Parameterized reduced order modeling of misaligned stacked disks rotor assemblies

Light and flexible rotating parts of modern turbine engines operating at supercritical speeds necessitate application of more accurate but rather computationally expensive 3D FE modeling techniques. Stacked disks misalignment due to manufacturing variability in the geometry of individual components constitutes a particularly important aspect to be included in the analysis because of its impact on system dynamics. A new parametric model order reduction algorithm is presented to achieve this goal at affordable computational costs. It is shown that the disks misalignment leads to significant changes in nominal system properties that manifest themselves as additional blocks coupling neighboring spatial harmonics in Fourier space. Consequently, the misalignment effects can no longer be accurately modeled as equivalent forces applied to a nominal unperturbed system. The fact that the mode shapes become heavily distorted by extra harmonic content renders the nominal modal projection-based methods inaccurate and thus numerically ineffective in the context of repeated analysis of multiple misalignment realizations. The significant numerical bottleneck is removed by employing an orthogonal projection onto the subspace spanned by first few Fourier harmonic basis vectors. The projected highly sparse systems are shown to accurately approximate the specific misalignment effects, to be inexpensive to solve using direct sparse methods and easy to parameterize with a small set of measurable eccentricity and tilt angle parameters. Selected numerical examples on an industrial scale model are presented to illustrate the accuracy and efficiency of the algorithm implementation.