Improved Mass Balancing of Turbo Machine Rotors

ABSTRACT: The efficient, effective balancing of jet engine rotors and subassemblies continues to be a challenge for key aerospace applications. While manufacturing methods for balancing have improved significantly over the last ten years, measurement methods and procedures and fixturing have not advanced at the same pace. Modern jet engines require multiple parts and subassemblies to be balanced to ensure proper engine operation. To assure that these specifications are met, parts must be balanced separately and then integrated as assemblies during production and refurbishment. The goal of this project is development of an optical measurement system and procedures that overcome the primary shortcomings of existing methods, such as: (1) the need for more accurate measurement of displacement than is currently state-of-the-art on commercial balancing systems, (2) use of fixtures that contribute significantly to the time it takes to perform precision balancing, and (3) inability to correct for inconsistencies in the balancing process. During Phase I, we demonstrated the feasibility of an optical measurement system that improves displacement measurement accuracy by an order of magnitude over currently available sensors and developed methods and procedures to help mitigate the issues that extend the time and cost of balancing jet engine rotors and subassemblies. BENEFIT: The technology developed on this project will provide new instrumentation and methodologies for balancing jet engine rotors and subassemblies. Use of technology is expected to reduce part to part variability and dramatically reduce production time and cost for in-the-field and in-the-factory fabrication activities.