Advanced Materials Research Vol 1039 (2014) pp 99-104 Submitted: 2014-05-31

© (2014) Trans Tech Publications, Switzerland Accepted: 2014-07-14

doi:10.4028/www.scientific.net/AMR.1039.99 Online: 2014-10-31

Research on Tolerance Simulation and Improvement of Gas Turbine

Generator

LIU Jing a , LI Mingb and ZHAN Gao Weic

School of Mechatronic Engineering and Automation, Shanghai Key Laboratory of Manufacturing
Automation and Robotics ,Shanghai University ,CHINA
a b c
liujing100@126.com, robotlib@edu.cn, gaoweizhan@126.com

Keywords: VisVSA Software ; Tolerance Analysis ; Gas Turbine Generator

Abstract. VisVSA is a kind of 3-D tolerance analysis software which offers high reliability
calculation based on Monte Carlo simulation. This paper uses VisVSA to improve the design of gas
turbine generator. In many factors that affect designing properties, the impact of manufacturing
precision and assembly precision through comparative analysis are discussed.

Introduction
Gas turbine generator is the most common in aircraft industry. Although gas turbine generator
has received a lot of attention for the optimal design , no attempt has been made so far to investigate
the effect caused by different manufacturing precision and assembly precision[1] .so these previous
results are unsatisfactory and questionable .This paper ,according to the actual situation to simplify
the gas turbine generator , which consists of turbine guide components, bearing sleeve components,
fore bearing, rear bearing, intermediate case, turbine rotor components, centrifugal impeller and so
on. VisVSA is applied in this paper.

Introduction of VisVSA
VisVSA facilitates statistical analysis of dimensional variations in parts and assemblies,
mostly based on Monte Carlo simulation. Tolerance specific entities and attributes are interactively
extracted from CAD models with the Direct Model(.jt) format. Feature creation falls into three
classes: CAD geometry to derive its shape and position , CAD geometry to derive its position and no
CAD geometry. User-defined statistical distributions are used in simulation runs to determine the
contributors, the extent of contributions, sensitivities , and statistical distribution of the analysed part
dimension or assembly clearance/interference[2].

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100 Advanced Manufacturing and Automation

Fig.1 Modeling and Analysis Process

Firstly, The objectives define the goals for the product. Objectives are the up-front targets that
are established through research tools such as benchmarking, trade journals ,and past design
experience, to name a few. Assembly sequences identify how each component and sub-assembly is
located within the final assembly[3].
Secondly, The purpose of using VisVSA is to perform statistical analysis on a three-dimensional
model of an assembly. Up to this point, functional feature model creation is essential. Based on the
part geometry selected ,functional features(pins ,holes, slots, planes, and points) need to be created
that will be used in the simulations. Tolerances also need to be defined , in most case ,will follow
GD&T.
Thirdly, Defining the assembly operations is one step in the creation of a functional assembly
model. The next and final step is the creation of measurements. Measurements are integral to a
functional assembly model because they quantify the relationship between components.
Measurements are defined to determine if the dimensional requirements can be met, if there are any
out-of-specification conditions that could occur, and to identify the key contributors to the variation
for the product.
Fourthly,There are three simulation methods, such as Monte Carlo simulation ,High-Low-Median
simulation and Mean Shift Contributor simulation .In most case ,Monte Carlo simulation is the first
choice ,because it replicates the random nature of manufacturing processes, closer the reality.
After simulation, Process Contributor , Histogram and Customized Reports display.
Tolerances would be continually tightened until one of the following were to occur.
a) All measurements affected improved to >1.0 Cpk.
b) The tolerances were as tight as technology was capable of producing. (This information would
come from the manufacturing and/or quality sectors.)
c) If tolerances had been tightened to their lowest possible limits and still did not achieve
satisfactory process capability, loosening the specification limits on the measurements may be
considered.

Test Settings
A gas turbine generator consists of turbine guide components , bearing sleeve components,
fore bearing, rear bearing, intermediate case, turbine rotor components, centrifugal impeller and so
on[4]. See Fig.2.
Take the radial run-out of centrifugal impeller as an example to verify the effect on the design
quality caused by manufacturing precision and assembly precision.
 Advanced Materials Research Vol. 1039 101

Turbine guide
components
Fore bearing Turbine rotor components

Centrifugal impeller
Rear bearing

Bearing sleeve components

Intermediate case

Fig.2 Assembly Operation

Firstly. Define the measurement datum : nominal center of rotation axis
Secondly, Define assembly sequence
1. Assembly operation for the bearing sleeve components to intermediate case.
2. Assembly operation for the fore bearing and rear bearing to bearing sleeve components
3. Assembly operation for the turbine rotor components to bearings
4. Assembly operation for the centrifugal impeller to turbine rotor components
5. Assembly operation for the turbine guide components to intermediate case.
Sometimes, assembly sequences have no effect on the 3-D tolerance analysis[5].
Thirdly, Define measurement operation (radial run-out tolerance of centrifugal impeller is
0.05mm, as required)

Fig.3 Distribution of Measurement Points

Fourthly, Run simulation and review reports.
102 Advanced Manufacturing and Automation

Fig.4 Histogram Report and Contributor Report

The results show that all the radial run-outs are out of specification limits , rate between 95%
-96%.The biggest contribution comes from floating locators in the Assembly operation for the turbine
guide components to intermediate case.

Improved Schemes
1.change the evaluation standard. Exclude the effect caused by turbine guide components

Fig.5 Improved Histogram Report and Contributor Report

Results have been improved greatly. Effect caused by floating locators has shifted from
98.53% to 62.06%.
2. Improve the manufacturing precision and reduce manufacturing errors.
Consider improving the manufacturing precision, assuming from 16µ reduced to 8µ, nominal design
interval remains the same. With the aid of VSA iterative simulation, draw a "manufacturing precision
raised - fraction defective improvement "curve, become the basis of studying the manufacturing
economy cost (quality).
 Advanced Materials Research Vol. 1039 103

Fig.6 Fraction Defective Curve (1)

3. Change clearance fit to transition fit
Consider reducing nominal design interval, in the minimum guarantee ease of assembly limit
conditions , gradually reduce clearance volume, assuming from 9µ reduced to 1µ, processing
precision remains the same.
With the aid of VSA iterative simulation, draw a "assembly precision raised- fraction
defective improvement "curve, become the basis of studying the manufacturing economy cost
(quality).

Fig.7 Fraction Defective Curve (2)

Fig.8 shows the reduction of out of specification of radial run-out of centrifugal impeller.
Three improved schemes have provided good solution to the problem.
104 Advanced Manufacturing and Automation

Fig.8 Contrast Figure of Result

Conclusions
From above figures, fraction defective of gas turbine generator decreases as the improvement
of manufacturing precision and assembly precision. The quantitative analysis of relationship between
manufacturing precision, assembly precision and fraction defective has proved that quality is
designed. In the design process, manufacturing capacity and assembly level should be considered
synthetically , especially from the economical aspect.

References
[1] Rahmani Hanzaki A, Rao P V M, Saha S K, in: Kinematic and Sensitivity Analysis and
Optimization of Planar Rack-and-Pinion Steering Linkages, edited in Mechanism and
Machine Theory, Vol.44(2009), p42-56.
[2] Zheng shushen. Tolerance Analysis with EDS/VisVSA. Journal of computing and Information
Science in Engineering.Vol.3(2003),p95
[3] Fu Xinliang. Tolerance design research of car body based on VisVSA.(2013)
[4] Information on http:// www.wikipedia.org.cn
[5] Stefan Dahlstrom, Lars Lindkvist: Variation Simulation of Sheet Metal Assemblies Using the
Method of Influence Coefficients With Contact Modeling, edited in Journal of Manufacturing
Science and Engineering,Vol.129(2007),p615
Advanced Manufacturing and Automation
10.4028/www.scientific.net/AMR.1039

Research on Tolerance Simulation and Improvement of Gas Turbine Generator

10.4028/www.scientific.net/AMR.1039.99