Case Study of Aeroengine System Failure Based on Co-Word Analysis
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摘要: 航空发动机是多学科交叉、多组件耦合的复杂系统，其工况复杂，一旦发生故障便会造成灾难性后果。采用共词分析法将航空发动机系统失效领域内的关键词加以分类，归纳出了主要的失效形式并实现了结果可视化。研究发现考虑自相关性后的聚类分析效果更佳，且对于不同失效机理的研究更加具体和准确。对于服役过程中的常见故障，结合聚类分析结果和多维尺度分析图可以更快速地采取检查手段进行失效分析，有效避免类似事件的再次发生。Abstract: Aero-engine is a complex system with interdisciplinary and multi-component coupling, and its working conditions are complex. It can have catastrophic consequence once the failure of aero-engine occurs. Therefore, the failure analysis of aero-engine system can provide important reference for its design, maintenance and safe operation. In this work, co-word analysis method is adopted, and three multivariate analysis methods of factor analysis, cluster analysis and multidimensional scale analysis are used to classify the keywords in the field of aero-engine system failure, and the main failure forms are summarized and the results are visualized. It is found that clustering analysis with autocorrelation is better than the other two methods. Generally, compared with traditional statistical analysis or theoretical analysis, the analysis results of typical failure forms are basically consistent, but co-word analysis is more specific, detailed and accurate for the study of different failure mechanisms. The results of traditional statistical analysis only stay at the level of general quantitative analysis, and can only indicate the general failure direction for practical engineering application. Multi-dimensional scale analysis realizes visual similarity visualization of failure keywords. The closer to the origin of coordinates, the more core the failure forms are, the higher the frequency of occurrence is. For these common faults in the service process, combining cluster analysis results and multidimensional scale analysis charts, it is convenient for technicians to find out the failure reasons of faulty equipment more quickly, grasp the key points of work more accurately, and determine the protection scheme more effectively, effectively avoiding the recurrence of similar events and prolonging the service life of the engine.
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Key words:
- aero-engine /
- failure analysis /
- co-word analysis /
- autocorrelation
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图 3 未考虑自相关性的叶盘聚类树状图
Figure 3. Dendrogram of blade and wheel disc without considering autocorrelation
图 4 叶盘失效关键词的MDS分析图
Figure 4. MDS analysis chart of failure keywords of blade and wheel disc
图 5 机械传动系统失效关键词的MDS分析图
Figure 5. MDS analysis chart of failure keywords of mechanical transmission system
图 6 其他附件失效关键词的MDS分析图
Figure 6. MDS analysis chart of failure keywords of other accessory equipment
表 1 叶盘失效相似矩阵（部分）
Table 1. Similar matrix of blade and wheel disc failure (Part)
Keyword Cosine value Blade Fracture Creep Crack Fatigue Selective oxidation Blade 1.0000 0.9842 0.8024 0.9898 0.9902 0.8410 Fracture 0.9842 1.0000 0.7965 0.9680 0.9889 0.8146 Creep 0.8024 0.7965 1.0000 0.7948 0.8018 0.6909 Crack 0.9898 0.9680 0.7948 1.0000 0.9853 0.8227 Fatigue 0.9902 0.9889 0.8018 0.9853 1.0000 0.8146 Selective oxidation 0.8410 0.8146 0.6909 0.8227 0.8146 1.0000 
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表 2 叶盘失效相异矩阵（部分）
Table 2. Dissimilar matrix of blade and wheel disc failure (Part)
Keyword Cosine value Blade Fracture Creep Crack Fatigue Selective oxidation Blade 0 0.0158 0.1976 0.0102 0.0098 0.1590 Fracture 0.0158 0 0.2035 0.0320 0.0111 0.1854 Creep 0.1976 0.2035 0 0.2052 0.1982 0.3091 Crack 0.0102 0.0320 0.2052 0 0.0147 0.1773 Fatigue 0.0098 0.0111 0.1982 0.0147 0 0.1854 Selective oxidation 0.1590 0.1854 0.3091 0.1773 0.1854 0
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表 3 叶盘失效关键词
Table 3. Failure keywords of blade and wheel disc
Number Keyword Number Keyword Number Keyword A01 Blade A16 Cyclic alternating load A31 Recrystallization A02 Fracture A17 Coating shedding A32 Surface damage A03 Creep A18 High temperature A33 Low cycle fatigue A04 Crack A19 Etch pit A34 Fretting wear A05 Fatigue A20 Forging defect A35 Incorrect mounting A06 Selective oxidation A21 Machining mark A36 Exciting force A07 Foreign body impact A22 Friction A37 High-low cycle complex fatigue A08 Hole defect A23 Overload A38 Overtemperature and oversintering A09 Stress concentration A24 Improper manufacturing process A39 Resonance A10 Vibration A25 Blister A40 Bending vibration A11 High cycle fatigue A26 Excessive blade bending A41 Oxidation defect A12 Poor processing quality A27 Thermal corrosion A42 Structural degradation A13 Material defect A28 Thermal damage A43 Abnormal microstructure A14 Pit corrosion A29 Carbide A15 Corrosion A30 Coating degradation
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表 4 机械传动系统失效关键词
Table 4. Failure keywords of mechanical transmission system
Number Keyword Number Keyword Number Keyword B01 Shaft B16 Cyclic load B31 Bengding and torsional fatigue B02 Bearing cage B17 Friction B32 Insufficient lubrication B03 Bearing B18 Pit corrosion B33 Rotating bending fatigue B04 Bearing ball B19 Spalling damage B34 Fretting wear B05 Rivet of bearing cage B20 Machining mark B35 Abnormal bending load B06 Fracture B21 Irregular design B36 Skidding damage B07 Crack B22 Foreign body impact B37 Torsional fatigue B08 Stress concentration B23 Overload B38 Resonance B09 Fatigue B24 Electric arc damage B39 Inappropriate fit clearances B10 Abrasion B25 Incorrect mounting B40 Abrasive contamination B11 Improper material selection B26 Abnormal axial load B41 Improper heat treatment B12 Improper manufacturing or maintenance process B27 Forging defect B42 Governor idle gear B13 Material inclusion B28 High temperature damage B43 Transfer and bevel gear B14 Surface contact fatigue B29 Overheating and overheating B44 Clutch gear B15 High contact stress B30 High cycle fatigue B45 Improper case hardening
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表 5 其他附件失效关键词
Table 5. Failure keywords of other accessory equipment
Number Keyword Number Keyword Number Keyword C01 Cylinder C17 Hydraulic actuator C33 Kink C02 Cylinder head C18 Cited trachea clamp C34 Surface damage C03 Auxiliary power supply inlet valve C19 Engine actuating cylinder C35 Stress corrosion C04 Combustor liner C20 Tappet body C36 Shear failure C05 Hydraulic pressure line C21 Afterburner fuel manifold C37 Overload C06 Exhaust system pipeline C22 Crack C38 Abrasion C07 Bleed valve clamp bolt C23 Fracture C39 Corrosion C08 Wheel disc connecting pin C24 Material defect C40 Explosion failure C09 Fuel line C25 Fatigue C41 Poor quality of the roll welding seam C10 Combustion chamber shell C26 Improper manufacturing or production process C42 Unqualified welding process C11 Combustion control system adapter C27 High cycle fatigue C43 Pit corrosion C12 Air radiator C28 Stress concentration C44 Impurity residue in molding process C13 Reed C29 High temperature C45 Foreign object damage C14 Oil pipeline C30 Vibration C46 Machining mark C15 Corrugated pipe C31 Oxidation C16 Gas cylinder conduit C32 Thermal fatigue
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表 6 叶盘类因子分析总方差解释表
Table 6. Explanatory table of total variance of factor analysis of blade and wheel disc
Component number Variance of initial
eigenvalueVariance of extraction sums of
squared loadingsRotation sums of
squared loadingsTotal Percentage/% Cumulative/% Total Percentage/% Cumulative/% Total Percentage/% Cumulative/% 1 23.554 54.776 54.776 23.554 54.776 54.776 14.331 33.328 33.328 2 5.363 12.471 67.247 5.363 12.471 67.247 6.193 14.402 47.730 3 3.285 7.639 74.886 3.285 7.639 74.886 5.519 12.835 60.564 4 1.982 4.609 79.495 1.982 4.609 79.495 3.610 8.395 68.960 5 1.588 3.693 83.188 1.588 3.693 83.188 3.411 7.932 76.892 6 1.506 3.503 86.691 1.506 3.503 86.691 3.009 6.997 83.889 7 1.278 2.972 89.663 1.278 2.972 89.663 2.338 5.437 89.326 8 0.827 1.924 91.586 0.827 1.924 91.586 0.972 2.260 91.586
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表 7 机械传动系统因子分析总方差解释表
Table 7. Explanatory table of total variance of factor analysis of mechanical transmission system
Component number Variance of initial
eigenvalueVariance of extraction sums of
squared loadingsRotation sums of
squared loadingsTotal Percentage/% Cumulative/% Total Percentage/% Cumulative/% Total Percentage/% Cumulative/% 1 13.984 31.075 31.075 13.984 31.075 31.075 9.911 22.025 22.025 2 12.586 27.969 59.044 12.586 27.969 59.044 5.569 12.375 34.400 3 5.001 11.112 70.157 5.001 11.112 70.157 5.349 11.886 46.286 4 2.910 6.467 76.624 2.910 6.467 76.624 4.905 10.899 57.185 5 2.374 5.276 81.900 2.374 5.276 81.900 4.837 10.750 67.935 6 1.798 3.996 85.896 1.798 3.996 85.896 4.303 9.563 77.498 7 1.395 3.101 88.997 1.395 3.101 88.997 3.336 7.414 84.913 8 1.146 2.546 91.542 1.146 2.546 91.542 2.983 6.630 91.542 9 0.991 2.203 93.745 0.991 2.203 93.745 2.829 6.286 90.325 10 0.627 1.394 95.139 0.627 1.394 95.139 2.009 4.465 94.790 11 0.467 1.037 96.176 0.467 1.037 96.176 0.624 1.386 96.176
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表 8 其他附件因子分析总方差解释表
Table 8. Explanatory table of total variance of factor analysis of other accessory equipment
Component number Variance of initial
eigenvalueVariance of extraction sums of
squared loadingsRotation sums of
squared loadingsTotal Percentage/% Cumulative/% Total Percentage/% Cumulative/% Total Percentage/% Cumulative/% 1 19.670 42.762 42.762 19.670 42.762 42.762 9.624 20.922 20.922 2 5.181 11.264 54.025 5.181 11.264 54.025 4.630 10.066 30.988 3 4.085 8.880 62.906 4.085 8.880 62.906 4.344 9.443 40.432 4 3.247 7.058 69.964 3.247 7.058 69.964 3.982 8.657 49.089 5 3.114 6.769 76.733 3.114 6.769 76.733 3.592 7.810 56.898 6 2.031 4.414 81.147 2.031 4.414 81.147 3.417 7.429 64.327 7 1.907 4.145 85.292 1.907 4.145 85.292 3.119 6.781 71.109 8 1.385 3.010 88.302 1.385 3.010 88.302 3.041 6.612 77.720 9 1.090 2.370 90.672 1.090 2.370 90.672 2.652 5.764 83.485 10 0.770 1.674 92.345 0.770 1.674 92.345 2.484 5.400 88.885
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表 9 叶盘类因子分析总方差解释表（未考虑自相关性）
Table 9. Explanatory table of total variance of factor analysis of blade and wheel disc(without considering autocorrelation)
Component number Variance of initial
eigenvalueVariance of extraction sums of
squared loadingsRotation sums of
squared loadingsTotal Percentage/% Cumulative/% Total Percentage/% Cumulative/% Total Percentage/% Cumulative/% 1 27.294 63.475 63.475 27.294 63.475 63.475 21.932 51.004 51.004 2 5.661 13.165 76.640 5.661 13.165 76.640 5.511 12.817 63.821 3 3.013 7.008 83.648 3.013 7.008 83.648 4.530 10.534 74.355 4 1.818 4.227 87.875 1.818 4.227 87.875 3.324 7.729 82.085 5 1.261 2.932 90.807 1.261 2.932 90.807 1.735 4.035 86.120 6 0.921 2.142 92.949 0.921 2.142 92.949 1.574 3.660 89.779 7 0.731 1.700 94.649 0.731 1.700 94.649 1.545 3.593 93.373 8 0.483 1.123 95.772 0.483 1.123 95.772 0.861 2.003 95.375
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