Rotor dynamics-oriented assembly interface design

• Experiments on rotor dynamics are conducted to validate simulations. • Adaptive assembly interface shape design method is proposed for rotor dynamics. • Effect of assembly interface shape on critical speed and vibration is revealed. • Thermal-structural coupling condition is involved. • Rotor dynamics can be improved significantly. Assembly interfaces are inherent in practical rotor systems and significantly influence rotor dynamics. Tuning dynamic behavior through interface property design represents a promising yet underexplored strategy. This study focuses on interface geometry and aims to regulate rotor dynamics by proactively designing the interface shape. The shape is modeled using sequentially connected control points, with adjustments made by varying their positions. Influence of interface shape on rotor dynamics is determined through a parametric correlation analysis. An adaptive multi-objective optimization approach that combines Kriging and multi-objective genetic algorithm is employed to identify the optimal interface shape within a finite element framework. Rotor dynamics experiments are conducted to validate the simulation results. The proposed design methodology is applied to a bolted thin-shell rotor system under both thermal-structural coupled and isothermal conditions. Results demonstrate that the designed interface shape increases critical speed and reduces unbalanced vibration.