Exploratory Factor Analysis for Machining Error Data of Compressor Blades Based on Dimensionality-Reduced Statistical Analysis Method

Various machining errors inevitably occur on aero-engine compressor blades, including leading-edge contour error, trailing-edge contour error, camber contour error, and more. The current complexity surrounding the numerous machining error types and their obscure interrelationships imposes immense effort for aerodynamic analysis and hinders overall error control. Thus, elucidating error correlations to achieve error dimensionality reduction is imperative. This study pioneers a dimensionality reduction approach via exploratory factor analysis to conduct a comprehensive statistical analysis of 13 types of blade machining errors. The proposed technique can categorize the 13 errors into three groups, each dominated by a distinct common factor. Furthermore, bootstrap resampling establishes the 95% confidence intervals for the factor scores. Capitalizing on the grouping structure uncovered by exploratory factor analysis, multiple linear regression models are built for the errors within each group, and then, a preliminary conjecture is made about the potential control error types for each group of errors based on the regression coefficients. This hypothesis is then evidenced by the statistical analysis of cross section profile error data of 28 blades. The present work can not only optimize machining processes but also relax tolerance requirements and diminish the effort of aerodynamic analysis.