实验技术与管理

为提升复杂精密装备装配连接界面的接触性能，该文基于点对点接触理论，提出一种面向装配连接界面形貌的优化设计方法，并系统阐释了其理论基础与实现机理。为促进理论研究成果向教学实践转化，设计了“理论分析-仿真优化-实验验证”三阶递进式实验教学方案。以航空发动机止口螺栓装配连接界面为典型案例，开展形貌优化实验，结果表明优化后接触压力方差降低了94.04%，有效接触面积提升了171.71%，界面接触性能得到实质性改善。该案例同时验证了教学方案的可行性，有助于深化学生对接触力学与优化设计理论的理解，培养其问题导向的创新思维与工程探索能力。

[Objective] With the intensifying global technological revolution and industrial transformation, the assembly and connection performance of complex and precision equipment has become a strategic factor in safeguarding national core competitiveness. This performance largely depends on the contact state of the assembly interface, which serves as a crucial medium for load transmission between components. The uniformity of contact pressure distribution and the effective contact area directly affect the reliability and service life of the system. Traditional methods for improving contact performance exhibit considerable limitations in engineering practice. Studies have shown that the geometric morphology of the assembly interface greatly influences contact behavior. However, existing optimization methods often suffer from low computational efficiency, poor convergence stability, and limited applicability in educational settings. Therefore, there is an urgent need for an efficient, robust morphological optimization method for assembly interfaces, along with a practical teaching system, to support both high-end equipment performance and the development of innovative engineering talent. [Methods] Based on point-to-point contact theory and finite element discretization, this study proposes an optimized morphological design method for assembly interfaces. In this method, discretized contact nodes are treated as design variables, and the stress distribution characteristics across the interface serve as the objective function. The procedure begins by discretizing the interface into contact nodes. Contact stress at each node is then extracted through simulation analysis, and positional adjustments for each node are computed based on extreme stress values. By modifying node coordinates, the interface morphology is regulated, ultimately achieving a more uniform stress distribution. An experimental teaching scheme based on this method is also proposed, and its implementation process is elaborated. To validate both the method and its educational application, a case study was conducted using the stop bolt connection interface in a high-pressure aeroengine rotor. [Results] The experimental teaching plan was carried out systematically. Results showed:(1) the variance of contact pressure decreased from 314.27 MPa2 to 18.73 MPa2, a reduction of 94.04%;(2) the effective contact area increased from 286.65 mm2 to 778.85 mm2, an increase of 171.71%;(3) before optimization, pressure-sensitive paper displayed a roughly circular pattern with a 6.4 mm inner diameter and an 11.7 mm outer diameter;(4) after optimization, the developed color range expanded to a 6.4 mm inner diameter and 17.1 mm outer diameter;(5) a verification experiment confirmed the effectiveness of the proposed optimization method. [Conclusions] The proposed morphological optimization method, based on point-to-point contact theory, significantly enhances contact performance by dynamically adjusting node coordinates. It provides an effective solution to the problem of connection reliability in complex equipment. The accompanying teaching scheme integrates research into education, promoting problem-based learning that enhances students' innovation and engineering abilities. This method is also applicable to precision assembly scenarios such as aerospace sealing structures and turbine blade hubs, providing technical support for high-end equipment performance improvement while establishing a replicable model for innovation-driven engineering education.