Based on the fixed interface component mode synthesis, a multiple and multi-level substructure method for the modeling of complex structures is proposed in this paper. Firstly, the residual structure is selected according to the structural characteristics of the assembled complex structure. Secondly, according to the assembly relationship, the parts assembled with the residual structure are divided into a group of substructures, which are named the first-level substructure, the parts assembled with the first-level substructure are divided into a second-level substructure, and consequently the multi-level substructure model is established. Next, the substructures are dynamically condensed and assembled on the boundary of the residual structure. Finally, the substructure system matrix, which is replicated from the matrix of repeated physical geometry, is obtained by preserving the main modes and the constrained modes and the system matrix of the last level of the substructure is assembled to the upper level of the substructure, one level up, until it is assembled in the residual structure. In this paper, an assembly structure with three panels and a gear box is adopted to verify the method by simulation and a rotor is used to experimentally verify the method. The results show that the proposed multiple and multi-level substructure modeling method is not unique to the selection of residual structures, and different classification methods do not affect the calculation accuracy. The selection of 50% external nodes can further improve the analysis efficiency while ensuring the calculation accuracy.
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