Innovation Takes Off 1 C lean Sky 2 Information Day dedicated to - - PowerPoint PPT Presentation

Innovation Takes Off

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Innovation Takes Off

ENGINE ITD

SAFRAN Rolls-Royce

Brussels, 22 February 2017

Clean Sky 2 Information Day dedicated to the 6th Call for Proposal (CfP06)

ENGINE – ITD in Clean Sky 2

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• Clean Sky, through SAGE (Sustainable And Green Engines), is

delivering significant step changes in key engine technologies along the following themes:

– Open Rotor, Composites, Lean Burn combustors, high power gearboxes, enhanced turbines and compressors, advanced materials and improved structures

• Clean Sky 2 is about providing and demonstrating new

engine technology for the whole of the civil market

• The Clean Sky 2 engines ITD will build on Clean Sky and

demonstrate technology at a whole engine level

From Clean Sky towards Clean Sky 2

High-Level Objectives

• Environmental objectives for the engines ITD are to

demonstrate at TRL6 the following: – 20-30% reduction in CO2* – Significant contribution to ACARE 2020 NOx reduction target (-80%*) – Upto -11EPNdB per operation reduction in noise*

• Industrial objectives are to ensure future competitiveness
• f European Aero Engine industry, securing trade,

employment and high technology knowledge and skills

*relative to year 2000 baseline

Overview of the ITD/IADP

ITD ENGINES Work Breakdown Structure

ENGINE ITD

WP0: ITD Coordination (RRUK / Safran Aircraft Engines / MTU) WP2: UHPE Demonstrator for SMR aircraft (Safran Aircraft Engines) WP3: Business Aviation/SR Regional TP Demonstrator (Safran Helicopter Engines) WP4: Advanced Geared Engine Configuration (MTU) WP5: VHBR Middle of Market Turbofan Technology (RRUK) WP6: VHBR Large Turbofan Demonstrator (RRUK) WP7: Light weight and efficient jet-fuel reciprocating engine (Safran SMA) WP8: Reliable and more efficient operation of small turbine engines (PAI/GE Avio) WP9: ECO Design Activities (MTU / Safran Aircraft Engines / RRUK / FhG)

WP2 : Ultra High Propulsive Efficiency for SMR aircraft – Safran Aircraft Engines

Main Technology Objectives

• from design to ground test of an engine demo to validate LP modules &

nacelle technologies Key Technologies

• Low pressure ratio fan
• High power gear box
• High efficiency LP turbine & LP compressor
• Engine / aircraft specific integration

Potential Partner participation:

• Fixed structures in propulsive system, low pressure turbine components,

controls and systems components, shafts, bearings

UHBR turbofan for SMR aircraft

Safran Aircraft Engines proprietary data

• Main Technology Objectives

– From design to ground test of a new turboprop engine demo for business aviation and short range regional. – Improvement of advanced core engine technologies

• Key Technologies

– HP core small size – Advanced propeller / air inlet / gear box – Controls, lub & actuation systems

WP3 : Business Aviation/SR Regional TP Demonstrator – Safran Helicopter Engines

From ARDIDEN 3 existing turboshaft engine to full Integrated Turboprop System

WP3 : Business Aviation/SR Regional TP Demonstrator – Safran Helicopter Engines

Rolls-Royce Clean Sky 2 activities are split into two work packages:

Integration Transmissions Control & Power Systems Externals & Structures Turbines Composites

WP6: VHBR technologies for the long range airliner market with Engine Demonstrator WP5: underlying technologies for VHBR engines with focus on the “Middle-of- Market” short range aircraft

WP5 : VHBR Middle of Market Turbofan Technology WP6 :VHBR Large Turbofan Demonstrator

UltraFan

TM

Main Technology Objectives

• Virtual Engine Integration
• Technology Maturation
• Component/Module Validation

Key Technologies

• Material Technologies
• Manufacturing Technologies
• Compressor
• Combustor
• Turbine

Timeframe: 2015 - 2019

WP8 :Reliable and more efficient operation of small turbine engines – Piaggio Aero / GE AVIO

• Next generation turboprop engines and propeller for up to 19 seats aircraft

Engine ITD timelines

2014 2018 2022 2016 2020 WP2 Safran Aircraft Engines WP3 Safran Helicopter Engines WP4 MTU WP5 RR WP6 RR WP7 SMA VHBR Turbofan Long Range VHBR Turbofan Middle of Market Business Aviation Regional Turboprop Geared engine Configuration (HPC-LPT) UHPE demonstrator

Ground Demonstrator Ground Demonstrator Ground Demonstrator Flight Demonstrator

Technology Demonstrator

Several demonstrators

Small Aircraft Engine

Overview of the ITD/IADP

WP8 PAI/GE Avio Reliable and more efficient operation of small turbine engines

Technology Demonstrator

Overview of ITD ENGINES topics

Identification Code Title Type of Action Value (Funding in M€) Topic Leader JTI-CS2-2017-CfP06- ENG-01-15 Bearing chamber in hot environment RIA 1,7 Safran Aircraft Engines JTI-CS2-2017-CfP06- ENG-01-16 Torque measurement in turbofan IA 1 Safran Aircraft Engines JTI-CS2-2017-CfP06- ENG-01-17 Advanced turbine system performance improvement through dual-spool rig tests IA 1,1 GEDE JTI-CS2-2017-CfP06- ENG-01-18 Development of innovative methods and tooling for machining of slender shafts RIA 0,4 GKN JTI-CS2-2017-CfP06- ENG-01-19 Thermoplastic Thrust reverser cascade IA 0,45 SAFRAN NACELLES JTI-CS2-2017-CfP06- ENG-01-20 Long Fiber Thrust reverser cascade IA 0,45 SAFRAN NACELLES JTI-CS2-2017-CfP06- ENG-01-21 Aerothermal characterization in the engine compartment RIA 0,9 Safran helicopter Engines JTI-CS2-2017-CfP06- ENG-01-22 Advanced Instrumented Engine cradle of the Turboprop demonstrator IA 0,4 Safran helicopter Engines JTI-CS2-2017-CfP06- ENG-03-15 IP Turbine Rear Stages Aero/Noise Rigs IA 2,25 ITP JTI-CS2-2017-CfP06- ENG-03-16 Development of non-intrusive engine emissions instrumentation capability IA 2 RRUK JTI-CS2-2017-CfP06- ENG-03-17 VHBR Engine – Journal Bearing Technology IA 3 RRUK JTI-CS2-2017-CfP06- ENG-03-18 Development of capability to understand & predict sub-idle & idle behaviour of geared VHBR engines. RIA 1,02 RRUK JTI-CS2-2017-CfP06- ENG-03-19 Intermediate Compressor Case Duct Aerodynamics RIA 0,5 GKN JTI-CS2-2017-CfP06- ENG-04-07 Advanced investigation of ultra compact RQL reverse flow combustor RIA 0,6 GE AVIO JTI-CS2-2017-CFP06- ENG 14 Topics 15,77

Preliminary information from Clean Sky JU website

CS2- CfP#6- ITD ENGINE TOPICS

• 9 topics :

– WP2 (Safran Aircraft Engines & its Core Partners) : 6 topics – WP3 (Safran Helicopter Engines) : 2 topics – WP5 & 6 (Rolls Royce and its Core Partners) : 5 topics – WP8 (PAI / GE AVIO) : 1 topic

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CS2 Info day, 22 February 2017

WP2 TOPICS

6th Call for Proposal (CfP06) – ENGINE ITD

CfP#6 – Bearing chamber in hot environment– Safran Aircraft Engines Topic Description

• Improvement of design of

compact bearing chamber in hot environment.

• Determine influence of key

parameters

• n

heat rejections and heat transfer. Images / Graphics

Mixture Conduction Heat rejection Oil flow

CfP#6 – Torque Measurement – Safran Aircraft Engines Topic Description

• Measuring shaft torque is key to

understand aircraft engine behavior. Nevertheless space around engine shaft is limited and current torque meters or telemetry systems cannot be easily implemented.

• The aim of this CFP is to develop

a torque measurement system without telemetry for engine test bench (possibility to use on a flying test bench would be an asset but is not mandatory it will not be embedded

• n

a commercial flight)

Images / Graphics

CfP#6 – Long Fiber Thrust Reverser Cascade – Safran Nacelles Topic Description

Objective: To develop an alternative Thrust reverser Cascade that offers improvements in cost and aerodynamic performance. The applicant will :-

• Assist in the DFM of a the cascades
• Manufacture demonstrator articles for test
• Assist in the testing and analysis of results

Main tasks 1. Definition phase (T0 – T3 months) i. Definition of technology issues ii. Definition of test plan 2. Manufacture and testing of sub-scale test articles. (T4 – T15) i. Prototype/ specimen manufacture ii. Mechanical testing 3. Manufacture and test of full size demonstrator articles (T16 – T30) i. Prototype/ specimen manufacture ii. Demonstrator testing 4. Anaylsis of results (T30 – T36) i. Results analysis ii. Final reporting

CfP#6 – Thermoplastic Thrust reverser cascade – Safran Nacelles Topic Description

Objective: To develop an alternative Thrust reverser Cascade that offers improvements in cost and aerodynamic performance. The applicant will :-

• Assist in the DFM of a the cascades
• Manufacture demonstrator articles for test
• Assist in the testing and analysis of results

Main tasks 1. Definition phase (T0 – T3 months) i. Definition of technology issues ii. Definition of test plan 2. Manufacture and testing of sub-scale test articles. (T4 – T15) i. Prototype/ specimen manufacture ii. Mechanical testing 3. Manufacture and test of full size demonstrator articles (T16 – T30) i. Prototype/ specimen manufacture ii. Demonstrator testing 4. Anaylsis of results (T30 – T36) i. Results analysis ii. Final reporting

CfP#6 – Advanced Turbine System Performance Improvement Through Dual-Spool Rig Tests – GEDE Topic Description

• Dual-spool turbine rig test to support

turbine vane frame (TVF) aerodynamic design maturation for UHPE architectures

• Engine-representative rig operating

conditions required (continuous, rig PR ≥ 4, TVF inlet Mach ≈ 0.3-0.5, Re ≈ 1e6)

• Detailed system (HPT, TVF, LPT) and

component performance determination for trade studies

• Advanced instrumentation (unsteady,
• ptical access) to quantify/visualize

complex component interactions

• 1,100 k€ indicative funding, 36 months

JTI-CS2-2017-CfP06 ITD-ENG

TVF design evolution

(Solano et al. 2011)

Possible TVF configurations

(Bader et al. 2014)

Planned rig layout

(Aero design, mechanical design, and hardware provided by GEDE)

CfP#6 –Development of innovative methods and tooling for machining of slender shafts– GKN

Topic Description

Summary

• New turbofan engine designs incorporate

a more slender LPT shaft and this challenges the manufacturing processes.

• This topic asks for technology development in

the areas of new intelligent and sensorized tool concept for internal machining of bottle bore geometry where the L/D is above 30. Work Packages

• Establishment of requirements and concepts for

new tool system

• Sensors, signal processing and presentation
• Tool and system design
• Demonstration and verification

CS2 Info day, 22 February 2017

WP3 TOPICS

6th Call for Proposal (CfP06) – ENGINE ITD

CfP#6 – Aerothermal characterization in the engine compartment – SafranHE Topic Description

• Numerical analysis of air flow behavior in the engine bay with transient

aerothermal coupling method.

• Unsteady numerical simulations will be performed for shutdown

conditions to analyze the air flow in the engine bay and in the engine’s internal channel.

• Network level methods and the impact on the equipments skin

temperatures will be investigated.

Strategy for simulations

CfP#6 – Advanced Instrumented Engine cradle of the Turboprop demonstrator – SafranHE Topic Description

• To Design and manufacture the engine cradle

that will support the engine on ground in the test facility.

• The purpose is to develop a light weight

engine cradle with advanced instrumentation (in particular, loads, vibrations, temperatures).

• The applicant will also propose numerical

studies over the flight envelope, focusing in particular on vibration damping and to be later compared with the tests results.

• The study shall take into account the

installation of various equipments in the engine bay (air cooling oil cooler, actuators, etc)..

Preliminary requirements for instrumentation on Engine Cradle

CS2 Info day, 22 February 2017

WP5&6 TOPICS

6th Call for Proposal (CfP06) – ENGINE ITD

CfP#6 –Intermediate Compressor Case (ICC) Duct Aerodynamics – GKN/Rolls-Royce

Topic summary

• Experimental test campaign to validate ICC

aerodynamic performance

• Second test campaign including new

technologies and innovative duct designs

• The duct flowfield will be characterized in detail

in order to provide validation data for CFD methods.

• Off-design performance will be of specific

interest to this exercise.

• Development of CFD tools, including more

advanced modelling techniques (such as hybrid LES methods) will be an important task to be able to predict part-speed performance and separation margin of the ICC duct.

Skills & capabilities

• The CfP Partner/consortium should have access

to a single-stage compressor test facility suitable for duct integration and testing.

• The compressor should be operating at

representable low/intermediate-pressure compressor rear-stage conditions. Based on pre- studies this implies flow coefficient 0.55 < Φ < 0.65, work coefficient Ψ ~ 0.3 at ADP and a hub- to-tip ratio of about 0.85.

• The preliminary duct non-dimensional

characteristics are L/Hin ~ 3.6, ΔR/L ~ 0.6 and Aout/Ain ~ 1.

• To perform the necessary loss measurements

with sufficient accuracy it is estimated that the compressor exit radius needs to be >200 mm and the duct height >40 mm.

• For a low-speed test facility it is estimated that

this setup would require a 50 kW motor and an additional 20 kW motor for the bleed extraction.

CfP#6 – IP Turbine Rear Stages Aero/Noise Rig– ITP

Topic Description

• Rear part of VHBR IP turbine, featuring

transonic aerodynamics, is key for aerodynamic and noise performance of VHBR engine

• Within

WP5.2 aeroacoustics technologies are being developed to achieved SFC and noise targets

• A 2 ½ stages high speed rig is required

for the validation of the technologies

• Aerodynamic design will be provided by

ITP to the partner

• The work to be performed in the CfP

comprises detailed design, hardware manufacturing, rig assembly and instrumentation and rig testing.

• The partner will supply all experimental

data to ITP to complete technology validation process

Images / Graphics

Vane1 blade1 Vane2 Blade2

OGV

IGV

Shaft

R~400mm 150mm

Schematic Rig Lay-out

CfP#6 – Development of non-intrusive engine emissions instrumentation capability– Rolls-Royce PLC Topic Description

• Development and

demonstration of non- intrusive measurement and 2D tomography of nvPM/soot and CO2 concentrations in aero- engine exhaust to a TRL 6 maturity

• Validation of the technology

will be through measurement

• f representative lean burn

combustion emissions and engine testing 2D tomography of Engine Exhaust Emissions

CfP#6 – Development of capability to understand & predict sub-idle & idle behaviour of geared VHBR engines – Rolls-Royce

Topic Description

• Develop methods and techniques

to predict engine performance &

• perability at sub-idle and idle.
• Identify novel methods to model,

manage & improve performance & operability at idle & sub-idle.

• Toolset to be matured to TRL6 by

validation against test data collected from UltraFan™ demonstrator program.

Compressor Characteristic Combustor Spray Characteristic Whole Engine Integration

CfP#6 – VHBR Engine – Journal Bearing Technology – Rolls-Royce Deutschland Topic Description

• Development of high-

performance journal bearings in a lightweight aero-engine epicyclic gear box supporting planet gears under high loads and speeds.

• Validation of the technology

will be through material, sub-scale bearing and engine testing Journal Bearing & Gear Journal bearing material on gear or pin

CS2 Info day, 22 February 2017

WP8 TOPICS

6th Call for Proposal (CfP06) – ENGINE ITD

CfP#6 – Advanced investigation of ultra compact RQL reverse flow combustor– GE AVIO Topic Description

Objective: Complete of Full Annular Test of a reverse flow combustor

by additive manufacturing with an advanced cooling system

The topic manager will provide a complete instrumented combustor and a dedicated rig ready for the combustion test. The applicant have to provide:

• Set of numerical models to predict and validate the experimental results
• Advanced instrumentation for metal temperature monitoring
• Test cell capable to evaluate the combustor performances

Main Tasks

1) Preparation Phase [04/18 – 03/18]

I. Test prediction using Advanced CFD modelling methodologies (LES approach) II. Test cell set up III. Innovative Aero-Thermal numerical model development (CFD coupled with thermal prediction of the metal temperature)

2) Test phase [04/18 – 10/18]

I. Execution of the combustion test with pattern factor, emission and liners metal temperature measurement

3) Validation Phase [10/18 – 09/19]

I. Test results elaboration II. Advance Aero-Thermal models validation and tuning on experimental results

Combustor swirler by additive Rig for combustion test

Innovation Takes Off

Not legally binding

Q&A

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Any questions? Info-Call-CFP-2017-01@cleansky.eu

Last deadline to submit your questions: 29th March 2017

Thank You

Not legally binding

Disclaimer The content of this presentation is not legally binding. Any updated version will be regularly advertised on the website of the Clean Sky 2 JU. Not legally binding 37