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Innovation Takes Off 1
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
3
• 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 of 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
ENG
INE
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
UltraFanTM
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
PAI (WAL, requirement definition and integration with SAT GAM)
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
16
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 on 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 on 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, optical 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
Van
e1
bla
de1
Van
e2
Bla
de2
OGV
IGV
Shaft
R~4
00
mm
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 of 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 & operability 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
35
Any questions?
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
