Innovation Takes Off clean sky 2

Transcription

1 Infoday ENGINES ITD Innovation Takes Off clean sky 2

2 ENGINES ITD Major Demonstrators WP2 WP3 WP4 WP5 & 6 Ultra High Propulsive Efficiency (UHPE) demonstrator for Short/Medium Range aircraft TRL 5+ mid 2023 Business aviation / short range Regional Turboprop Demonstrator TRL 5 in 2022 Advanced Geared Engine Configuration (LPT technology demonstration) TRL 5 in 2023 Ultrafan Very High Bypass Ratio (VHBR) Turbofan demonstrator TRL WP7 WP8 WP9 Light weight and efficient jet fuel 6 cylinder reciprocating engine TRL MAESTRO Reliable and more efficient operation of small turbine engines TRL 5 in 2019 Life Cycle inventories for several engine manufacturing technologies, allowing to fully quantify and potentially optimize the actual eco benefit and Life Cycle Impact of these technologies.

3 ENGINES ITD consortia overview Rolls Royce plc Rolls Royce Corporation Rolls Royce Controls and Data Services Limited ANSYS UK GE Aviation Systems Limited University of Nottingham Safran Aero Boosters GKN Aerospace Norway GKN Aerospace Services GKN Aerospace Sweden GKN Aerospace Applied Composite Aero Gearbox International MTU Aero Engines Polska General Electric Company Polska Leaders Participating affiliate Airbus Operations SAS Airbus SAS Safran Aircraft Engines Safran Transmission Systems Safran Helicopter Engines Societe Lorraine De Construction Aeronautique Safran SAS Societe de Motorisations Aeronautiques Safran Nacelles Akira Technologies SARL ONERA Price Induction MTU Aero Engines DLR FhG Rolls Royce Deutschland GE Marmara Technology Centre MT Propeller Entwicklung NLR GE Aviation Czech Avia Propeller Core Partner Participating affiliate Desarrollos Mecánicos de Precisión Egile Corporation XXI Industria de Turbo Propulsores ITP Next Generation Turbines ITP Externals 6/11/2018 Piaggio Aero Industries GE AVIO Srl Nuovo Pignone GE Marmara Technology Centre 3

4 WP2 Programme Overview UHPE (Ultra High Propulsive Efficiency) attends to design, develop, build and ground test a scale 1 demonstrator engine for Short / Medium range passenger aircraft. The target engine architecture is an Ultra High Bypass Ratio turbofan (ducted architecture) having a by pass ratio preliminary anticipated within the range WP2 is aimed to procure TRL 5 6 maturation mid 2023 for a set of specific technologies dedicated to Ultra High Propulsive Efficiency concept.

5 WP2 - To answer the UHBR challenges Mechanical Integration Engine Dynamics More electric engine ICF, TRF and SHAFT improvements Overall Engine cycle optimization Best modules performance and operability Whole Engine Thermal Studies Oil System design Carcass Distorsion

6 CfP09 Proposed Topics: ENG ITD JU Topic # Title Work Package Project Duration Strategic Topic Leader Action Type Topic Value ( ) JTI CS CFP09 ENG JTI CS CFP09 ENG JTI CS CFP09 ENG JTI CS CFP09 ENG Measurement of rotor vibration using tip timing for high speed booster certification and quantification of associated uncertainties Turbulence modeling of heat exchange and roughness impact Ground vortex characterization & simulation Additive manufacturing boundary limits assessment for Eco design process optimization (ECO) WP2 36 WP2 36 WP2 24 WP9 Safran Aero Boosters Safran Aero Boosters Safran Aircraft Engines RIA RIA RIA 600k 500k 750K Safran Aircraft Engines RIA 1500k CS2 Info Day CfP09 Brussels (08/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

7 JTI CS CFP09 ENG Turbulence modeling of heat exchangers and roughness impact Innovation Takes Off clean sky 2

8 JTI CS CFP09 ENG WP 2.5.4: Oil Equipments Leader : Safran Aero Boosters Contributor : Safran Aircraft Engines Title: Turbulence modeling of heat exchangers and roughness impact Objective: For geared turbo fan engine architectures, the thermal management will be one of the most important challenge to face. The heat exchangers are the main products that drive the performances of the thermal management system and the additive manufacturing (AM) has a great potential to optimize their global efficiency. However, new numerical modellings are needed to predict correctly the aerothermal performances of these AM innovative geometries with unusual roughness. Thus, the aim of this call proposal is to manage the turbulent behavior and the roughness in AM heat exchangers in order to optimize their aero performances. Volume: 600 k funding CS2 Info Day CfP09 Brussels (08/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

9 JTI CS CFP09 ENG Schedule/Milestones WP 1 WP 2 WP 3 WP 4 WP 5 Identification of physical parameters and CFD modeling Modelization of test cases incompressible internal rough flow Modelization of test cases compressible internal rough flow Modelization of two fluids AM heat exchangers Benchmark of LES modelization on test cases rough flow Year 1 Year 2 Year 3 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Targeted applicant: Applicants will be experts in Computational Fluid Dynamics (CFD) and particularly in turbulent flow modelling with multi physics interactions. They shall demonstrate their skills detailing their activities, own bibliographic references and description of relevant past projects. Required skills: Strong expertise in fluid numerical simulations and analysis is required : Aerodynamic, Fluid Dynamics and Aerothermal High Performance Computing for Computational Fluid Dynamics (CFD) simulations Large Eddy Simulation Aerothermal simulation coupling conduction Laminar to turbulent flow simulations Knowledge of AM process and impact on geometries Required capabilities: In house computing facilities to performs the tasks In house CFD tolls : for RANS simulations, the ANSYS Fluent solver (version>18.1) and for LES simulations, the YALES 2 solver. CS2 Info Day CfP09 Brussels (08/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

10 JTI CS CFP09 ENG Measurement of rotor vibration using tip timing for high speed booster certification and quantification of associated uncertainties Innovation Takes Off clean sky 2

11 JTI CS CFP09 ENG WP 2.5.5: Booster Leader : Safran Aero Boosters Contributor : Safran Aircraft Engines Title: Measurement of rotor vibration using tip timing for high speed booster evaluation of associated uncertainties Objective: Build and validate a complete chain of sensors, acquisition system and tools to permit measurement of rotor vibration for high speed booster blades. To sustain certification of high speed booster using this measurement topology, uncertainties have to be quantified. These uncertainties remain important/unknown for low pressure compressors, due to the numbers of (known or unknown) parameters (clearances, axial positioning, temperature, ) which are not taken into account by actual systems, methodologies or algorithms and also due to the quality of the acquired signal, not homogeneous and down sampled resulting in a complex post processing. With the goal of avoiding telemetry/slip ring system to perform certification, those uncertainties have to be known and quantified to insure safety and margin of the low pressure compressor. A validation test should be performed on a representative low pressure compressor rig test vehicle provided by the Topic manager organisation. Volume: 500 k funding CS2 Info Day CfP09 Brussels (08/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

12 JTI CS CFP09 ENG Schedule/Milestones D1 D2 D3 D4 Identification of physical parameter (intermediate) D1.1 Identification of physical parameter (intermediate) D1.2 Identification of physical parameter (final Modelization of physical parameter influences (intermediate) D2.1 Modelization of physical parameter influences (intermediate) D2.2 Modelization of physical parameter influences (intermediate) Tip timing chain design and implementation D3.1 Tip timing chain design D3.2 Tip timing chain implementation Tip timing chain validation D4.1 Tip timing chain validation D4.2 Tip timing chain uncertainties determination Year 1 Year 2 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Targeted applicant: Applicants will be experts in tip timing and especially in processing and analyzing its signals. They shall demonstrate their skills by detailing their activities, their own bibliographic references and by describing their relevant past projects. Required skills: Knowledge on non homogeneous under sampled signals Knowledge on synchronous & asynchronous phenomena observed in boosters Knowledge on uncertainties quantification Capability to build analytical and semi empirical models of vibration behavior of blades Capability to adapt acquisition system and associated softwares (mainly Human Machine Interface) Capability to design post processing softwares Required capabilities: Test bench & representative high speed rotor Software development tools CS2 Info Day CfP09 Brussels (08/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

13 JTI CS CFP09 ENG Ground vortex characterization & simulation Innovation Takes Off clean sky 2

14 JTI CS CFP09 ENG When a turbojet engine operates at ground conditions, ground vortices can form and be ingested by the engine intake. This is typically the case with high crosswinds. Knowing the characteristics of these vortices is critical for the aeromechanical design of fan blades : Vortex strength (vorticity, tangential speed) Appearance conditions (wind speed, massflow) Eventhough ground vortices can be simulated and analyzed with CFD tools, validation of such studies is challenging : deploying the necessary instrumentation tools on an engine test survey is incompatible with the integration constraints (stress, intrusiveness, cost) CS2 Info Day CfP09 Prague (10/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

15 JTI CS CFP09 ENG Goal of this CFP topic : to develop a methodology to characterize a ground vortex during an engine test survey, with tools compatible with the test constraints (stress, intrusiveness, cost) CFP 09 Engine test campaign SoA study CFD test plan CFD simulations XWind Engine test Classic+ instrumentation Test matrix Test setup spec/design Wind tunnel test Classic instrumentation Wind tunnel test HiFi instrumentation Method CFD simulations? Vortex Data Wind tunnel facility has to be compatible with characteristics provided in the topic description document Test setup : inlet geometry will be provided by Safran; a metallic model can also be provided (scale 6.5 used in Onera F1 WT). No fan is required, provided targeted inlet massflows are effectively generated CFD simulations will be made at different stages of the project to i) define the test matrix and instrumentation location, ii) mature the targeted methodology and iii) produce numerical data to compare with test results CS2 Info Day CfP09 Prague (10/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

16 JTI CS CFP09 ENG Additive manufacturing boundary limits assessment for Eco design process optimization (ECO) Innovation Takes Off clean sky 2

17 JTI CS CFP09 ENG Additive manufacturing (AM) is a key technology for improved design and production process of aviation parts Applied to heat exchangers, it could dramatically improve global eco efficiency through access to radically new designs and open new horizons in terms of shape, weight, efficiency Nevertheless, a lot remains to be done in order to perfectly master all the design and manufacturing process, as heat exchangers are complex and critical parts. Key questions such as capability of AM to manufacture thin walls, resulting surface roughness, resulting mechanical strength The objective of this CfP, proposed by Safran in the frame of EITD ECO topics, is to enhance the basic knowledge of AM capability to manufacture thin layers, and consequently be able to optimize heat exchanger design process Source : 3Dprintingindustry.com March 2018 (design by Bremen University and printed by the MetalFAB1) CS2 Info Day CfP09 Prague (10/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

18 JTI CS CFP09 ENG CfP content : Manufacturing and characterization of selected samples based on a DOE approach Variation of selected parts characteristics such as wall thickness, layer thickness, finishing process, wall orientation, scanning strategy, scanning speed Various parts geometry (from basic geometry to more complex one) according to the type of characterization. Geometries to be finalized with the contractor. Skills needed : single partner or Consortium gathering additive manufacturing capability, part characterization. Expertize in material properties modelling would be a plus CS2 Info Day CfP09 Prague (10/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

19 Wall thickness Wall surface state Design and manufacturin g cost AM Heat exchanger Eco Design optimization Mechanical strength global shape and compacity weight Heat exchanger efficiency