Abstract: This paper studies a failure case of a fuel pressure supply tube from an aircraft engine. Multiple fracture cases of the fuel pressure control tube from aircraft engines have been reported. The studied set was composed by the mentioned tube, a welded connecting pipe, where the fracture has been produced, and a union nut. The fracture has been produced in one of the most critical zones of the tube, in a region next to the supporting body of the union nut to the connector. The tube material was X6CrNiTi18-10, an austenitic stainless steel. Chemical composition was determined using an X-Ray fluorescence spectrometer (XRF) and combustion equipment. Furthermore, the material was characterized mechanically, by a hardness test, and microstructurally using a stereo microscope and an optical microscope. The results confirmed that the material was within specifications. To determine the macrofractographic features, a visual examination and an observation using a stereo microscope of the tube fracture surface were carried out. The results revealed a tube plastic macrodeformation, surface damaged and signs of a possible corrosion process. Fracture surface was also inspected by scanning electron microscopy (FE-SEM), equipped with an energy-dispersive X-ray microanalysis system (EDX), to determine the microfractographic features in order to find out the failure mechanism involved in the fracture. Fatigue striations, which are typical from a progressive fracture by a fatigue mechanism, were observed. The origin of the fracture was placed in defects located on the outer wall of the tube, leading to a final overload fracture.
Abstract: This paper describes a method for analyzing penetration for composite material using an explicit nonlinear Finite Element Analysis (FEA). This method may be used in the early stage of design for the protection of military vehicles, aircraft engines and nuclear power plant structures made of composite materials. This paper deals with simple ballistic penetration tests for composite materials and the FEA modeling method and results. The FEA was performed to interpret the ballistic field test phenomenon regarding the damage propagation in the structure subjected to local foreign object impact.
Abstract: The authors have studied a method for analyzing containment and penetration using an explicit nonlinear Finite Element Analysis. This method may be used in the stage of concept design for the protection of external configurations or components of aircraft engines and nuclear power plant structures. This paper consists of the modeling method, the results obtained from the method and the comparison of the results with those calculated from simple analytical method. It shows that the containment capability obtained by proposed method matches well with analytically calculated containment capability.
Abstract: For scarf inlet design, the primary variable of interest is the circumferential extent over which the extended lower lip is formed. In this paper, an attempt has been made to optimize the aerodynamic shape of a subsonic scarf inlet with aerodynamically shaped center-body with a particular value of the circumferential extent. The parametric analytical studies have been carried out using a Spalart-Allmaras turbulence model. From our preliminary studies, we concluded that for a particular value of circumferential extent, there will be an exact shape of the center-body with certain geometric orientation for the existence of an aerodynamically efficient scarf inlet for modern aircraft engines. This numerical study is a pointer towards for the design optimization of scarf inlets for modern aircraft engines.
Abstract: The paper presents another structural scheme of high-temperature starter-generator with external rotor to be installed on High Pressure Shaft (HPS) of aircraft engines (AE) to implement More Electrical Engine concept. The basic materials to make this starter-generator (SG) were selected and justified. Multi-criteria optimization of the developed structural scheme was performed using a genetic algorithm and Pareto method. The optimum (in Pareto terms) active length and thickness of permanent magnets of SG were selected as a result of the optimization. Using the dimensions obtained, allowed to reduce the weight of the designed SG by 10 kg relative to a base option at constant thermal loads. Multidisciplinary computer simulation was performed on the basis of the optimum geometric dimensions, which proved performance efficiency of the design. We further plan to make a full-scale sample of SG of HPS and publish the results of its experimental research.
Abstract: This paper is devoted to solve the problem of increasing the electrification of aircraft engines by installing a synchronous generator at high pressure shaft. Technical solution of this problem by various research centers is discussed. A design solution of the problem was proposed. To evaluate the effectiveness of the proposed cooling system, thermal analysis was carried out in ANSYS software.
Abstract: Compressor fans in modern aircraft engines are of considerate importance, as they provide majority of thrust required by the aircraft. Their challenging environment is frequently subjected to non-uniform inflow conditions. These conditions could be either due to the flight operating requirements such as take-off and landing, wake interference from aircraft fuselage or cross-flow wind conditions. So, in highly maneuverable flights regimes of fighter aircrafts affects the overall performance of an engine. Since the flow in compressor of an aircraft application is highly sensitive because of adverse pressure gradient due to different flow orientations of the aircraft. Therefore, it is prone to unstable operations. This paper presents the study that focuses on axial compressor response to inlet flow orientations for the range of angles as 0 to 15 degrees. For this purpose, NASA Rotor-37 was taken and CFD mesh was developed. The compressor characteristics map was generated for the design conditions of pressure ratio of 2.106 with the rotor operating at rotational velocity of 17188.7 rpm using CFD simulating environment of ANSYS-CFX®. The grid study was done to see the effects of mesh upon computational solution. Then, the mesh giving the best results, (when validated with the available experimental NASA’s results); was used for further distortion analysis. The flow in the inlet nozzle was given angle orientations ranging from 0 to 15 degrees. The CFD results are analyzed and discussed with respect to stall margin and flow separations due to induced distortions.
Abstract: A bird strike can cause damage to stationary and
rotating aircraft engine parts, especially the engine fan. This paper
presents a bird strike simulated by blocking four stator blade
passages. It includes the numerical results of the unsteady lowfrequency
aerodynamic forces and the aeroelastic behaviour caused
by a non-symmetric upstream flow affecting the first two rotor blade
stages in the axial-compressor of a jet engine. The obtained results
show that disturbances in the engine inlet strongly influence the level
of unsteady forces acting on the rotor blades. With a partially
blocked inlet the whole spectrum of low-frequency harmonics is
observed. Such harmonics can lead to rotor blade damage. The lowfrequency
amplitudes are higher in the first stage rotor blades than in
the second stage. In both rotor blades stages flutter appeared as a
result of bird strike.
Abstract: The Canadian aerospace industry faces many
challenges. One of them is the difficulty in estimating costs. In
particular, the design effort required in a project impacts resource
requirements and lead-time, and consequently the final cost. This
paper presents the findings of a case study conducted for recognized
global leader in the design and manufacturing of aircraft engines. The
study models parametric cost estimation relationships to estimate the
design effort of integrated blade-rotor low-pressure compressor fans.
Several effort drivers are selected to model the relationship.
Comparative analyses of three types of models are conducted. The
model with the best accuracy and significance in design estimation is
retained.
Abstract: Pollution emission levels of aircraft engines are a
nowadays high concern. Any technological advance that could reduce
emission levels is always welcome. In what concerns aircraft engines,
a possible solution for this problem could be the use of regenerators
and intercoolers. These components might reduce the specific fuel
consumption, increase efficiency and specific thrust and consequently
reduce the pollution levels of the engine. This is not a novel solution.
These heat exchangers are already is use in stationary engines. For
aircraft engines, the extra weight of the needed hardware could
overcome the fuel saved. This work compares a conventional engine
with configurations that use intercoolers and regenerators.
Abstract: This paper considers the problem of scheduling maintenance actions for identical aircraft gas turbine engines. Each one of the turbines consists of parts which frequently require replacement. A finite inventory of spare parts is available and all parts are ready for replacement at any time. The inventory consists of both new and refurbished parts. Hence, these parts have different field lives. The goal is to find a replacement part sequencing that maximizes the time that the aircraft will keep functioning before the inventory is replenished. The problem is formulated as an identical parallel machine scheduling problem where the minimum completion time has to be maximized. Two models have been developed. The first one is an optimization model which is based on a 0-1 linear programming formulation, while the second one is an approximate procedure which consists in decomposing the problem into several two-machine subproblems. Each subproblem is optimally solved using the first model. Both models have been implemented using Lingo and have been tested on two sets of randomly generated data with up to 150 parts and 10 turbines. Experimental results show that the optimization model is able to solve only instances with no more than 4 turbines, while the decomposition procedure often provides near-optimal solutions within a maximum CPU time of 3 seconds.
Abstract: This paper presents the optimal controller design of
the generator control unit in the aircraft power system. The adaptive
tabu search technique is applied to tune the controller parameters
until the best terminal output voltage of generator is achieved. The
output response from the system with the controllers designed by the
proposed technique is compared with those from the conventional
method. The transient simulations using the commercial software
package show that the controllers designed from the adaptive tabu
search algorithm can provide the better output performance compared
with the result from the classical method. The proposed design
technique is very flexible and useful for electrical aircraft engineers.