Overview
The ATOS project addressed innovative transmission and oil system concepts in commercial aero-engines. It seeked to develop profitable and sustainable business in the EU through innovative concepts and technologies in response to Key Action 4 'New Perspectives in Aeronautics' within the 'GROWTH' programme.
The technical objectives were to develop innovative products such as hybrid (ceramic) bearings, electrically driven oil pumps and innovative dual-alloy shaft technology, as well as optimised design methods for aero-engine bearing chamber design, two-phase flow separation, and oil fire prevention.
The work comprised the detailed definition of experimental set-ups, system configurations and test schedules for all work packages. Rig experiments were conducted to define most promising bearing materials. Full size hybrid bearings have been manufactured and successfully tested under aero-engine representative operating conditions. Feasibility of an electrostatic sensor has been investigated to detect onset of wear.
Two-phase flow in a typical bearing chamber has been experimentally and numerically studied. Focus was on droplet generation by bearings and modelling of wall film flow. Rig experiments on bearing chamber sealing have been conducted to characterise flow conditions during leakage. Auto-ignition temperatures of oils and ignition delays have been measured under elevated pressures and varied boundary conditions.
Funding
Results
Prototypes of electrically driven oil pumps were designed, manufactured, and tested for function. In order to develop shafts that can sustain higher torque at given dimensions, buckling and dual alloy shafts have been experimentally investigated. Predictive tools such as CFD and Finite Element codes were validated to measured data.
Technical Implications
The project results should have contributed to more efficient, reliable, and lighter transmission components and systems as well as to optimised tools and methods. This shall enable aero-engine manufacturers and airlines to increase product performance, efficiency, and reliability, reduce development and operating costs, and time to market.