Overview
The Project GREENBARRELS aimed to find out a way to produce 360º components for aircraft engines by spinning methods, such as: spinning lathe, flowforming, shearforming. In particular the manufacturing of barrels for CROR propellers of SAGE2 ITD was assessed. The materials to be used for this development were Inconel718 and Titanium Alloy.
Thus, the project looked for a cost effective way of producing barrels of about 1 m. diameter in these alloy. The project included barrels design and looked to verify compliance with certification requirements of design and process. The aim was to get a process to replace intensive energy consuming processes and also to get a process with almost non-waste material.
Funding
Results
Executive Summary:
The aircraft manufacturers need to find higher engine efficiency with much lower fuel consumptions. For this target, several developments have been launched by engine manufacturers. One of the most amazing engines from the architecture point of view is the so called the Contra Rotating Open Rotor. This engine is to be proven to save 30% fuel consumption over successful engines such as CFM56.
To prove this the SAGE 2 in CLEANSKY was the Integrated Technology Demostrator initiative in which a full engine was developed to carry out a Ground test managed by the CS engine leader’s companies. A Consortium of two organisations from Spain, was formed to develop from the conceptual design up to the delivery of rotating barrels to the SAGE 2 Open Rotor Demo Engine. These components were in the contra rotating area on a highly vibrational contra rotating environment and high thermally stressed as well. The weight constraint is a capital requirement to meet the full weight goal of the engine. These constraints and the multitude of interfaces has made the GREENBARRELS project of a high complexity R&T.
The Greenbarrels project, led by EURECAT (former ASCAMM) and with partner Industrias Puigjaner (Denn), had to consider the following main components functions, for transition and aero ducts (technical name for the barrels in the Open Rotor engine):
Transition ducts:
- To channel the flow of main hot gases stream to the exhaust;
- To channel the secondary airstream (together with rotating cowls).
Aero ducts:
- To channel cooling air for the lubrication oil.
During the project is has been addressed different work steps with the aim to achieve the final target. The steps can be summarized as:
- Analysis of requirements;
- Selection of architecture for the barrels;
- Material and process detailed selection;
- Risk analysis continuous monitoring;
- Selection and analysis of concept for the Concept Review (CoR);
- Performing all preliminary design phase;
- Carrying out manufacturing trials;
- Passing the Preliminary Design Review (PDR);
- Carry out Critical Design Phase;
- Pass CDR;
- Perform manufacturing, control and delivery of all barrels’ part to SAGE 2 OPEN ROTOR Demo Engine;
- To research about manufacturing techniques that allows minimal chip removal.
With this approach the project had fully achieved the marked objectives and all components were assembled in the demo engine.