Infoday – ENGINES ITD

Innovation Takes Offhttp://www.cleansky.eu/content/homepage/about‐clean‐sky‐2

Business aviation / short range Regional Turboprop 

DemonstratorTRL 5 in 2022

Advanced Geared Engine Configuration (LPT 

technology demonstration)TRL 5 in 2023

Ultrafan® ‐ Very High Bypass Ratio (VHBR) 

Turbofan demonstratorTRL 6 ‐ 2023

WP2 WP3 WP4 WP5 & 6

Ultra‐High Propulsive Efficiency (UHPE) demonstrator for Short/Medium Range aircraftTRL 5+ mid‐2023 

Light weight and efficient jet‐fuel 6‐cylinder 

reciprocating engineTRL 6 ‐ 2019

MAESTRO ‐ Reliable and more efficient operation of small 

turbine enginesTRL 5 in 2019

WP7 WP8

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.

WP9

ENGINES ITD ‐Major Demonstrators

6/11/20183

Desarrollos Mecánicos de Precisión Egile Corporation XXIIndustria de Turbo PropulsoresITP Next Generation Turbines ITP Externals

Rolls‐Royce plcRolls‐Royce CorporationRolls‐Royce Controls and Data Services LimitedANSYS UKGE Aviation Systems LimitedUniversity of Nottingham

Airbus Operations SASAirbus  SASSafran Aircraft EnginesSafran Transmission SystemsSafran Helicopter EnginesSociete Lorraine De Construction AeronautiqueSafran SASSociete de Motorisations AeronautiquesSafran NacellesAkira Technologies SARL ONERAPrice Induction 

GKN Aerospace SwedenGKN Aerospace Applied Composite

MTU Aero EnginesDLRFhGRolls Royce DeutschlandGE Marmara Technology CentreMT‐Propeller EntwicklungNLR

Aero Gearbox InternationalMTU Aero Engines PolskaGeneral Electric Company Polska

Piaggio Aero Industries GE AVIO SrlNuovo Pignone

GE Aviation Czech Avia Propeller

Leaders

Participating affiliate

Participating affiliate

Core Partner

GE Marmara Technology Centre 

GKN Aerospace NorwayGKN Aerospace Services

Safran Aero Boosters 

ENGINES ITD – consortia overview

WP2 Programme Overview

UHPE (Ultra High Propulsive Efficiency) attends to design, develop, build and ground test ascale 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 15‐20.

WP2 is aimed to procure TRL 5‐6 maturation mid‐2023 for a set of specific technologiesdedicated to Ultra High Propulsive Efficiency concept.

WP2 - To answer the UHBR challenges

Mechanical Integration Engine Dynamics

Overall Engine cycle optimizationBest modules’ performance and operability

Whole Engine Thermal Studies

Oil System design

ICF‐, TRF‐ and SHAFT improvements 

More electric engine

Carcass Distorsion

CfP09 Proposed Topics: ENG ITD

CS2 Info Day CfP09 – Brussels (08/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

JU Topic # Title Work Package

Project Duration

Strategic Topic Leader Action Type Topic Value 

(€) 

JTI‐CS2‐2018‐CFP09‐ENG‐01‐39

Measurement of rotor vibration using tip timing for high speed booster certification and quantification of associated uncertainties

WP2 36 Safran Aero Boosters  RIA 600k

JTI‐CS2‐2018‐CFP09‐ENG‐01‐40

Turbulence modeling of heat exchange and roughness impact

WP2 36 Safran Aero Boosters  RIA 500k 

JTI‐CS2‐2018‐CFP09‐ENG‐01‐41

Ground vortex characterization & simulation

WP2 24 Safran Aircraft Engines  RIA 750K

JTI‐CS2‐2018‐CFP09‐ENG‐01‐42

Additive manufacturing boundary limits assessment for Eco design process optimization (ECO)

WP9Safran Aircraft 

Engines  RIA 1500k

JTI‐CS2‐2018‐CFP09‐ENG‐01‐39

Turbulence modeling of heat exchangers and roughness impact

Innovation Takes Offhttp://www.cleansky.eu/content/homepage/about‐clean‐sky‐2

JTI‐CS2‐2018‐CFP09‐ENG‐01‐39

CS2 Info Day CfP09 – Brussels (08/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

• 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

JTI‐CS2‐2018‐CFP09‐ENG‐01‐39

CS2 Info Day CfP09 – Brussels (08/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

• Schedule/Milestones

• Targeted applicant: Applicants will be experts in Computational Fluid Dynamics (CFD) andparticularly in turbulent flow modelling with multi‐physics interactions. They shall demonstrate theirskills 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 .  

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

WP 1 Identification of physical parameters and CFD modeling

WP 2 Modelization of test cases incompressible internal rough flow

WP 3 Modelization of test cases compressible internal rough flow

WP 4 Modelization of two fluids AM  heat exchangers

WP 5 Benchmark of LES modelization on test cases rough flow

Year 1 Year 2 Year 3

JTI‐CS2‐2018‐CFP09‐ENG‐01‐40

Measurement of rotor vibration using tip timing for high speed booster certification and quantification of 

associated uncertainties

Innovation Takes Offhttp://www.cleansky.eu/content/homepage/about‐clean‐sky‐2

JTI‐CS2‐2018‐CFP09‐ENG‐01‐40

CS2 Info Day CfP09 – Brussels (08/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

• 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 permitmeasurement of rotor vibration for high speed booster blades. To sustain certification of high speedbooster 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 oralgorithms

• and also due to the quality of the acquired signal, not homogeneous and down‐sampledresulting in a complex post processing.

– With the goal of avoiding telemetry/slip ring system to perform certification, those uncertainties haveto 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 vehicleprovided by the Topic manager organisation.

• Volume: 500 k€ funding

JTI‐CS2‐2018‐CFP09‐ENG‐01‐40

CS2 Info Day CfP09 ‐ Brussels (08/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

• Schedule/Milestones

• Targeted applicant: Applicants will be experts in tip timing and especially in processing and analyzing itssignals. They shall demonstrate their skills by detailing their activities, their own bibliographic referencesand 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

Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4D1 Identification of physical parameter (intermediate)

D1.1 Identification of physical parameter (intermediate)D1.2 Identification of physical parameter (final

D2 Modelization of physical parameter influences (intermediate)D2.1 Modelization of physical parameter influences (intermediate)D2.2 Modelization of physical parameter influences (intermediate)

D3 Tip‐timing chain design and implementationD3.1 Tip‐timing chain designD3.2 Tip‐timing chain implementation

D4 Tip‐timing chain validationD4.1 Tip‐timing chain validationD4.2 Tip‐timing chain uncertainties determination

Year 1 Year 2

JTI‐CS2‐2018‐CFP09‐ENG‐01‐41

Ground vortex characterization & simulation

Innovation Takes Offhttp://www.cleansky.eu/content/homepage/about‐clean‐sky‐2

JTI‐CS2‐2018‐CFP09‐ENG‐01‐41

CS2 Info Day CfP09 – Prague (10/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

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)

JTI‐CS2‐2018‐CFP09‐ENG‐01‐41

CS2 Info Day CfP09 – Prague (10/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

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

Method

XWind Engine test‘Classic+’ instrumentation

CFD simulations ?

Vortex Data

CFD simulations

Wind‐tunnel test‘HiFi’ instrumentation

Wind‐tunnel test‘Classic’ instrumentation

•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

SoA study

Test matrix

Test setup spec/design

CFD test plan

JTI‐CS2‐2018‐CFP09‐ENG‐01‐42

Additive manufacturing boundary limits assessment for Eco design process optimization (ECO)

Innovation Takes Offhttp://www.cleansky.eu/content/homepage/about‐clean‐sky‐2

JTI‐CS2‐2018‐CFP09‐ENG‐01‐42

CS2 Info Day CfP09 – Prague (10/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

• 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.comMarch 2018(design by Bremen University and printed by the MetalFAB1)

JTI‐CS2‐2018‐CFP09‐ENG‐01‐42

CS2 Info Day CfP09 – Prague (10/10); Toulouse (26/10); Bilbao (30/10) and Lisbon (22/11)

• 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

Wall thicknessWall 

thickness

Wall surface state

Wall surface state

Mechanical strength

Mechanical strength

weightweight

Heat exchanger efficiency

Heat exchanger efficiency

global shape and 

compacity

global shape and 

compacity

Design and manufacturin

g cost

Design and manufacturin

g cost

……

AM Heat exchanger Eco‐Design optimization