Final Report Summary - LIGHT-TANK (Feasibility study and prototypes manufacturing of oil tank in thermoplastic for Helicopter Engine)
Executive Summary:
The LIGHT-TANK projects is framed in the CLEANSKY program and it is intended to show manufacturing feasibility of some rotocraft engine components
For this, teh following steps will be carried out:
• To select material and process for manufacturing prototypes of oil tank and pipes to show manufacturing feasibility
• To perform redesign phase
• To perform manufacturing of pipes and tank prototypes,
• To control the prototypes
• To deliver to TM five prototypes of tank and 5 prototypes of pipes
Project Context and Objectives:
The LIGHT-TANK projects is framed in the CLEANSKY program and it is intended to show manufacturing feasibility of some rotocraft engine components
The main objectives of the project LIGHT-TANK were:
• To show feasibility of manufacturing an oil tank in thermoplastics according with the following main drivers:
1. Thermoplastic material
2. General dimensions: 400mm x 450mm x 150mm
3. Differential pressure between internal and external: 15 kPa
4. Oil temperature range: -50ºC; +120ºC with a normal working temperature of 80ºC
5. Compliant with HTS (High thermal stability) oils, fuel, cleaning agents
6. Oil tank integrating equipments mountings (oil filling plug, draining plug and oil level sight indicator)
• To show feasibility of manufacturing two type of pipes in thermoplastic according with the following main drivers:
a) Thermoplastic material
b) General dimensions: Ø= 10-15 mm; L= 400-500 mm
c) Pressure range 150 kPa to 700 kPa
d) Oil temperature range: -50ºC; +120ºC with a normal working temperature of 80ºC
e) Compliant with HTS (High thermal stability) oils, fuel, cleaning agents
f) Pipes ((oil flow circulation) to connect the gearbox casing and the oil pump to the tank
To split project objectives by WP:
• WP1 => Select materials and confirm process selection as well as cost estimations for the parts
• WP2 => Define design guidelines, according to received specifications and perform material characterization
• WP3 => Finalize a design compatible with specification document, global objectives and manufacturing constraints for the oil tank
• WP4 => Finalize a design compatible with specification document, global objectives and manufacturing constraints for the pipes and connectors. It is worthwhile to mention that instead of two pipes, for oil circulation, finally four pipes geometries were supplied by TM, where two of them did not have clear integration to the pipes and tank under development, nevertheless the four pipes and connectors have been designed and prototyped by ASCAMM.
• WP5 => Design and Manufacture the tooling for rotomolding and manufacture the 5 oil tank for delivery
• WP6 => Design and Manufacturing of tooling required for manufacturing the pipes and the connectors and manufacture the 5 pipes with connectors integrated for delivery.
• WP7 => Perform a list of control test to give an initial view of the quality of produced prototypes and a view of next steps for a hypothetic industrialization phase.
• WP8 => Report in very summarized way the work performed during the full project development (Final Report)
All project objetives were achieved and prototypes delivered to the Topic Manager of this CfP of CLEANSKY.
Project Results:
Material and processes were selected
Cost comparative was also achieved and provided
Guidelines for design were written and followed
Material characterization was carried out and reported
Tank design following the new material and manufacturing process was followed, achieved and delivered.
Final pipe design was achieved and delivered.
The tooling for manufacturing and the manufacturing itself of oil tank have been achieved.
The tooling for manufacturing pipes and connectors and the manufacturing itself of pipes and connectors and its integration have been achieved.
The validation of components by a number of tests and extra CAE have been achieved.
The management tasks of WP8 have been achieved.
Potential Impact:
The potential impacts are fundamentally:
Less fuel consumption
Recyclable components
Potetiality to extend the application developed here to other markets and sectors
Relevant contact is:
Angel Lagraña
Market and Project Manager for Aeronautics
e-mail: alagrana@ascamm.com
phone: +34648725077
The LIGHT-TANK projects is framed in the CLEANSKY program and it is intended to show manufacturing feasibility of some rotocraft engine components
For this, teh following steps will be carried out:
• To select material and process for manufacturing prototypes of oil tank and pipes to show manufacturing feasibility
• To perform redesign phase
• To perform manufacturing of pipes and tank prototypes,
• To control the prototypes
• To deliver to TM five prototypes of tank and 5 prototypes of pipes
Project Context and Objectives:
The LIGHT-TANK projects is framed in the CLEANSKY program and it is intended to show manufacturing feasibility of some rotocraft engine components
The main objectives of the project LIGHT-TANK were:
• To show feasibility of manufacturing an oil tank in thermoplastics according with the following main drivers:
1. Thermoplastic material
2. General dimensions: 400mm x 450mm x 150mm
3. Differential pressure between internal and external: 15 kPa
4. Oil temperature range: -50ºC; +120ºC with a normal working temperature of 80ºC
5. Compliant with HTS (High thermal stability) oils, fuel, cleaning agents
6. Oil tank integrating equipments mountings (oil filling plug, draining plug and oil level sight indicator)
• To show feasibility of manufacturing two type of pipes in thermoplastic according with the following main drivers:
a) Thermoplastic material
b) General dimensions: Ø= 10-15 mm; L= 400-500 mm
c) Pressure range 150 kPa to 700 kPa
d) Oil temperature range: -50ºC; +120ºC with a normal working temperature of 80ºC
e) Compliant with HTS (High thermal stability) oils, fuel, cleaning agents
f) Pipes ((oil flow circulation) to connect the gearbox casing and the oil pump to the tank
To split project objectives by WP:
• WP1 => Select materials and confirm process selection as well as cost estimations for the parts
• WP2 => Define design guidelines, according to received specifications and perform material characterization
• WP3 => Finalize a design compatible with specification document, global objectives and manufacturing constraints for the oil tank
• WP4 => Finalize a design compatible with specification document, global objectives and manufacturing constraints for the pipes and connectors. It is worthwhile to mention that instead of two pipes, for oil circulation, finally four pipes geometries were supplied by TM, where two of them did not have clear integration to the pipes and tank under development, nevertheless the four pipes and connectors have been designed and prototyped by ASCAMM.
• WP5 => Design and Manufacture the tooling for rotomolding and manufacture the 5 oil tank for delivery
• WP6 => Design and Manufacturing of tooling required for manufacturing the pipes and the connectors and manufacture the 5 pipes with connectors integrated for delivery.
• WP7 => Perform a list of control test to give an initial view of the quality of produced prototypes and a view of next steps for a hypothetic industrialization phase.
• WP8 => Report in very summarized way the work performed during the full project development (Final Report)
All project objetives were achieved and prototypes delivered to the Topic Manager of this CfP of CLEANSKY.
Project Results:
Material and processes were selected
Cost comparative was also achieved and provided
Guidelines for design were written and followed
Material characterization was carried out and reported
Tank design following the new material and manufacturing process was followed, achieved and delivered.
Final pipe design was achieved and delivered.
The tooling for manufacturing and the manufacturing itself of oil tank have been achieved.
The tooling for manufacturing pipes and connectors and the manufacturing itself of pipes and connectors and its integration have been achieved.
The validation of components by a number of tests and extra CAE have been achieved.
The management tasks of WP8 have been achieved.
Potential Impact:
The potential impacts are fundamentally:
Less fuel consumption
Recyclable components
Potetiality to extend the application developed here to other markets and sectors
Relevant contact is:
Angel Lagraña
Market and Project Manager for Aeronautics
e-mail: alagrana@ascamm.com
phone: +34648725077