Periodic Reporting for period 4 - BEATTI (BEaring Advanced Technologies for Turboprop engine Innovation)
Reporting period: 2020-07-16 to 2021-08-15
Turboprop engine is the key to contribute to the EU competitiveness growth as well as to tackle the important commitment of sustainable and green transport (ENG programme). This innovation will be clearly addressed by the bearings that are directly involved in power efficiency and reliability, highly crucial for the engine development.
BEATTI project proposes advanced bearings (in term of material and design) with improved dynamic and thermal behaviours, resistance to harsh environment, such as corrosion, particle pollution and poor lubrication condition.
The BEATTI project is thus “the development of advanced bearing solutions, enablers for the next generation of Turboprop engines that will overcome current bearing performances.
BEATTI is full in line with the Clean Sky 2 programme supporting the key Societal Challenge i.e. ‘smart, green and integrated transport’ defined in H2020 and thereby supporting society’s needs for strengthening global industry leadership.
It will enable cutting edge bearing solutions for further gains in decreasing fuel burn, CO2, NOX, noise emissions and contribute to the renewed ACARE SRIA.
BEATTI project contributes to the development of Turboprop engine, strategic for EU to be more competitive on the market and thus to European aeronautical industry and specifically to Helicopter turboshaft engine.
BEATTI project contributes to the raising of the Technology Readiness Level (TRL) of the proposed bearing technologies
The new bearing technologies development had the following main objectives in comparison with the corresponding baseline technologies solutions:
• Increase of contact pressures capacities
• Increase of bearing life in oil off condition
• Better behaviour against spalling
• Reduction o skidding
With the advanced monitoring solution put in place, the testing campaign could put in evidence some performance advantages of proposed technologies respect the baseline ones.
BEATTI project proposes advanced bearings (in term of material and design) with improved dynamic and thermal behaviours, resistance to harsh environment, such as corrosion, particle pollution and poor lubrication condition.
The BEATTI project is thus “the development of advanced bearing solutions, enablers for the next generation of Turboprop engines that will overcome current bearing performances.
BEATTI is full in line with the Clean Sky 2 programme supporting the key Societal Challenge i.e. ‘smart, green and integrated transport’ defined in H2020 and thereby supporting society’s needs for strengthening global industry leadership.
It will enable cutting edge bearing solutions for further gains in decreasing fuel burn, CO2, NOX, noise emissions and contribute to the renewed ACARE SRIA.
BEATTI project contributes to the development of Turboprop engine, strategic for EU to be more competitive on the market and thus to European aeronautical industry and specifically to Helicopter turboshaft engine.
BEATTI project contributes to the raising of the Technology Readiness Level (TRL) of the proposed bearing technologies
The new bearing technologies development had the following main objectives in comparison with the corresponding baseline technologies solutions:
• Increase of contact pressures capacities
• Increase of bearing life in oil off condition
• Better behaviour against spalling
• Reduction o skidding
With the advanced monitoring solution put in place, the testing campaign could put in evidence some performance advantages of proposed technologies respect the baseline ones.
At the beginning of the project, the activities were started with the strategy analysis of the introduction of a new bearing technology, the technologies that will be deployed in BEATTI were also selected and confirmed with the topic manager.
From that point, different aspects of the development were put in place.
First of all, the test plan for the technologies assessment was prepared considering the tests to perform and the instrumentation. Advanced monitoring solutions to put in place during the testing campaigns were selected and developed in order to maximise the testing results. The objective is to be able to measure directly on the bearings. Bearing geometry (grooves, holes machining) and specific embedded instrumentation were developed and successfully delivered. In complement to the instrumentation activities, specific testing tooling was also designed and manufactured taking in account the testing objectives and the instrumentation specificities.
On the bearing technologies side, the detailed design process of the bearings was carried on.
The new technologies development was conducted and frozen, reaching the adequate maturity level for the implementation in the bearing demonstrators.
For that purpose, a strong focus has been put on the bearing rings new material development with processes setup up definition and specific characterization tests realisation.
In parallel of the technologies development, the process to realize the bearing prototypes was put in place.
Bearings calculations and drawing preparation were conducted to confirm the design and the expected performances of the new material bearings demonstrators.
All the prototypes were successfully manufactured. They corresponds to ten bearings references for both bearing type covered by the project, with a total quantity of around 80 samples.
Some references were delivered to the topic manager for engine testing assessment and the others to the SKF testing department for their performance assessment.
And finally, the testing campaign was put in place in SKF testing facilities in the last part of the project period in order to assess the innovative bearings compared to same geometry baseline bearings.
The testing campaign could put in evidence some performance advantages of hybrid technologies versus baseline bearings, behaviour in case of oil off interruption and contribution to lower frictional power losses.
Concerning corrosion, the hybrid bearings with carburized stainless steel showed also much better resistance, also higher the rolling contact fatigue compare to baseline versions.
For the dissemination activities, the main topic concerns bearing material for Aerospace application and with a focus on the heat treatment applied on the innovative material introduced in the BEATTI prototypes, presenting advantages regarding corrosion and resistance to harsh environment. This will also constitute the base of the exploitation study of such bearings made with this steel in combination with ceramic rolling elements.
And finally, the results of the BEATTI testing campaign will also be exploited for other research activities regarding power loss assessment.
From that point, different aspects of the development were put in place.
First of all, the test plan for the technologies assessment was prepared considering the tests to perform and the instrumentation. Advanced monitoring solutions to put in place during the testing campaigns were selected and developed in order to maximise the testing results. The objective is to be able to measure directly on the bearings. Bearing geometry (grooves, holes machining) and specific embedded instrumentation were developed and successfully delivered. In complement to the instrumentation activities, specific testing tooling was also designed and manufactured taking in account the testing objectives and the instrumentation specificities.
On the bearing technologies side, the detailed design process of the bearings was carried on.
The new technologies development was conducted and frozen, reaching the adequate maturity level for the implementation in the bearing demonstrators.
For that purpose, a strong focus has been put on the bearing rings new material development with processes setup up definition and specific characterization tests realisation.
In parallel of the technologies development, the process to realize the bearing prototypes was put in place.
Bearings calculations and drawing preparation were conducted to confirm the design and the expected performances of the new material bearings demonstrators.
All the prototypes were successfully manufactured. They corresponds to ten bearings references for both bearing type covered by the project, with a total quantity of around 80 samples.
Some references were delivered to the topic manager for engine testing assessment and the others to the SKF testing department for their performance assessment.
And finally, the testing campaign was put in place in SKF testing facilities in the last part of the project period in order to assess the innovative bearings compared to same geometry baseline bearings.
The testing campaign could put in evidence some performance advantages of hybrid technologies versus baseline bearings, behaviour in case of oil off interruption and contribution to lower frictional power losses.
Concerning corrosion, the hybrid bearings with carburized stainless steel showed also much better resistance, also higher the rolling contact fatigue compare to baseline versions.
For the dissemination activities, the main topic concerns bearing material for Aerospace application and with a focus on the heat treatment applied on the innovative material introduced in the BEATTI prototypes, presenting advantages regarding corrosion and resistance to harsh environment. This will also constitute the base of the exploitation study of such bearings made with this steel in combination with ceramic rolling elements.
And finally, the results of the BEATTI testing campaign will also be exploited for other research activities regarding power loss assessment.
The main technical results of this proposal are to provide bearing technologies for improved performance compare to the baseline bearings references, such as:
• Increase of contact pressures capacities in ideal and degraded running conditions.
• Increase of bearing life in oil off condition
• Better behaviour against spalling
• Better dynamic behaviour
The technologies proposed by the BEATTI project will allow a breakthrough in terms of rolling bearing performance and design possibilities with higher reliability in harsh environment.
Multi scale testing and monitoring system allows a better understanding about performances and more specifically about potential failure phenomenon.
The first part of the testing campaign already showed better performance of the innovative bearings.
The impact of the project could concern turboprop and next generation of turboshaft engines development with the objectives of the Clean Sky 2 programme in terms of environmental benefits and European competitiveness.
For example, bearing with lower power losses will directly contribute to engine efficiency with a reduction of fuel consumption and CO2/NOX emissions.
Bearings, more resistant to harsh environment, such as particle contaminated oil, corrosion favourable conditions, will be more reliable. They could become a contributor to the improvement of engine maintenance interval providing positive environmental and economic impacts.
Once fully developed, the technologies could also be used in other aero engine applications with other bearing geometries, other loading conditions, such as main shaft bearings, power gearbox bearings …, where the resistance to harsh environment is also a key factor.
So BEATTI project contributes to strengthen the European competence in rolling bearings and the development of new Turboprop/turboshaft engine, and corresponding European Aerospace manufacturers global competitiveness
And finally regarding the education impact, BEATTI project has also been promoting education with the involvement of a university/research centre, for instance for bearing rings material heat treatment development activity and with the participation of a student for an internship regarding BEATTI bearing performance simulation.
• Increase of contact pressures capacities in ideal and degraded running conditions.
• Increase of bearing life in oil off condition
• Better behaviour against spalling
• Better dynamic behaviour
The technologies proposed by the BEATTI project will allow a breakthrough in terms of rolling bearing performance and design possibilities with higher reliability in harsh environment.
Multi scale testing and monitoring system allows a better understanding about performances and more specifically about potential failure phenomenon.
The first part of the testing campaign already showed better performance of the innovative bearings.
The impact of the project could concern turboprop and next generation of turboshaft engines development with the objectives of the Clean Sky 2 programme in terms of environmental benefits and European competitiveness.
For example, bearing with lower power losses will directly contribute to engine efficiency with a reduction of fuel consumption and CO2/NOX emissions.
Bearings, more resistant to harsh environment, such as particle contaminated oil, corrosion favourable conditions, will be more reliable. They could become a contributor to the improvement of engine maintenance interval providing positive environmental and economic impacts.
Once fully developed, the technologies could also be used in other aero engine applications with other bearing geometries, other loading conditions, such as main shaft bearings, power gearbox bearings …, where the resistance to harsh environment is also a key factor.
So BEATTI project contributes to strengthen the European competence in rolling bearings and the development of new Turboprop/turboshaft engine, and corresponding European Aerospace manufacturers global competitiveness
And finally regarding the education impact, BEATTI project has also been promoting education with the involvement of a university/research centre, for instance for bearing rings material heat treatment development activity and with the participation of a student for an internship regarding BEATTI bearing performance simulation.