Project description
Bearing technology for innovative gearbox
Ultra-high bypass ratio engines decouple fan and turbine speeds, which reduces environmental harm. However, diverse technological issues are associated with their implementation related to rotational speed, harsh lubrication conditions and power density. The design of the rolling bearing can affect the gearbox and engine efficiency, performance and reliability. The EU-funded BrEATHE project will develop, design, model and try a rolling bearing that will be integrated into a high-power gearbox. The team will also investigate new high loaded materials, work to develop models that predict bearing conduct, and produce samples and try them in testbeds. BrEATHE will demonstrate a reduction in power loss and oil flow and an increase in rolling contact stress capacity.
Objective
The Ultra High By-pass Ratio (UHBR) engine provides environmental benefits through a high power gearbox decoupling fan and turbine speeds. To implement such engine different technological issues raise: the increase of the i) rotational speed, ii) harsh lubrication conditions and iii) power density. The design of the rolling bearing, crucial component, can affect the gearbox and engine efficiency, performance and reliability.
The aim of BrEATHE is to develop, design, model and test a rolling bearing to be mounted in a high power gearbox, including investigation for new high loaded materials, development of models to predicts bearing behavior, producing samples and test them in dedicated test bench.
Specific project objectives are:
- To define the geometry and perform the design of the bearing. To predict heat generation and transfer in the planet bearing through interactions between dynamic and thermal behaviours.
- To demonstrate a -30% in power loss & oil flow and a 15% increase in rolling contact stress capability in comparison to the current baseline solutions and without any detrimental effect on reliability.
- To assess the benefits of different process technologies and materials in reaching the efficiency and stress capability required by the gearbox and engine architecture. Including design optimization, comparison of different case hardened steel grade coupled with ceramic rolling elements.
- To produce a sufficient number of bearings to sustain the test plan based on a dedicated test bench.
To demonstrate their enhanced performances, the BrEATHE new bearing technologies will firstly assessed through modelling and then testes in full-scale testing, with full duty cycle representing the real flight spectrum. The gained theoretical knowledge will enable the transfer and exploitation of projects results to the industrial field by providing analysis tools and new design rules.
Fields of science
Programme(s)
Funding Scheme
RIA - Research and Innovation actionCoordinator
78180 Montigny Le Bretonneux
France