Final Report Summary - GTFTR (Geared Turbofan Test Rig) Executive Summary:The Geared Turbo Fan engine represents one of the most promising architectural innovations in the aeronautical market, which meets the requirements of constant improvement in engine performance in terms of fuel consumption, noise and gas emission.The concept on which this engine architecture is based involves the mechanical uncoupling of the turbine shaft from the fan section, by means of introducing an epicyclic Power Gearbox (PGB), named Integral Drive System (IDS). By adding a further degree of freedom to the system, this solution allows the separate optimization of both power turbine and fan in terms of rotational speed, with overall enhancement of the whole engine performanceAs a result, the IDS represents a new engine core module.In accordance with objectives defined by the Topic Manager (TM) in the call for proposal (CfP), the present GTFTR project aims at performing a demonstration on a full scale power rig of the technologies developed by the TM within the Clean Sky frame.The approach proposed by the Topic is innovative since it opens the collaboration on the experimental validation phase, which is generally retained by the system design responsible being strongly close to the design, with an external Partner.Therefore the opportunity given to the Consortium is to demonstrate its capability to propose itself as a technological partner which can be useful for promoting future collaboration.The Consortium is strongly interested to establish long lasting collaborations focused on development of advanced technologies for transmission systems like future geared engines.The collaboration between the TM and the Consortium could move forward behind the project conclusion.Such future collaboration could leverage the GTFTR project results including sharing of the developed test rig as required by the CfP Topic, through forms to be agreed (inclusive but not limited to transfer of property).The research theme proposed by the CfP Topic meets the scientific interests and the strategic aims of Consortium Partners.The participation to the GTFTR project is in accordance with the strategic proposition of the Partners, which have already experience of successful collaborations among them and intend to reinforce the existing relationship.In agreement with this approach DICI has already launched an initiative to enhance the capability of its experimental center by means of a new test facility dedicated to both power transmissions and rotordynamics. This initiative, developed with the support of important international Companies is also supported by Tuscany Region.Project Context and Objectives:Geared configuration for engine represents one of the most promising architectural innovations in the aeronautical market, considerably increasing the opportunity to improve engine performances. The concept on which the geared engine architecture is based involves the mechanical uncoupling of the turbine from the fan section, byintroducing a PGB – Power GearBox. By adding a further degree of freedom to the system, this solution allows the optimization of either power turbine or the fan performances in terms of rotational speed, with an overall enhancement of the whole engine efficiency. The IDS architecture has to envisage sophisticated and distinctive interfaces (mechanical, fluidic, functional) with the engine, therefore the experimental evaluation of its performance has to be carried out in a complex test environment that is able to:• reproduce the distinctive interface conditions typical of the real installation environment of the test article;• reproduce the complex and interdependent time history of the test parameters (e.g. speed, load, lubricant flow-rate and temperature);• ensure proper behaviour of the IDS during the test, for instance avoiding unwanted dynamic coupling or instabilities.The research theme proposed met the scientific interests and the strategic aims of Consortium Partners:• University of Pisa – Department of Civil and Industrial Engineering (DICI), a centre of excellence, with high level multidisciplinary scientific competences in the field of advanced mechanical power transmissions;• AM Testing srl (AMT), founded in 2008 as a spinoff of University of Pisa. The core business is the design of high performance test rig including support systems and the execution of relevant comprehensive test campaigns on components/systems;• Catarsi Ing. Piero & c. srl (CAT), leader Company in the field of manufacturing of precision mechanic devices. CAT business has grown over the last 40 years and now the Company can provide the most innovative production systems and control/measuring machines.The proposed approach is innovative since it opens the collaboration with external partners on the experimental validation phase, which is generally retained by the system design responsible being strongly close to the design.Project Results:The work plan is structured into 7 technical work packages, a Management work package and a Dissemination work package:WP1 - Preliminary Rig DesignWP2 - Detailed Rig DesignWP3 - Rig ProcurementWP4 - Test Facility AdaptationWP5 - Rig Integration & CommissioningWP6 - IDS TestWP7 - IDS Post TestWP8 - ManagementWP9 – Dissemination.The back to back power rig has been designed together with all required test bed equipment systems (WP1, WP2).The test rig has been completely procured and delivered (WP3). Two power gearboxes, provided by Avio Aero, have been installed in the test rig (D3.2 – Test Article andSlave gearboxes procurement, Topic Manager). One of these, the Test Article gearbox, has a dedicated instrumentation.In parallel to the rig development, a new Test Facility has been built and made available by the University of Pisa for rig installation. The Test Facility is the result of a different research project, co-funded by Tuscany Region and sponsored by other important international Companies.Dedicated adaptation activities (WP4) have been performed in order to allow the installation and the operation of the test rig.After the test rig installation in the test facility, the main commissioning activities (WP5) have been:• verification that the required performances are reached;• test rig characterization and identification of optimal testing regimes.In WP6, several detailed test procedures for the execution of the functional tests in agreement with the test plan were defined.The planned tests were carried out and the experimental data were validated. The tests conducted in steady state regime were mainly aimed to reach the following bjectives:• to validate the experimental apparatus;• to evaluate the IDS performances in terms of efficiency;• to evaluate the LSF (Load Sharing Factor);• to evaluate the performances of the IDS oil system.Tests carried out in transient regime (load and speed ramp) were dedicated to the experimental investigation of the operating envelope and to the complete characterization of the system dynamic response.In WP7, the main carried out activities have been:• the preparation of a validated database of experimental data;• the analysis of the experimental data;• the final reporting and the means of evidence about the carried out experimental activities.A complex testing system was developed and commissioned. The carried out experimental activity enabled the Topic Manager to the validatation of the SAGE4 architecture. The system is suitable and ready for the execution of further expermental activities.Potential Impact:Get Future project contributes to reach ACARE and Horizon 2020 environmental goals by enabling, through the maturation of the IDS module, the development of next generation engine architectures.In addition, testing on power rig can contribute to enhancement of general purpose technologies, like the selection of next generation materials, which can be applied to other gearboxes or other transmission systems with the aim at improving the overall product performances. List of Websites:http://www.gtftr.euCoordinator contact details: Immacolata VivaLargo Lucio Lazzarino 2, 56126 Pisa (PI) - ITALY+39 0502217833 i.viva@ing.unipi.itMarco BeghiniLargo Lucio Lazzarino 2, 56126 Pisa (PI) - ITALY+39 0502218016 m.beghini@ing.unipi.itParticipating members contact details:AM TESTING SRL http://www.amtesting.it/Salvatore ManconiVia Padre Eugenio Barsanti n.10 56121 Pisa (PI) - ITALY+39 050 316 0001s.manconi@amtesting.netinfo@amtesting.netCATARSI ING. PIERO & C.http://www.catarsisrl.it/Rebecca CatarsiVia T. Romagnola, km.17 56012 Fornacette (PI) - ITALYTel. +39-0587-420090Fax. +39-0587-420414rebecca@catarsisrl.it Related documents final1-gtftr-publishable-summary-rev-00.pdf
