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GILD Report Summary

Project ID: 267617
Funded under: FP7-JTI
Country: Belgium

Final Report Summary - GILD (Green & Innovative Lubrication Devices)

Executive Summary:
The technical objectives of the project were:
• to design lubrication equipment's according to SAGE-2 environment conditions --> CAD activities
• to validate lubrication equipments according to SAGE-2 environment conditions --> FEA activities
• to test equipment's
• the correlate numerical models based on the test results
--> In order to achieve those objectives, CAD and FEA numerical assessments have been realized.
The main objective is to design lubrication equipement's but also to correlate numerical models with tests.

Project Context and Objectives:
a/ Background:
The economical and ecological perspectives lead to reduce the fuel consumption.
Engines manufacturers and leaders are so continuously working on new technologies breakthroughs and especially for next aircrafts generation (2015-2025).
The coming engines present more electrical devices and more bearings and gears, it is so mandatory to cool down these using available cooling sources.
Up to nowadays the usual source was the fuel that had to be heated before been used in combustion chamber. However due to the reducing of the fuel consumption, this source is not sufficient anymore and the 2nd logical cooling source is so the environment air surrounding engines and aircraft.
The intent to have access to surrounding air leads to develop new systems architecture and new lubrication systems (including heat exchanger).

b/ Rationale for the WP:
Concerning the specific needs of a counter rotating open rotor engine design (cf. goal of SAGE 2 demonstrator),the main challenges concerns:
• the conception of efficient heat exchanger.
• the FEA validation of the equipments due to harsher environment (cf. new specifications vs. classic engines ones --> t°, vibrations, blade off conditions,...).
• the optimisation of the equipments size due to low available space.

c/ Technical objectives
The technical objectives have been:
• to design equipments according to SAGE-2 environment conditions
• to validate equipments according to SAGE-2 environment conditions
• to test equipments
• the correlate numerical models based on the test results

Project Results:
During period #1 (year 2013), performed activities were related to lowest TRL equipments (cf. heat exchanger).
Documents research of the existing state-of-the-art has been realized covering technological aspects (e.g. materials, assembly, design, assessment,...)
Open Rotor SAGE-2 demonstrator specifications have been acquired and analyzed regarding the design and numerical simulation assessments.
The heat exchanger (ACOC) development plan has been defined.
Thermal and mechanical sizing of the heat exchanger (ACOC) have been realized.
Moreover, CFD numerical assessment has been realized (+ benchmark of CFD Open software solution).
Important note: due to SAGE2 requirements update, the heat exchanger activity has not been concluded to a hardware delivery (see Topic Manager for more details)

During period #2 (year 2014), performed activities were related to higher TRL equipments (cf. oil tank).
According with the Topic Manager experience legacy, in order to avoid use of elastomer dampers, a "hard mounting" configuration of the oil tank on the engine has been defined as the technical solution for Open Rotor thermal conditions.
According with this statement, it has been highlighted that the HCF dynamic behaviour was the main sensitive concern to investigate and assess.
The 2nd period has been dedicated to an oil tank test tooling specifications, design and validation (using numerical Finite Element Model) regarding correlation test.

The 3rd (ended) period has benefit from the dynamic test tooling in order to realize a bottom-up approach correlating FE mechanical model with tests results.
During the 3rd period (years 2015 & 2016), the activities carried out are:
a) WP4.1: Numerical investigation on academic cases --> good-practice rules
b) WP4.2: FEA on the single parts and vibration tests --> correlation & optimisation
c) WP4.3: FEA on assembled parts and vibration tests --> correlation & optimisation
d) WP4.4: vibration tests of the oil tank with the fluid

Potential Impact:
For GDTech, the realized activities have permitted to get added value on design and numerical (CFD & structural mechanical FEA) assessments of heat exchanger.
The acquired experience have currently been used on industrial application --> direct socio-economic benefit
However according with the Clean sky JTI aeronautical field, the final goal would be to have opportunity to deploy experience on a full scale application (including RIG test data).
Important note: in January 2014, the GDTech's activity in the GILD project have been presented to the ENOVAL project executive board (including MTU, Avio, Safran, RR,...)
The current benefits of the GILD project have been related with business case (aerospace + other industry).
In addition with the reinforcement of the relationship with the Topic Manager, the GILD research cases are presented as showcases toward new business prospect.
Currently we can already conclude that the project has a "springboard" effect on business opportunity --> e.g. there is a current joint venture with a (additive) manufacturer to design and supply oil equipment's for industry application but also for transport (automotive + aerospace) ones.

List of Websites:
Michael BRUYNEEL (Pr. Dr. Ir. Scientific director) -->

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