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SHEFAE 2 Report Summary

Project ID: 690808
Funded under: H2020-EU.3.4.

Periodic Reporting for period 2 - SHEFAE 2 (Surface Heat Exchangers For Aero Engines 2)

Reporting period: 2017-02-01 to 2018-01-31

Summary of the context and overall objectives of the project

The project aim is to develop and demonstrate lighter and more efficient integrated heat exchanger systems for the turbofan engine. Currently in turbofan engines, heat exchangers are used to cool the oil that is supplied to the bearing chambers and generators. They contribute to achieving the best engine performance by maintaining oil and fuel temperatures within defined limits. In the future, core temperatures of turbofans will be higher leading to extensive use of heat exchangers in order to get the very lowest levels of fuel burn to reduce the environmental impact of aviation. Therefore development of compact, lightweight and low cost heat exchanger systems is required. In this context, research and development activities are foreseen, to assess, develop, design and manufacture:

High Length to depth ratio Surface Air Cooled Oil Coolers;
Utilisation of engine structural components for thermal cooling;
Robust mounting systems to integrate the high length to depth Surface Air Cooled Oil Cooler on the turbofan engine;
High efficiency Fuel Oil Heat Exchanger;
High reliability Modulating Oil Bypass Valve that is integrated within the Fuel Oil Heat Exchanger.

The heat exchanger systems will be tested on the rig and Rolls-Royce demonstrator engines to validate their performance and structural capabilities. The integration of the high length to depth ratio Surface Air Cooled Oil Coolers on the engine will require a robust mounting system to tolerate the induced stresses due to thermal and vibrational loads. Advanced manufacturing capability will be developed for the designs of the high length to depth ratio Surface Air Cooled Oil Coolers and the Fuel Oil Heat Exchanger with the integrated Modulating Oil Bypass Valve.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

At the outset of the first period the requirements for the project and the components were established and the necessary functional and geometrical specifications were established. This led to the formation of numerous concept designs for the Surface Air Cooled Oil Cooler (SACOC) and it's mounting system, in addition the specifications informed the early concept studies for the Fan Outlet Guide Vane Coolers (FOGVCs). By the end of the first period Preliminary Design Reviews (PDRs) were held for the SACOC and Mounting System to down-select the concept to go forward to the detailed design phase. In addition to concept down-select there has been production of prototype components and some testing carried out to validate the computational modelling used to predict the performance of the coolers. Through the second period the concepts have been further refined, a single concept for the SACOC has been selected and developed to final design, as well as the mounting system. Some geometrical changes to the engine installation location led to a redesign in the mounting system, increasing the complexity by reducing the available space. A preliminary Critical Design Review (CDR) was conducted towards the end of period 2, following this further work has been conducted into the reaction of the cooler and mountings under loading, further FEA is to be completed early in period 3 before a final CDR.

Concepts have been generated and analysed for the FOGVCs and down-selected to a proposed component to manufacture to determine the feasibility of such a design, the validation testing will also validate some of the CFD modelling that has been conducted.

Specifications have been communicated in period 2 for the Fuel Oil Heat Exchanger (FOHE) and Modulating Oil Bypass Valve (MOBV) which will be studies as part of enhancements to the overall oil system. Some prototype parts have been manufactured in period 2 following communication of the specifications, with subsequent testing conducted to understand the current and potential capabilities of the components.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The activity to date has focused on determining the current state of the art as well as defining the requirements for future technologies which will improve upon the current standard and work towards a reduction in fuel burn leading to environmental benefits. Concepts have been produced for all of the products under consideration and have been down-selected to the most likely candidates. Some further work is now being carried out to progress these concepts to the final review.

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