Life Test Optimization for Gas Turbine Engine Based on Life Cycle Information Support and Modeling †
Abstract
:1. Introduction
2. Problem Definition
- 1.
- To define the efficiency criteria of the GTE life tests.
- 2.
- To choose the main parameters of the GTE LC that will be applied in the GTE model.
- 3.
- To choose simulation software and design a GTE model of the LC.
- 4.
- To implement the series of computer-based simulations within the defined plan of experiments.
- 5.
- To find the optimal values of the life test parameters based on the LC simulation.
3. Building Statistical Model of GTE Life Cycle
- Some parameters of GTE batch selection and preparation of chosen GTE for testing CSP = [cSP1, …, cSPυ]Т;
- Characteristics of acceptance and shipment of engine processes based on testing results CCAS = [cCAS1, …, cCASξ]Т);
- Performance of special test equipment CE = [cE1, …, cEμ]Т and others.
4. GTE Life Test Optimization
5. Case Study
- Air starting of aircraft propulsion engines at airfields;
- The supply of compressed air to air-driven devices in flight during emergency use in the case of failure of the main energy sources;
- The power supply of the aircraft onboard network with AC and DC power on the ground and in flight in case of failure of the main power sources.
- Relative rotational speed of the rotor n, %;
- Engine inlet temperature tн, °C;
- Air consumption taken from the compressor Gext, kg/s;
- Fan air consumption Gfan, kg/s;
- AC and DC generators’ useful power NG1 and NG2, kw.
- The duration of the experimental tests was compared. Herewith, the maximum allowable difference in the damageability of the engine components in serial and experimental tests was set to the same value: (δD*i)exp = (δD*i)ser = 20%;
- The difference between the accumulation of damage by engine components was compared with the same test time (τLT.exp = τLT.ser).
- Damageability model of the radial thrust bearing:
- Damageability model of the turbine’s first stage rotor blade:
- Damageability models of auxiliary fan bearing, drive gear of the reducer, DC generator, and AC generator:
- The limits of the values of the parameters of the loading mode:
- Test and operational hour cost:
- Possible number of presenting for test engines (NLT∈1…3).
6. Results and Discussion
7. Conclusions
Author Contributions
Funding
Conflicts of Interest
Nomenclature
ELT | Integral efficiency of the engine life tests |
Z’DES | Design stage costs |
Z’DEV | Development stage costs |
Z’DT | Development testing costs |
Z’PR | Production stage costs |
Z’PT1 | Life testing costs |
Z’OP | Operation stage costs |
Z’PT2 | Optimized life testing costs |
Z’REP | Repair stage costs |
Z’REC | Reclamation stage costs |
ZR.DEV | Additional development costs related to risks of incorrect life tests |
ZR.PR | Additional production costs related to risks of incorrect life tests |
ZR.OP | Additional operation costs related to risks of incorrect life tests |
P0 | Vector of initial state parameters related to production (strength, wear resistance, geometry, etc.) |
NLT | Number of tested engines |
RLTς | Modes of life test loading, ς = 1, NLT |
τLTς | Duration of life test loading, ς = 1, NLT |
NOP | Number of operating engines |
ROPk | Modes of the operation loading, k = 1, NOP |
τOP | Loading time during operation, k = 1, NOP |
CSP | Parameters of GTE batch selection and preparation of chosen GTE for testing |
CCAS | Characteristics of GTE acceptance and shipment based on test results |
CE | Quality parameters of the test equipment used |
DLT | Engine damageability during life tests |
DOP | Engine damageability during operation |
КA | Life test acceleration factor |
Abbreviations | |
GTE | Gas turbine engine |
LC | Life cycle |
LT | Life test |
APU | Auxiliary power unit (R4) |
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Parameter (Description) | Given Value |
---|---|
Cycles of loading | 3000 cycles |
Stage of testing duration | 50 h |
Cycle time | 40 min |
Number of testing stages | 40 stages |
The number of cycles per stage | 30 cycles |
Total testing time | 2000 h |
Engine Part | Level of the Engine Elements Damageability Equivalence δDi, % | ||
---|---|---|---|
Serial Periodical Test | Experimental Test (δDi)LT = (δDi)OP | Experimental Test (τLT.exp = τLT.ser) | |
Turbine rotor blade | 47 | 95 | 100 |
Radial thrust bearing | 45 | 13 | 100 |
Auxiliary fan bearing | 171 | 142 | 100 |
Drive gear of the reducer | 29 | 18 | 46 |
DC generator | 110 | 110 | 48 |
AC generator | 105 | 112 | 50 |
Periodic Tests | δDi, % | τLT, Hours | CLT_OP, c.u. |
---|---|---|---|
Serial | 29.8 | 2000 | 380.1 |
Experimental (δDi)LT = (δDi)OP | 29.5 | 608 | 159.7 |
Experimental (τLT.exp = τLT.ser) | 1.1 | 2000 | 377.9 |
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Valeev, S.; Kondratyeva, N. Life Test Optimization for Gas Turbine Engine Based on Life Cycle Information Support and Modeling. Energies 2022, 15, 6874. https://doi.org/10.3390/en15196874
Valeev S, Kondratyeva N. Life Test Optimization for Gas Turbine Engine Based on Life Cycle Information Support and Modeling. Energies. 2022; 15(19):6874. https://doi.org/10.3390/en15196874
Chicago/Turabian StyleValeev, Sagit, and Natalya Kondratyeva. 2022. "Life Test Optimization for Gas Turbine Engine Based on Life Cycle Information Support and Modeling" Energies 15, no. 19: 6874. https://doi.org/10.3390/en15196874