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Lean design and maintenance of gas turbine engines

Based on the authors’ experience in creating new gas turbine engines and developing new designs and maintenance technologies within the framework of import substitution, the issues of organizing their lean design are briefly considered, including the optimal choice of the design appearance of a new gas turbine engine, the design of individual parts and assemblies, the influence of new technologies and material selection, the development of design documentation, and experimental confirmation of their reliability and parameters.

Keywords: GTE, lean design, lean manufacturing, additive technologies, material selection, development of design documentation, confirmation of reliability, confirmation of parameters, implementation of improving measures

Glebovitskiy M.K., Kuznetsova Ya.V., Fedorchenko D.G.

Modernization of the UDS-1 diffusion welding unit at the engine industry’s stages of technological advancement for permanent joints of dissimilar materials

The technology of joining materials by diffusion welding is examined in the paper. A modernized UDS-1 unit with a continuous loading and unloading cycle of parts is presented. The software allowing to automate this process is reviewed. The results of the sample-based research are reported.

Keywords: diffusion welding, equipment, software, process automation

Marchukov E.Y., Chuklinov S.V., Denisov L.V.

Predictive calculation of the heat resistance of nickel alloys based on incomplete data

The artificial neural network method was used to obtain the most complete, lacking in open sources information regarding changes in the heat resistance of nickel alloys, allowing for the acquisition of all missing information with a statistically significant amount of initial data. A database containing all known information about 350 grades of heat-resistant nickel alloys has been created for this purpose. The optimal configuration for an artificial neural network has been developed to calculate the missing values of the long-term strength limit. The chosen network training method provided us with the highest prediction accuracy. The database's addition allowed to obtain the dependencies between changes in the heat resistance of nickel alloys and their chemical composition, as well as the temperature-time conditions that simulate operational ones. This information greatly facilitates the comparison of alloy properties. The resulting computing system, which includes a database and a mathematical model of changes in the heat resistance of nickel-based alloys, is able to predict the properties of the developed compositions even before pilot smelting and testing.

Keywords: heat-resistant nickel alloy, artificial neural network, prediction of properties, long-term strength limit

Tyagunov A.G., Milder O.B., Tarasov D.A.

Prospective directions for improving of rotorcraft transmissions

The paper presents a review of the main directions for the development of scientific and technological advances aimed at improving transmission quality indicators of promising rotary-wing aircraft. The questions of applying topological and parametric optimization methods in helicopter transmission design in order to reduce their specific weight are considered. Approaches to improving the reliability and service life of aircraft transmissions through the use of on-board diagnostic systems are described. Layouts and design solutions for multithreated adjustable transmissions in promising rotorcrafts with hybrid propulsion systems are proposed.

Keywords: rotorcraft, helicopter, gearbox, variable transmission, multithreaded transmission, variable gear ratio, topological optimization, parametric optimization, weight and size characteristics, service life, reliability, health and usage monitoring

Kalinin D.V.

Application of topological optimization to determine design parameters of the mount for an aircraft piston engine

The article considers the design features of attachment points for engines and propulsion systems specific to various types of aircraft engines: turboprop, turbojet, and piston (APE). The main load factors determining the design features of the attachment points of multi-cylinder in-line APEs are considered. The main factors in determining the loads on APE mounts are non-uniformity of operation and torque. The proposed approach using topological optimization in the development of APE mounts makes it possible to significantly reduce design time. As a result of topological optimization, a longeron-type mount for the APE-based propulsion system was designed.

Keywords: aircraft piston engine, propulsion system, engine mount, topological optimization

Kostyuchenkov A.N., Karyakin S.D., Kretinin R.I.

Thermal calculation of an electrically driven impeller for a regional aircraft’s distributed propulsion system

The article presents the results of computational studies carried out to determine the thermal state of an electric motor’s elements and a control unit’s power switches of an electrically driven impeller intended for installation on a flap of a regional aircraft’s high-lift system. The amount of heat generated by these elements in the impeller’s most demanding loading conditions is determined. Technical solutions to reduce heat generation are shown.

Keywords: distributed propulsion system, electric motor, electrically driven impeller, thermal calculations

Ovdienko M.A., Varyukhin A.N., Vlasov A.V., Brailko I.А., Lebedev A.O., Rat’kov I.V., Egoryan A.D.

Global trends in the development of electric propulsion systems based on high-temperature superconductors

The article gives an overview of the global developments in the application of high-temperature superconductors (HTS) for propulsion systems of future aircraft. The main emphasis is made on modern projects of superconductivity application for electric motors with high specific power, as well as electric power buses. The review summarizes the most promising approaches for cryogenic cooling as well as electrical machine layout. The projects are compared in terms of predicted power and specific characteristics, design and cooling method of HTS windings, as well as implementation timing and achieved results. A forecast is also given for the mass-dimensional characteristics of superconductor-based electric power buses as part of an electric or hybrid propulsion system. Based on the data from the reviewed projects and the characteristics achieved in modern electric machines without cryogenic cooling, a conclusion is made about the niche feasibility of HTS solutions, particularly when cryogenic hydrogen is available on board as a fuel.

Keywords: electric propulsion system, hybrid propulsion system, electric motor, high-temperature superconductivity

Yarmola A.P., Kalitka V.S.

Review of fan noise reduction technologies applied to the propulsion system of a supersonic civil aircraft

A review of foreign and domestic studies in fan noise reduction technologies for supersonic civil aircraft is presented. Different fan configurations have been under consideration: single fan rotor; two-stage fan; fan with initial and increased gap between rotor and inlet guide vane; rotor blades of swept back and swept shape. Estimations of noise reduction systems are presented. Different options of engine installation were considered to evaluate the effect of shielding, that is, “engine behind the wing”, “engine before the wing”, “engine over the wing” and “engine under the wing”. The dependence of the shielding effect on the distance between the nozzle and the tailunit of the plane is shown.

Keywords: supersonic civil aircraft, acoustics, turbofan, single-stage fan, two-stage fan, propulsion system, jet stream, noise shielding, sound-absorbing system

Khaletskii Iu.D., Pochkin Ia.S.

Analysis of design and manufacturing factors affecting the deviation of turbine tip clearances from the calculated values

The design and manufacturing factors that have the greatest influence on the deviation of turbine tip clearances from the calculated values are analyzed in this paper. The analysis is based on experimental data and verified mathematical models. The following factors have been highlighted: manufacturing and assembly accuracy; thermal state and displacement of case parts associated with the turbine case; installation of sector parts with reduction of circumferential clearances to zero; circumferential non-uniformity of case temperatures. A quantitative assessment of each factor’s influence is provided, and methods for minimizing the deviation of radial clearances from calculated values are described.

Keywords: turbine, tip clearance, tip clearance deviations, irregularity of tip clearances, active clearance control

Samoylenko N.A., Kashin N.N.