Overall scheme of civil turbofan engine with large bypass ratio
Break through key technologies and improve independent research and development capabilities. Based on the next generation advanced civil turbofan engine with 14 ton thrust, through pre-research and international cooperation, the design, processing and testing of components, systems, core machines and verification machines have been completed, which has broken through the key technologies of civil turbofan engine and basically possessed the independent research and development capability. On the basis of the verification machine, according to the market and aircraft demand, a large bypass ratio civil turbofan engine with independent intellectual property rights and market competitiveness is developed to meet the power demand of the development of trunk passenger aircraft in China, enter the market and gradually form an industry.
Main technical indicators: takeoff thrust14000 kgf; ; Cruise fuel consumption: no more than 0.56kg/(kgf.h) (h =11km, m = 0.8); The emission level of noise and harmful substances meets the airworthiness standards at that time; The comprehensive performance level of life, reliability and maintainability is better than that of the current CFM56 engine, and it is equivalent to its successor engine.
Key technology of turbofan engine with large bypass ratio
Main design key technologies
For military and civil turbofan engines with large bypass ratio, except for environmental protection, service life and economy, other main design technologies are the same, including the whole, components, system, whole machine and simulation. Therefore, the key technologies are studied in combination, mainly including:
(1) overall scheme design technology of large bypass ratio engine (including take-off synthesis and economic analysis);
(2) Civil engine airworthiness technology;
(3) Design technology of fan/booster stage with large bypass ratio;
(4) High-efficiency and advanced compression ratio compressor design technology;
(5) Design technology of low-emission long-life combustion chamber;
(6) Design technology of high-pressure and low-pressure turbines with high performance and long service life;
(7) Design technology of engine nacelle and thrust reverser;
(8) Core machine design technology;
(9) Design technology of verification machine;
(10) integrated numerical simulation technology of the whole machine/parts;
(1 1) Design technology of numerical control system for turbofan engine with large bypass ratio;
(12) Low noise design technology;
(13) Design technology with long life, high reliability and maintainability;
(14) bearing and transmission lubrication system design technology;
(15) Fault diagnosis and monitoring technology;
(16) turbine active clearance control technology;
(17) design technology of auxiliary power unit (APU).
Materials and technology
The military turbofan engine with large bypass ratio mainly adopts the existing mature materials and processes, but there are still some special requirements for the manufacture of some key parts (such as large fan blades, casing, etc.). ), this is a problem that needs to be solved. Compared with turbofan engines, civil large ductwork has higher technical requirements, more requirements for airworthiness certification, and more new materials and new processes are needed to meet the design requirements. The main materials and technical items to be solved in the development of large bypass ratio turbofan engine for military and civilian use include:
(1) manufacturing technology of hollow blades (titanium alloy or composite materials) of large-scale wide-chord fans;
(2) Casting, welding and manufacturing technology of large titanium alloy intermediate shell;
(3) Manufacturing and repairing technology of titanium alloy blisk/shroud;
(4) Manufacturing technology of composite material containing ring;
(5) Processing technology of arc tenon and groove of fan disk;
(6) Precision casting technology of three-dimensional bending-torsion combined turbine guide vanes;
(7) Precision casting technology of high aspect ratio low-pressure turbine blades with directionally solidified crowns;
(8) The inherent balance technology of fan rotor and engine;
(9) The processing technology of fan shell coating;
(10)600℃ high temperature resistant titanium alloy material engineering and manufacturing technology;
Low-cost manufacturing technology of (1 1) nickel-based superalloy blisk:
(12) Low-cost integral casting technology for combustion chamber shell;
(13) floating wall material of flame tube and its manufacturing technology;
(14) coating of high-pressure turbine blades and guide blades and its coating process;
(15) Low-cost materials, casting and stamping processes of single crystal turbine blades resistant to 1 100℃;
(16) Low-cost material, casting and stamping process of turbine guide vane with 1 100℃ resistance;
(17) Grinding, forging process and defect detection of grinding wheel.
Testing and testing technology
Compared with the military small bypass ratio turbofan engine, the large bypass ratio turbofan engine needs to improve the existing test equipment and technology because of the increase of size, flow and thrust. Because of the large bypass ratio turbofan engine, especially the civil large bypass ratio turbofan engine, a large number of special airworthiness tests, such as swallowing test, containment test and environmental test, are needed to meet the requirements of airworthiness regulations. Therefore, it is necessary to study the special test technology required by turbofan engine with large bypass ratio and formulate the corresponding test methods and specifications while stepping up the construction of relevant test equipment. Mainly includes:
(1) testing and debugging technology of the whole machine;
(2) Engine thrust test technology;
(3) Engine bird-throwing test technology;
(4) Test technology of engine swallowing water, ice and sand;
(5) Engine crosswind and headwind test technology;
(6) Measurement technology of engine noise field;
(7) Fan blade containment test technology;
(8) Life and reliability test technology of components and the whole machine.
Key technical solutions and measures.
Civil turbofan engine with large bypass ratio
Organize and implement the key technology research plan of advanced civil turbofan engine with large bypass ratio as soon as possible, and use 10 years or so to break through and master the key technologies, consolidate the technical foundation and improve the independent innovation ability through the development of components/systems/core machines/verification machines in combination with international cooperation. Then, on the basis of the verification machine, the civil turbofan engine with large bypass ratio with independent intellectual property rights, contemporary level and airworthiness certificate is further developed.
Research on Key Technologies and Development of Verifier
(1) engine overall scheme design and parts design, processing and testing. Complete the overall scheme design and performance analysis and calculation of the engine, numerical simulation analysis of aerodynamic/thermal performance of the whole machine/component, sketch design and material selection scheme of the engine scheme, and design technical indicators and parameter requirements of each component and system; Complete the overall/component/system specimen design and test, component strength life design and analysis, material selection and key processing technology design, component/system comprehensive numerical simulation analysis, auxiliary power device design and test, etc.
(2) Engineering design, processing and test verification of core machine and verification machine. Complete the engineering design and processing of the core machine and the verifier, the ground simulation test of the core machine, the performance adjustment test of the ground bench of the verifier, the 300-hour endurance test of the ground bench, the simulation test of the cruising performance of the high-altitude platform (H= 1 1km, M=0.8) and some airworthiness standard tests (such as noise and low pollution emissions).
4.2.2 Prototype development and airworthiness evidence collection
On the basis of verifying the performance of the aircraft high-altitude platform in the first stage, a prototype was developed according to the specific requirements of the main passenger aircraft engine in China, and the type certificate, production license and airworthiness certificate were obtained.
4.3 Actively carry out international cooperation
There is still a big gap between China's aviation power industry and the world's advanced level, especially in the aspect of large bypass ratio turbofan engine technology, the foundation is very weak, there is a lack of technical reserves, a large number of key technologies have not been broken through and mastered, there is no engineering experience, the gap between materials and technology is even greater, the test equipment is not matched, and high-level talents are lacking. It is very difficult to develop an advanced turbofan engine with large bypass ratio in a short time. To this end, we must strengthen the foundation, innovate independently, reform and open up, and actively carry out international cooperation with external forces.
At the same time, it should be noted that international cooperation in developing civil aviation engines has become a major trend in the world today. In order to raise funds, complement each other in technology, reduce risks and expand the market, even large state-owned companies are taking the road of cooperative development and expressing their intention to cooperate with us. Although there are still many contradictions and risks, the peaceful and open international environment provides favorable conditions for the international cooperation of turbofan engines with large bypass ratio.
Years of practice have proved that most key design technologies can be learned through technical cooperation with Russia, which cannot be achieved through cooperation with western countries. In addition, Russia has shown a strong willingness to cooperate with me. Therefore, in the research and development of key technologies and verification machines, it is important to pay close attention to cooperation with Russia. At the same time, we will strengthen the existing cooperation with the West in various ways, and constantly explore new ways of cooperation. Through commercial cooperation with the West, we will speed up the development of model products and enter the international market as soon as possible.
4.4 Strengthen the construction of basic conditions such as materials, processes and tests.