Geared Fan

VKI Aero Engine Design

Gnter Wilfert
Brussels, March 6, 2008

Content
Introduction Environmental and Economic Challenges

The Geared Turbo Fan Concept

Opportunities and Challenges for the GTFTM

The Low Spool Components Gearbox & LPT

Technology Validation

Summary

3/20/2008

G. Wilfert

Next Generation Requirements

No. of Airports with Noise Restrictions

400
350

No. Airports

300

Take-Off and Landing procedures

Limitation of flight movements
Fees
Absolute noise limits (no permission)
Quota regulation

Criteria

Existing Engine

Objective

Base

> -12%

-2 to -4 dB rel. ICAO stg. 4

> - 20dB rel ICAO stg. 4

-40% rel ICAO96

-60% rel ICAO 96

Maintenance Cost

Base

> - 30%

Reliability

Base

Zero Target (no IFSDs)

250

Fuel Burn

200

Noise
Emissions

150
100
50

Source: P&W

0
1980
Total number:
Thereof US/CND:
Europe:
Asia:

3/20/2008

1994
595
310
168
47

G. Wilfert

2000

Source: The Boeing Company,

595 airports in database (2000)

Noise Reduction
Stage 3

Generation
BPR=5-8

- 30 EPNdB

Reference
(Stage 4)

ACARE
Target

SIL

EN

en

Ro
to

4th Generation BPR >8

CE
R

VIT
AL

5th Generation BPR>10

Turbo Fan
Geared

1995
3/20/2008

DR
EA

3rd

- 40 EPNdB

Noise [EPNdB cum.]

Op

2000
G. Wilfert

2005

2010

Year

2015

Turbo
Fan

2020

2025
4

Increased BPR to reduce SFC

1,2

Fuel Burn

EIS

1,1

90
ren
s T
d

VITAL Objective
Up to +4 on
Optimal BPR

0,9

0,8

BREAKTHROUGH

EIS 80's & 90's

(Long Range)

BPR

0,7
4
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G. Wilfert

12

16
5

Effects of Increased Bypass Ratio

EIS = Engine In Service
30%

Weight/Thrust
25%

EIS up to 80's
EIS 90's

90

S
EI

80

10%

nd
e
Tr

Tr
Re
en
fe
re
d
nc
e
Tr
en
d

15%

BREAKTHROUGH

20%

EI
S

5%

BREAKTHROUGH

0%
-5%

BPR
-10%
4

10

11

12

13

14

+4
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G. Wilfert

Technology Requirements to Reduce Engine Noise

Noise Level EPNdB

Increase of Bypass Ratio

Development of Noise Absorbers
10 dB

Low Noise Components

Total Noise

Engine Component
Noise
(Fan ~ n5)

Turbofan

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G. Wilfert

Jet Noise
(~ vStrahl8)

GTF/ UHBR

10

15

Bypass Ratio, BPR

Turbo Fan Engine Concepts with Varying Bypass and Fan Pressure Ratio

Direct Drive
Turbofan

Fan Pressure Ratio

1,8
1,6

V2500-A5

1,4

Geared
Turbofan

GP7000

Counter
Rotating
Fan
Un-ducted
Fan

Geared TF

1,2

1
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Advanced
Turbofan

G. Wilfert

13
17
21
Bypass Ratio

90

100
8

Content
Introduction Environmental and Economic Challenges

The Geared Turbo Fan Concept

Opportunities and Challenges for the GTFTM

The Low Spool Components Gearbox & LPT

Technology Validation

Summary

3/20/2008

G. Wilfert

Limits of a Conventional Engine Concept

Blade tip speed limited by
Aerodynamics and noise, max. 430 m/s (Target 300 - 350 m/s)

Larger fan requires the

LP shaft to have:
Less revolutions

Fan
LPC

HP-Comp.

Comb.

HPT

LPT

Larger rotational moment

LP Shaft

(Fan)
(Fan)Shaft
Shaftdiameter
diameterlimited
limitedby
bythe
theHPT
HPTbore
borediameter
diameter
Solution:
Solution: Gearing
Gearingbetween
betweenFan
Fanand
andLP
LPShaft
Shaft

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G. Wilfert

10

Ducted Direct Drive Turbofan Noise, TSFC and Fuel Burn Trends

Noise

High

TSFC

todays
direct drive
turbofans

Low LP spool speed drives

increased weight and contributes
to increased Fuel Burn

Fuel Burn
Noise
TSFC
Fuel Burn

Direct Drive
Turbofan

advanced
component
efficiencies

Low
Low BPR
(High FPR)

Lower Flow Specific Thrust

(Larger Fan Diameter)

state-of-the-art
component
efficiencies

High BPR
(Low FPR)
Source: P&W

3/20/2008

G. Wilfert

11

Geared Fan as Enabler of High Bypass Ratio Turbofan Engines

High

Noise
TSFC

Noise
TSFC
Fuel Burn

todays
direct drive
turbofans

Fuel Burn

next generation
noise targets

Direct Drive
Turbofan

Geared
Turbofan

Low
Low BPR
(High FPR)

Lower Flow Specific Thrust

(Larger Fan Diameter)

High BPR
(Low FPR)
Source: P&W

3/20/2008

G. Wilfert

12

Content
Introduction Environmental and Economic Challenges

The Geared Turbo Fan Concept

Opportunities and Challenges for the GTFTM

The Low Spool Components Gearbox & LPT

Technology Validation

Summary

3/20/2008

G. Wilfert

13

Lower Fan Speed improves Engine Noise

Noise dB

Noise ~u4Tip
dB
Geared
Conventional

Fan-Speed
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G. Wilfert

14

Gearbox Allows LP Turbine Optimization

10

High speed LPT

with Gearbox
without Gearbox

~3xn

with Gearbox
without Gearbox

LPT Speed

Expansion Ratio, ER

Turbine Efficiency

9
8
7
6
5
4

conventional LPT

3
2
1
1

Stage No.

Optimization
long range

3/20/2008

Fuel burn
CO2 - Emission

G. Wilfert

Manufacturing/
Maintenance cost

Optimization
short range

15

Content
Introduction Environmental and Economic Challenges

The Geared Turbo Fan Concept

Opportunities and Challenges for the GTFTM

The Low Spool Components Gearbox & LPT

Technology Validation

Summary

3/20/2008

G. Wilfert

16

Fan Drive Gear System for GTF

MAIN FEATURES:

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G. Wilfert

10-30 MW Power Range

Single Stage Planetary

Spur and Bi-Helical Gears

High Gear Pitchline Velocity

High pv Journal Bearings

17

Fan Drive Gear System for GTF

3/20/2008

G. Wilfert

18

P&W Reduction Gearbox In Service Experience

PT6A

29,338 engines in service

> 235 Million operating hours
on Journal Bearings

PW100

4,845 engines in service

> 70 Million operating hours
on Ball/Roller Bearings

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G. Wilfert

PT6T

8,169 engines in service

> 33 Million operating hours
on Journal Bearings

Sikorsky Helicopters

Gear Reduction Units

to 10,000 SHP

19

Gearbox Transmitted Power at Takeoff Operation

Power [kSHP]

40
30
20
10

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G. Wilfert

MTR390

PT6

Tyne

TP400

ATFI - 1

D27

NK12

NK 93

NGSA

ADP

20

More than 20 Years Of Fan Drive Gear System Technology Maturation

Propfan Demo Engine
13K SHP

High

Risk

ADP Demo Engine

40K SHP
Planetary System

Flight Weight Design

32K SHP
Planetary & Star Systems

PWC ATFI Demo

11K SHP
Star System

GTF Demo
31K SHP
Star System

Low
1987

1992

1994

2001

2005

2008
Source: P&W

3/20/2008

G. Wilfert

21

Gearbox Allows LP Turbine Optimization

10

High speed LPT

with Gearbox
without Gearbox

~3xn

with Gearbox
without Gearbox

LPT Speed

Expansion Ratio, ER

Turbine Efficiency

9
8
7
6
5
4

conventional LPT

3
2
1
1

Stage No.

Optimization
long range

3/20/2008

Fuel burn
CO2 - Emission

G. Wilfert

Manufacturing/
Maintenance cost

Optimization
short range

22

Reduction of Part Numbers with High Speed LPT

Bypass Ratio =5

V2500 LPT
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G. Wilfert

Bypass Ratio =12

CLEAN High Speed LPT

23

Predicted Noise Breakdown of Long Range Aircraft

Approach
Fan
Compressor
Combustor
Turbine

High Speed LPT

Jet
Airframe

Turbofan (BPR = 5)

Total aircraft
60

70

80

90

Noise level (EPNdB)

3/20/2008

G. Wilfert

100

GTF (BPR = 12)

24

Conventional versus High Speed Blade Outer Shroud Design

Dependencies for
Lightweight LPT Design

4b

Casing Design (Blade Containment)

Blade
Design

4a

Outer Shroud Design

Airfoil Design

Root Design

Disk Design

Conventional LPT

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G. Wilfert

High Speed LPT

25

Conventional versus High Speed Blade Design

outer shroud
cutback

tapered airfoil

axial length of
blade root

Conventional LPT
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G. Wilfert

High Speed LPT

26

Conventional versus High Speed Disk Design

Conventional LPT
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G. Wilfert

High Speed LPT

27

Content
Introduction Environmental and Economic Challenges

The Geared Turbo Fan Concept

Opportunities and Challenges for the GTFTM

The Low Spool Components Gearbox & LPT

Technology Validation

Summary

3/20/2008

G. Wilfert

28

Geared Engine Configuration Demonstrators

PW6000
HPC

ADP
ADP Demonstrator
Demonstrator
50klb
50klb

1993

High Speed
CLEAN LPT

ATFI
ATFI
13klb
13klb

GTF
GTF Demonstrator
Demonstrator
28
28 klb
klb

2001

2007
Source: P&W

3/20/2008

G. Wilfert

29

ATFI I Demonstrator Engine in Cooperation with PWC

1st Engine Test: 04/2001

3/20/2008

G. Wilfert

30

CLEAN Engine Demonstrator Programme

Turbine Center Frame
MTU Aero Engines

High Speed LP Turbine

MTU Aero Engines, Volvo Aero

HP Turbine
Snecma Moteurs

Turbine Exhaust Case

Volvo Aero

Combustor
AVIO, Snecma Moteurs

HP Compressor
Snecma Moteurs

3/20/2008

G. Wilfert

TEST
MTU Aero Engines

Recuperator
MTU Aero Engines

31

High Speed Low Pressure Turbine of the CLEAN Demonstrator

3/20/2008

G. Wilfert

32

CLEAN Engine

3/20/2008

G. Wilfert

33

CLEAN Test at the Altitude Test Facility of the University of

Stuttgart

3/20/2008

G. Wilfert

34

CLEAN at the Altitude Test Facility at the University of Stuttgart

3/20/2008

G. Wilfert

35

GTF Engine Demonstrator

Fan, LPC

LPT

Nacelle
TEC

FDGS

Core Engine
Source: P&W

3/20/2008

G. Wilfert

36

Summary
The Geared Fan sets a step change in fuel burn (CO2) and in noise
Lower SFC based on a improved cycle and higher efficiency of the LP
components
Lower Noise due to the higher bypass ratio and the lower fan tip speed
The Geared Fan is the first step to all new architectures which are based on a ultra
high bypass fan concept (except the direct drive open rotor)
The Geared Fan is planned to power the Mitsubishi Regional Jet and the C-Series
from Bombardier (EIS 2012/2013)
The Geared Fan is the proposed engine for the A320 / B737 successor
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G. Wilfert

37

CLEAN Film

EEFAE

CLEAN

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38