Search Results (13)

In “no-bleed” engine architectures, bleed air is replaced by shaft power extraction to run the subsystems, avoiding the inefficiencies of traditional bleed systems. This approach is increasingly used in small turbofan engines, prompting analysis of its impact on engine performance and exergy efficiency. A small high-bypass turbofan engine was modeled in software under two control strategies: constant thrust (CT) and constant speed (CS), with shaft power extraction up to 18 kW. Exergy analysis evaluated efficiency losses and sustainability metrics (exergy efficiency, environmental effect factor, and exergetic sustainability index). Simulations indicate that an 18 kW shaft power extraction increases SFC by 13.6% (CT) and 42.1% (CS). Exergy efficiency rises from 47.3% to 50.7% (CT) and 54.2% (CS). However, these power draws also increase irreversibility and the environmental effect factor (EEF) grows from 0.678 to 0.732 (CT) and 0.744 (CS), while the exergetic sustainability index (ESI) drops from 1.48 to 1.34, signaling reduced sustainability at high extraction. Maintaining constant thrust during extraction incurs smaller fuel consumption and exergy efficiency penalties than constant speed control. The findings highlight the need for adaptive control strategies (e.g., limiting extraction levels or using variable-geometry components) to mitigate losses and enhance sustainability in no-bleed engine designs. Full article

Additive manufacturing (AM) presents significant cost savings and lead time reductions because of features inherent to the manufacturing process. The technology lends itself to rapid prototyping due to the streamlined workflow of quickly implementing design changes. Compared to traditional machining, AM techniques are simpler in execution for design engineers because they do not require detailed engineering drawings and they typically make use of the nominal geometry in computer models. A novel transonic fan casing assembly has been developed that makes use of AM inserts surrounding the rotor to provide an opportunity to cost-effectively change the corresponding flowpath. The rapid prototyping design philosophy developed from this work will allow for numerous experimental studies into the effects that different design parameters of casing geometries have on fan aerodynamic performance. A fan stage representative of a small turbofan engine was successfully tested with smooth-walled, additively manufactured inserts as a baseline case for future configurations. Before installing the 3D printed casing assembly, computational thermal stress analysis was performed to reduce the risk in implementation due to the demanding environment associated with the rotor. AM components and materials typically have nonlinear mechanical properties, adding to the complexity of the structural analysis. As part of the research, steady aerodynamic performance was measured over the entire relevant operating range of the fan. Full article

In industrial system health management, prognostics play a crucial role in ensuring safety and enhancing system availability. While the data-driven approach is the most common for this purpose, they often face challenges due to insufficient training data. This study delves into the prognostic capabilities of four methods under the conditions of limited training datasets. The methods evaluated include two neural network-based approaches, Convolutional Neural Network (CNN) and Long Short-Term Memory (LSTM) networks, and two similarity-based methods, Trajectory Similarity-Based Prediction (TSBP) and Data Augmentation Prognostics (DAPROG), with the last being a novel contribution from the authors. The performance of these algorithms is compared using the Commercial Modular Aero-Propulsion System Simulation (CMAPSS) datasets, which are made by simulation of turbofan engine performance degradation. To simulate real-world scenarios of data deficiency, a small fraction of the training datasets from the original dataset is chosen at random for the training, and a comprehensive assessment is conducted for each method in terms of remaining useful life prediction. The results of our study indicate that, while the Convolutional Neural Network (CNN) model generally outperforms others in terms of overall accuracy, Data Augmentation Prognostics (DAPROG) shows comparable performance in the small training dataset, being particularly effective within the range of 10% to 30%. Data Augmentation Prognostics (DAPROG) also exhibits lower variance in its predictions, suggesting a more consistent performance. This is worth highlighting, given the typical challenges associated with artificial neural network methods, such as inherent randomness, non-intuitive decision-making processes, and the complexities involved in developing optimal models. Full article

Increasing aviation activities have heightened concerns about particulate emissions from aircraft engines. Current ICAO standards mainly focus on large civil turbofan engines, leaving a gap in the research on PN emissions from small aircraft engines. This study examined the PN emission characteristics of micro-turbojet engines, including the morphology, PN, and size distribution under different load conditions, compared with a micro-piston engine. The results showed that the nvPM from micro-turbojet engines was larger and more complex than typical aviation soot, likely due to reduced combustion efficiency and incomplete fuel combustion. Micro-turbojet engines exhibited fewer fluctuations in their emission index number (EIn) and emission index mass (EIm) at lower speeds. The geometric mean diameter (GMD) of particles was inversely correlated with thrust, while the geometric standard deviation (GSD) slightly increased with thrust. Quantitative comparisons indicated that PN emissions from micro-turbojet engines were higher, with EIn values ranging from 2.0 to 3.3 × 10¹⁶/kg fuel compared with 1.2 to 1.5 × 10¹⁶/kg fuel for micro-piston engines. EIm values for micro-turbojet engines ranged from 8 to 40 mg/kg fuel, while micro-piston engines had slightly higher values due to better carbonization. These findings validated the measurement methodology used to accurately assess PN emissions under low-thrust conditions in micro-turbojet engines. These results provide crucial insights and support for the future monitoring and regulation of PN emissions across all thrust conditions in small aircraft engines. Full article

This article presents the development of the electric turbofan engine in distributed architecture with a design thrust in the range of 3 to 7.5 and from 7.5 to 30 kN for small and medium-sized unmanned aerial vehicles. The engine subsystems are considered as separate smart modules with a built-in control system, exchanging data via a digital channel with the central engine control and diagnostics unit. The key smart engine units are combined in the following subsystems: starter and turbine generators, oil pumps, actuator of guide vanes, fuel pumps, fuel metering unit, control and diagnostic unit. All pumps and guide vane actuator are electrically driven. Control and monitoring signals are transmitted via a digital bus. Functional and reliability analysis and the technical configuration design of each subsystem are presented. Based on analysis of the architecture of distributed control systems for a gearbox-free electric engine, different configurations of described subsystems are proposed. Full article

This paper investigates the control-oriented modeling for turbofan engines. The nonlinear equilibrium manifold expansion (EME) model of the multiple input multiple output (MIMO) turbofan engine is established, which can simulate the variation of high-pressure rotor speed, low-pressure rotor speed and pressure ratio of compressor with fuel flow and throat area of the nozzle. Firstly, the definitions and properties of the equilibrium manifold method are presented. Secondly, the steady-state and dynamic two-step identification method of the MIMO EME model is given, and the effects of scheduling variables and input noise on model accuracy are discussed. By selecting specific path, a small amount of dynamic data is used to identify a complete EME model. Thirdly, modeling and simulation at dynamic off-design conditions show that the EME model has model accuracy close to the nonlinear component-level (NCL) model, but the model structure is simpler and the calculation is faster than that. Finally, the linearization results are obtained based on the properties of the EME model, and the stability of the model is proved through the analysis of the eigenvalues, which all have negative real parts. The EME model constructed in this paper can meet the requirements of real-time simulation and control system design. Full article

The fine particulate matter (PM) emitted from jet aircraft poses a serious threat to the environment and human health which can be mitigated by using biofuels. This paper aims to quantify PM emissions from a small turbofan fueled with the alcohol to jet (ATJ) synthetic kerosene and its various blends (5%, 20%, and 30% of ATJ) with Jet A-1 fuel. Emissions from a turbofan engine (DGEN 380) with a high bypass ratio, applicable in small private jets, were studied. Among the four fuels tested, the PM-number emission index (EI_N) was the lowest for the ATJ 30% blend. EI_N for ATJ 30% dropped from 1.1 × 10¹⁷ to 4.7 × 10¹⁶ particles/kg of fuel. Burning alternative fuel blends reduced the particle mass emissions over the entire range of fuel flow by at least 117 mg/kg of fuel. The particles formed in the nucleation mechanism dominate PM emission, which is characteristic of jet engines. Thus, number-based particle size distributions (PSDs) exhibit a single mode log-normal distribution. The highest values of EI_N were found for Jet A-1 neat compared to other fuels. The use of the ATJ additive did not cause significant changes in the size of the particles from nucleation mode. However, a magnitude reduction of nucleation mode was found with the increase in the ATJ ratio. Full article

Manufacturing costs, along with operational performance, are among the major factors determining the selection of the propulsion system for unmanned aerial vehicles (UAVs), especially for aerial targets and cruise missiles. In this paper, the design requirements and operating parameters of small turbofan engines for single-use and reusable UAVs are analysed to introduce alternative materials and technologies for manufacturing their compressor blades, such as sintered titanium, a new generation of aluminium alloys and titanium aluminides. To assess the influence of severe plastic deformation (SPD) on the hardening efficiency of the proposed materials, the alloys with the coarse-grained and submicrocrystalline structure were studied. Changes in the physical and mechanical properties of materials were taken into account. The thermodynamic analysis of the compressor was performed in a finite element analysis system (ANSYS) to determine the impact of gas pressure and temperature on the aerodynamic surfaces of compressor blades of all stages. Based on thermal and structural analysis, the stress and temperature maps on compressor blades and vanes were obtained, taking into account the physical and mechanical properties of advanced materials and technologies of their processing. The safety factors of the components were established based on the assessment of their stress-strength characteristics. Thanks to nomograms, the possibility of using the new materials in five compressor stages was confirmed in view of the permissible operating temperature and safety factor. The proposed alternative materials for compressor blades and vanes meet the design requirements of the turbofan at lower manufacturing costs. Full article

Issues of gain scheduling control for aero-engines are addressed in this paper. An aero-engine is a system with high nonlinearity, and the requirement on controlling performance is high. Linear Parameter Varying (LPV) synthesis is commonly used to satisfy the requirements. However, the designing procedure of an LPV synthesis controller is complex, and may lead to undesirable design results when the variation rate of scheduling parameter is relatively fast. In this paper, an improved gain scheduling design procedure that can guarantee reliable stability and performance is developed. The method allows arbitrary variation of scheduling parameters, and is a modification for conventional LPV synthesis control. Special cases where traditional LPV synthesis control can still work are also discussed. The modified design procedure is evaluated on a small turbofan engine. Simulations show that for conditions where conventional scheduling fail to stabilize the plant, the proposed modification can ensure reliability and achieve desired performance. Full article

In modern aircraft engines, the low-pressure compressor (LPC) is subjected to a flow characterized by strong wakes and secondary flows from the upstream fan. This concerns ultra-high bypass ratio (UHBR) turbofan engines, in particular. This paper presents the aerodynamic and aeroelastic sensitivities of parametric variations on the LPC, driven by the design considerations in the upstream fan. The goal of this investigation was to determine the influence of design-based geometry parameter variations on the LPC performance under realistic inlet flow distributions and the presence of an s-duct. Aerodynamic simulations are conducted at the design and off-design operating points with the fan outflow as the inlet boundary conditions. Based on the aerodynamic results, time-linearized unsteady simulations are conducted to evaluate the vibration amplitude at the resonance operating points. First, the bypass ratio is varied by reducing the channel height of the LPC. The LPC efficiency decreases by up to $1.7\%$ due to the increase in blockage of the core flow. The forced response amplitude of the rotor decreases with increasing bypass ratio due to increased aerodynamic damping. Secondly, the fan cavity leakage flow is considered as it directly affects the near hub fan flow and thus the inflow of the LPC. This results in an increased total-pressure loss for the s-duct due to mixing losses. The additional mixing redistributes the flow at the s-duct exit leading to a total-pressure loss reduction of $4.3\%$ in the first rotor at design point. This effect is altered at off-design conditions. The vibration amplitude at low speed resonance points is increased by $19\%$ for the first torsion and $26\%$ for second bending. Thirdly, sweep and lean are applied to the inlet guide vane (IGV) upstream of the LPC. Despite the s-duct and the variable inlet guide vane (VIGV) affecting the flow, the three-dimensional blade design achieves aerodynamic and aeroelastic improvements of rotor 1 at off-design. The total-pressure loss reduces by up to $18\%$ and the resonance amplitude more than $10\%$. Only negligible improvements for rotor 1 are present at the design point. In a fourth step, the influence of axial gap size between the stator and the rotor rows in the LPC is examined in the range of small variations which shows no distinct aerodynamic and aeroelastic sensitivities. This finding not only supports previous studies, but it also suggests a correlation between mode shapes and locally increased excitaion with increasing axial gap size. As a result, potential design improvements in future fan-compressor design are suggested. Full article

This study addresses the performance analysis of a subcritical and supercritical Organic Rankine Cycle (ORC) with the addition of a preheater or superheater integrated with a turbofan engine. This analysis will try to explore the heat transfer throughout the evaporator for the purpose of determining the ORC output power and thermal efficiency. A simplified numerical model of the ORC for waste heat recovery is presented. The model depicts the evaporator by using a distributed model, and includes parameters such as the effectiveness, heat capacity and inlet temperature of the waste heat and the organic fluid. For a given set of initial parameter values, the output power and thermal efficiency, as well as the mass flow rate of the working fluid are acquired by solving the system’s thermodynamic cycle with the aid of MATLAB software. The model is then verified by using data from an industrial waste heat recovery system. The connection between the turbofan engine and the ORC system was established and evaluated by means of Thrust-Specific Fuel Consumption (TSFC) as well as fuel burn. It was found that the supercritical ORC with a preheater and superheater exhibits lower TSFC than the subcritical ORC, whereas the impact of the ORC in terms of waste heat recovery in relation to the environment and sustainability indices is quite small, but still considerable depending on the engine’s weight. Full article

In this study, the on-going research into the improvement of micro-gas turbine propulsion system performance and the suitability for its application as propulsion systems for small tactical UAVs (<600 kg) is investigated. The study is focused around the concept of converting existing micro turbojet engines into turbofans with the use of a continuously variable gearbox, thus maintaining a single spool configuration and relative design simplicity. This is an effort to reduce the initial engine development cost, whilst improving the propulsive performance. The BMT 120 KS micro turbojet engine is selected for the performance evaluation of the conversion process using the gas turbine performance software GasTurb13. The preliminary design of a matched low-pressure compressor (LPC) for the proposed engine is then performed using meanline calculation methods. According to the analysis that is carried out, an improvement in the converted micro gas turbine engine performance, in terms of thrust and specific fuel consumption is achieved. Furthermore, with the introduction of a CVT gearbox, the fan speed operation may be adjusted independently of the core, allowing an increased thrust generation or better fuel consumption. This therefore enables a wider gamut of operating conditions and enhances the performance and scope of the tactical UAV. Full article

The reduction in specific fuel consumption (SFC) is crucial for small/mid-size cost-controllable aircraft, which is very conducive to reducing cost and carbon dioxide emissions. To decrease the SFC, increasing the bypass ratio (BPR) is an important way. Conventional high-BPR engines have several limitations, especially the conflicting spool-speed requirements of a fan and a low-pressure turbine. This research proposes an air-driven fan with a tip turbine (ADFTT) as a potential device for a high-bypass propulsion system. Moreover, a possible application of this ADFTT is introduced. Thermodynamic analysis results show that an ADFTT can improve thrust from a prototype turbofan. As a demonstration, we selected a typical small-thrust turbofan as the prototype and applied the ADFTT concept to improve this model. Three-dimensional flow fields were numerically simulated through a Reynolds averaged Navier-Stokes (RANS)-based computational fluid dynamics (CFD) method. The performance of this ADFTT has the possibility of amplifying the BPR more than four times and increasing the thrust by approximately 84% in comparison with the prototype turbofan. Full article