
- •Foreword
- •Предисловие
- •Chapter 1. Introduction
- •From the history of aeroengines development. Classification of air gas turbine engines
- •Table 1.1
- •Table 1.2
- •1.2. Design features of manifold types of gas turbine engines
- •Main specifications for some serial turboprop and turboshaft
- •Fig. 1.3. Principal scheme of a two-shaft afterburning
- •Fig. 1.4. Principal scheme of a two-shaft tfe
- •Fig. 1.5. Principal scheme of a three-shaft tfe
- •Fig. 1.8. Principal scheme of a tpfe with a coaxial propfan
- •Main stages of gas turbine engines creation
- •1.4. Absolute and specific parameters of gas turbine engines
- •1.4.1. Absolute and specific parameters of turbojet engines
- •1.4.2. Absolute and specific parameters of turboprop engines
- •I.5. Air gas turbine engine’s lives
- •1.5.1. Nomenclature of lives
- •1.5.2. Sequence of assigning, setting and increase of lives
- •1.5.3. General requirements to life testing of engines and their main elements
- •1.5.4. Forming of test cycles
- •1.5.5. Forming of programs of life tests
- •Questions for self-check
- •2.1. Types of loads acting upon gas turbine engine structural elements
- •2.1.1. Classification of loads
- •2.1.2. Gas loads
- •2.1.3. Mass (inertial) forces and momenta
- •2.1.4. Temperature stresses
- •Fig. 2.4. For determination of the centrifugal forces
- •Fig. 2.5. For determination of the disc temperature stresses
- •2.1.5. Concept of dynamic loads
- •Fig. 2.9. Gas flow velocity behind nozzle vanes
- •2.2. Axial gas forces coming into action in gas turbine engines. Formation of thrust in gas turbine engines of manifold types
- •2.2.1. Axial gas forces acting on the basic gas turbine engine units
- •Fig. 2.10. Scheme of axial forces acting on basic gte units
- •2.3. Determination of axial gas force acting on impeller of gas turbine engine centrifugal compressor
- •2.4. Torques coming into action in gas turbine engines. Balance of torques
- •In gas turbine engines
- •2.4.1. Torques in turbine and compressor
- •Fig. 2.14. For determination of turbine rotor wheel torque
- •2.4.2. Torque balance in gas turbine engines of manifold types
- •Questions for self-check
- •Engine blades
- •Loads acting on blades. The blade stressed state characteristic
- •Fig. 3.1. Loads acting on the blade (a) and the scheme of blade loading
- •Determination of rotor blade tensile stress caused by centrifugal forces
- •The design scheme
- •3.2.2. Equation of a rotor blade stressed state
- •Integrating equation (3.3) in view of the ratio (3.1), we will get
- •3.2.3. Calculation of tensile stress at manifold laws of change of blade section area along its length
- •If the blade section area decreases from the root to periphery under the linear law:
- •In this case an integration by formula (3.7) yields
- •Determination of rotor blade bending stress caused by gas forces
- •3.3.1. Design scheme of a blade
- •3.3.2. Determination of gas load intensities
- •Determination of the bending momenta in axial and circumferential planes
- •3.3.4. Determination of the blade section geometrical characteristics
- •Determination of bending stress caused by gas force
- •Determination of rotor blade bending stress caused by centrifugal forces
- •The design scheme
- •3.4.2. Equation of the bending momenta
- •3.5. Guide and nozzle diaphragm vanes strength calculation features
- •3.5.1. Console type vanes
- •3.5.2. Double-support vanes
- •3.5.3. Frame type vanes
- •3.6. Evaluation of gte rotor blades strength
- •3.6.1. Grounding of blade stressed state criterion
- •3.6.2. Estimation of the blade temperature
- •3.6.3. Determination of blade strength safety factor coefficients
- •Questions for self-check
- •4.1. Loads affecting discs
- •The design scheme and assumptions made at disc strength calculations
- •Fig.4.1. Design scheme of the disc
- •4.3. Design ratings
- •4.4. Disc thermal condition
- •4.5. The disc stressed state equation. Boundary conditions
- •4.5.1. An equilibrium equation
- •4.5.2. Equation of deformations generality
- •4.5.3. Determination of stresses in rotating, unevenly heated elastic disc with an arbitrary profile
- •Fig. 4.2. Elementary disc forms
- •Fig. 4.3. Discs of arbitrary profiles
- •4.5.4. The procedure of the arbitrary profile disc stresses calculation
- •4.6. Disc durability criteria and safety factor coefficients
- •4.6.1. Selection of the stressed state criteria
- •4.6.2. Disc safety factor coefficients
- •Integrating an equilibrium equation, we find
- •4.7. Features of strength calculation of centrifugal compressor and radial-inflow turbine discs
- •The weight of the carrier disc for a chosen ring makes
- •Fig. 4.5. Design scheme and character of the radial and circumferential stresses change along radius of two-sided impeller of centrifugal compressor
- •4.8. Peculiarities of stresses calculation in drum-and-disc designs
- •Fig. 4.6. Design scheme of a drum-and-disc rotor
- •From here
- •Questions for self-check
- •Chapter 5. Static strength of gas turbine engine shafts
- •Loads acting on shafts
- •Design schemes and stressed state of shafts. Safety factor coefficient estimation
- •In an axial direction the shaft tensile (compressive) stresses are equal to
- •The shaft static strength is estimated by a safety factor coefficient value
- •Questions for self-check
- •Chapter 6. Dynamic strength of gas turbine engine blades
- •6.1. Vibrations of blades and forces causing vibrations
- •6.2. Kinds and forms of blade normal modes
- •Fig. 6.3. Flexural vibration modes of rotor blades
- •Fig. 6.4. For rotor blade normal mode frequency definition
- •6.3. Normal modes of blades with a stationary cross-section area
- •6.4. Normal modes of blades with a variable cross-section area
- •6.5. Influence of blade attachment effort to the disc
- •6.6. Influence of centrifugal forces on blade vibration frequency
- •F ig. 6.7. Determination of blade dynamic normal mode frequency
- •Influence of variable temperature
- •6.8. Forces damping blade vibrations
- •6.9. Resonant modes of the blade vibrations. The frequency diagram
- •F ig. 6.8. Example of turbine rotor wheel frequency diagram
- •6.10. Torsional and composite blade vibrations
- •6.11. Elimination of blade vibrational breakages
- •6.12. Concept of blades self-oscillations
- •Versus vibration amplitude
- •Questions for self-check
- •Chapter 7. Dynamic strength of gas turbine engine discs
- •General information
- •Forms of disc normal modes
- •Wave linear speed equals
- •Disc normal mode frequency
- •The compressor and turbine rotor wheel vibration calculation
- •Factors influencing the disc normal mode frequency
- •Disc forced undulations
- •The ways to eliminate dangerous resonance oscillations of rotor wheels
- •Questions for self-check
- •Chapter 8. Critical rotational speeds of gas turbine engine rotor
- •8.8. Measures taken to reduce intensity of rotor oscillation connected with critical rotational speeds.
- •Concept of critical rotational speeds of gas turbine engine rotor
- •Critical rotational speed of the two-support weightless shaft with disc
- •Fig. 8.8. Value of shaft static sag for different rotor schemes
- •Fig. 8.9. To the problem of a rotated rotor stability in a subcritical area
- •Connection of rotor critical rotational speed with its
- •Concept of two-support rotor critical rotational speeds of higher order
- •Critical rotational speed of the two-support ponderable shaft without disc
- •8.6. Critical rotational speeds of the ponderable shaft with several discs
- •8.6.1. Method of decomposition into elementary systems
- •8.7. Operational factors affecting critical rotational speeds of gas turbine engine rotor
- •Fig. 8.11. Taking into account supports elasticity influence on rotor critical speeds
- •Fig. 8.12. Static elastic anisotropy of a casing
- •Determination of critical rotational speeds taking into account
- •Influence of gyroscopic moment
- •Table 8.1
- •Values of the influence coefficients
- •8.7.2. Reduction of a real flexural system to equivalent computational
- •Example of rotor critical speed calculation
- •The rotor operational rotational speed margin is equal to:
- •The rotational speed margin at an idle is equal to:
- •8.8. Measures taken to reduce intensity of rotor oscillation connected with critical rotational speeds
- •Questions for self-check
- •8.7. What is dependence of rotor critical rotational speed on its cross-sectional oscillation frequency?
- •Of gas turbine engine shell designs
- •9.1. Shell strength calculation
- •Fig .9.1. Design scheme of a shell
- •9.2. Stability of cylindrical and conical shells
- •9.3. Vibrations of cylindrical shells
- •Questions for self-check
- •Chapter 10. Control of gas turbine engine
- •Vibration state
- •10.2. Control of gas turbine engine vibrations
- •10.3. The ways to lower the vibration level of gas turbine engines
- •10.3.1. The procedures of vibration level lowering at stage of designing
- •10.3.2. The procedures of the vibration level lowering at production stage
- •Fig. 10.3. Scheme of the rotor static balancing
- •Fig. 10.4. Scheme of the rotor dynamic balancing
- •Will be compensated by centrifugal force of balanced elements weights
- •10.3.3. The procedures of the vibration level lowering at maintenance stage
- •Questions for self-check
- •Сhapter 11. Gas turbine engine rotor supports
- •11.1. Brief data about gas turbine engine rotor supports
- •Fig. 11.3. Scheme of gte rotor support
- •11.2. Calculation of support bearings
- •Fig. 11.9. Ball bearing:
- •For roller bearings we use the formula
- •11.2.2. Estimation of the bearing safe life
- •11.2.3. Check of the bearing high-speed
- •11.2.4. Check of the bearing static load-bearing capacity
- •11.2.5. Definition of the necessary oil circulation through the bearing
- •Questions for self-check
Table 1.1
Main specifications for TJE, serial production of which began before 1950
Engine |
Country – manufacturer |
Year of manu-facture |
Takeoff rating thrust R, kN |
Specific fuel consumption
|
Type of compressor |
Не-53В |
Germany |
1939 |
5,0 |
0,145 |
Centrifugal |
UМО-004А |
Germany |
1940 |
7,6 |
0,143 |
Axial |
UМО-004В |
Germany |
1940 |
9,0 |
0,140 |
Axial |
ASX |
England |
1943 |
11,8 |
0,130 |
Centrifugal |
UМО-012 |
Germany |
1943 |
27,6 |
0,120 |
Axial |
BMW-003А |
Germany |
1944 |
8,8 |
0,150 |
Axial |
Derwent 1 |
England |
1944 |
9,1 |
0,117 |
Centrifugal |
UМО-004С |
Germany |
1944 |
10,2 |
0,148 |
Axial |
Derwent 5 |
England |
1944 |
18,2 |
0,112 |
Centrifugal |
NIN 1 |
England |
1944 |
22,7 |
0,110 |
Centrifugal |
Yankee-19В |
USA |
1944 |
6,2 |
0,128 |
Axial |
Не-S-011 |
Germany |
1945 |
13,0 |
0,131 |
Axial |
BMW-018 |
Germany |
1945 |
35,0 |
0,118 |
Axial |
Avon RA-3 |
England |
1947 |
29,5 |
0,105 |
Axial |
ТР-1 |
USSR |
1947 |
13,0 |
0,135 |
Axial |
РД-10 |
USSR |
1947 |
10,2 |
0,140 |
Axial |
РД-20 |
USSR |
1947 |
8,8 |
0,140 |
Axial |
РД-45 |
USSR |
1948 |
18,2 |
0,109 |
Centrifugal |
РД-500 |
USSR |
1948 |
22,7 |
0,108 |
Centrifugal |
ТР-3А |
USSR |
1948 |
38,0 |
0,110 |
Axial |
J-34-WE |
USA |
1948 |
19,0 |
0,105 |
Axial |
Аtar-101С |
France |
1948 |
28,0 |
0,107 |
Axial |
J-35-A-17 |
USA |
1949 |
22,7 |
0,105 |
Axial |
ВК-1 |
USSR |
1949 |
27,0 |
0,105 |
Centrifugal |
АМ-3 |
USSR |
1949 |
85,2 |
0,105 |
Axial |
АМ-5 |
USSR |
1950 |
20,0 |
0,107 |
Axial |
J-35-A-21 |
USA |
1950 |
23,6 |
0,112 |
Axial |
Perfection of single-shaft ATJE with variable guide vanes of compressor stators was completed by creation of a serial АЛ-7Ф engine with maximum rating thrust of 78 kN for fighters-interceptors and fighters-bombers. This ATJE also became the basis model for single-shaft engines.
The most widespread turbojet engines, created in the USA in the middle of 1950s are the Pratt & Whitney J-57-P with maximum thrust of 45...61 kN, depending on modification, and the General Electric J-79-GE with the maximum rating thrust of 55...75 kN. These engines are still used in military airplanes. Moreover, J-57-P engines were set in the first modifications of B-707 passenger airplanes.
At the same time turboprop engines were being designed in the USSR. The most powerful in the world TPE НК-12МВ (Nе=11 000 kW) was created under the supervision of the general designer M.D. Kuznetsov. It provided operation of giant transport airplane Ан-22 “Антей” and once the biggest passenger airplane Tу-114.
At the end of 1950s the АИ-20 and the НК-4 TPEs were created for passenger and transport airplanes for long stage distances. They were set in Ил-18, Ан-10А, Ан-8 airplanes, and АИ-20 engines are still used in Ан-12 and Ан-32 airplanes.
АИ-20 (Nе=3 200 kW) TPE is followed by АИ-24 (Nе=1 875 kW) and АИ‑24ВТ (Nе=2 075 kW) TPEs for Ан-24, Ан-26 and Ан-30 airplanes. They are distinguished by high serviceability.
Aeroengine building corporations of the USA, France, England and other countries have reached a considerable success in development of turboprop engines. In 1950s and 1960s TPEs of manifold types were designed: “Dart”, that was used as a power plant for Vickers “Wiscount” airplanes, “Protey” – in Bristol “Britain” airplanes, “Allison 501” – in Lockheed “Electra” airplanes, “Tine 512” – in Vickers “Vengard” airplanes and others.
The turboshaft engines for helicopters were developed in design bureaus headed by P.A. Solovyov, V.A. Glushenkov, S.P. Izotov. They include Д‑25В, ТВ2‑117А, ТВ3‑117, ГТД‑350 engines and others. So, in the heavy Ми-6 and Ми-10 (“flying crane”) helicopters two Д-25В engines (with the power of 4 100 kW each) are set, and Д‑136 engines (with the power of 8 800 kW) are set in the helicopters of new generation of Ми‑26.
S.P. Izotov’s and V.A. Glushenkov’s turboshaft engines, which have small overall dimensions and weight, permitted to create Ми-2, Ми-8, Ка-32 helicopters and others with high flight performances.
The increasing volume of air traffic required higher flight speed combined high economic efficiency. This problem was solved by development of turbofan engines. In the USSR the first serial turbofan Д-20П engine was created in 1955 by P.A. Solovyov design bureau. Then TFEs of the second generation (Д‑30, Д‑30КУ, НК‑8‑2У, АИ‑25) have been designed under the supervision of the general designers M.D. Kuznetsov, P.A. Solovyov and A.G. Ivchenko. They have been successfully used in the Tу‑134, Ил‑62М, Tу‑154 and Як‑40 airplanes for many years.
The second generation of TFEs is distinguished by small bypass ratio (m=1...3). However, cruise rating specific fuel consumption is 15...25 % lower, than TJEs’ with the same thrust.
As the researches have shown, the increase of TFE bypass ratio is accompanied by the lowering of specific fuel consumption.
Examples of successful designing of TFEs with large bypass ratio are Д‑36 and Д‑136 engines of the third generation for Як-42, Ан-72 and Ан-74 airplanes, and also Д‑18Т engine for the special heavy Ан‑124 “Руслан” and Ан‑225 “Мрія” aeroplanes.
In 1970s and 1980s in the USA, England and other countries a number of turbofan engines, which had new design solution, were created. Among them is RB‑211 TFE (England), distinguished by a high degree of design perfection and reliability. The manifold series of RB-211 engine, with different values of thrust and operational characteristics are used on several types of passenger airplanes.
CFM-56 engine, which is a joint design of French and American companies, is noiseless, high efficient GTE for passenger airplanes with takeoff mass varying from 60 up to 160 tons, equipped with two, three or four engines.
In the USA there have been designed a lot of mean and large thrust TFEs for passenger and transport airplanes. Various modifications of JT‑9D, CF6, TF‑39, JT‑10, V‑2500, РW‑4000 engines appear to be most interesting from the standpoint of design and technology.
Engines of a new type – turbopropfan engines – intended for subsonic passenger airplanes have been intensively designed lately. They differ from turboprop engines by a new type of a propeller, which is called propfan, and developed control of working process. The researches have shown, that the gain in specific fuel consumption of TPFE, in comparison with perspective TFE, can make up to 20...30 %.
The most perspective TPFEs are ТВ7-117, Д-27, НК-93 engines, which are set in Ил-114, Ан-70 airplanes and others.
The main specifications for modern GTEs used in civil aviation are given in Tab.1.2 and Tab.1.3.
Analyzing the history of the global aeroengine building development, it becomes obvious, that the development of ABE fundamental theory and techniques of their production, dates back to 1920 – 1930s, while putting into practice coincides with the beginning of the World War II. Intensive rise in gas turbine engines development and production for military aviation has been observed since 1950s. Such engines were set in the first passenger jet airplanes, and only since the second half of 1950s gas turbine engines, specially intended for passenger airplanes, have been designed. Many polytypic gas turbine engines have been designed and put into operation lately. The main directions of engines perfection for civil aviation are associated with the solution of the problems of profitability growth and steel intensity decrease at a high level of reliability. Nevertheless, not only the technical requirements are taken into consideration when creating such engines.
Since 1970s still higher ecological requirements have been made of the newly developed engines used in civil aviation. They concern decrease in noise and noxious substances emission, which issue from GTE when much fuel is burnt.
Compliance with all technical and ecological demands of GTE results in considerable increase in the cost of research engineering and experimental development associated with engine design, extension of terms for designing as well as engine operational development prior to putting it into operation. As practice shows, expenses to make modern highly efficient aviation GTEs with thrust of 200…300 kN for wide-body passenger airplanes constitute from 2 to 4 bln. dollars, and the process takes some 10…12 years of intense work of design bureau staff, research institutes and plants of serial production.