Off-Design Performance Prediction of the CFM56-3 Aircraft Engine Aerospace Engineering

114 Pages·2015·4.96 MB·English

by  Andre C. Marta

Off-Design Performance Prediction of the CFM56-3 Aircraft
Engine
Daniel Alexandre Rodrigues Martins
Thesis to obtain the Master of Science Degree in
Aerospace Engineering
Supervisor(s): Prof. André Calado Marta
Eng. António Miguel Abreu Ribeiro Henriques
Examination Committee
Chairperson: Prof. Filipe Szolnoky Ramos Pinto Cunha
Supervisor: Prof. André Calado Marta
Member of the Committee: Prof. João Eduardo de Barros Teixeira Borges
November 2015
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Tomyfamilyandfriends.
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Acknowledgments
FirstlyIwouldliketothankEngineerAnto´nioFerreira,fortheopportunityofdevelopingthisworkinTAP
Portugal.
To both my supervisors, Engineer Anto´nio Miguel Abreu Ribeiro Henriques, of TAP, and Professor
Andre´ Calado Marta, of IST, for all the support, confidence, solutions and encouragements. I am ex-
tremely thankful and indebted to them for sharing expertise, and sincere and valuable guidance which
resultedinalltheimprovementsthatledtothefinalversionofthisthesis.
ToeverypersonthatIhaveworkedwithinTAPM&Eduringmyinternship. Theirknowledgeintheir
areasofexpertisecontributedtothedevelopmentofthiswork.
TomycolleaguesMa´rioFerreira,JulienPabiotandLuisdeBotton.
I am also grateful to my IST colleagues who supported me throughout these last five years of my
academiclife.
Tomyparents,Iwouldliketothanktheirunconditionalsupport,encouragementsallacrossmylife.
Finally, totherestofmyfamilyandfriends, forbeingpresent, inallthegood, butspecially, inallthe
badmoments.
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Resumo
Desde o aparecimento das aeronaves no inicio do se´culo passado, estas teˆm transformado o mundo.
A sua capacidade de viajar a velocidades muito superiores a`quelas que os comboios ou navios con-
seguematingirajudouomundofacilitandotrocasecono´micaseajudandoaspessoasaconheceroutras
culturas.
O desempenho global de um turbina de ga´s pode ser estimado sabendo os principais paraˆmetros
de desenho do motor, no entanto, isto e´ bastante dif´ıcil devido a` quantidade limitada de informac¸a˜o
queosproductoresdemotoresdeixamescaparparaopu´blicoemgeral. Apesardeosproductoresde
turbinasnormalmentefornecereminformac¸o˜essobreainterfacedesta,ainformac¸a˜oquee´ necessa´ria
paraestimarociclotermodinaˆmicodeumacertaturbinaaga´sna˜oesta´ dispon´ıvel. Ummodelocapaz
deestimarestesdadosdesconhecidostementa˜odesercriado.
Nestatese,ummodelodedesempenhodomotorCFM56-3foidesenvolvidoutilizandoosoftwarede
modelac¸a˜o GasTurb. O motor escolhido foi o CFM56-3 pelos factos de ser um dos mais utilizados por
todoomundoedeaTAPManutenc¸a˜o&EngenhariaestarcertificadaparaorecebernasuaOficina. O
modeloe´ criadoemprimeirolugarparaassuascondic¸o˜esnominais,ondeasuageometriae´ definida. O
desempenhoforadascondic¸o˜esnominaise´ depoismodeladautilizandodadosprovenientesdobanco
deensaiosdaTAPM&E.Omodeloe´ u´tilparapreverosdadosquena˜osa˜oreveladospeloscontructores
dosmotores.
A melhor aplicac¸a˜o deste trabalho e´ analisar a condic¸a˜o de motores CFM56-3. Com alguns dados
provenientesdobancodeensaiosdeummotoremparticular,omodelopermiteperceberosproblemas
dessemesmomotor.
Esta dissertac¸a˜o coloca maior eˆnfase no desenvolvimento e validac¸a˜o do modelo do motor, bem
como na sua utilidade para a Oficina de Motores da TAP Manutenc¸a˜o e Engenharia. O modelo do
motorpossibilitara´ a` TAPManutenc¸a˜oeEngenhariaanalisarodesempenhodeumaturbinaaga´sbem
como comparar o desempenho de qualquer motor CFM56-3 com o desempenho do modelo com vista
aestimardegradac¸o˜esnosseuscomponentes.
Omaiorbenef´ıcioparaaTAPM&Eporusaromodelodedesempenhoe´ apossibilidadedeefectuar
reparosselectivos,permitindopouparhorasdetrabalhoereduzindooscustosdereparac¸a˜o.
Palavras-chave:
Turbinadega´s,modelodedesempenho,GasTurb,efeitosdedegradac¸o˜es,
custosdereparac¸a˜o,folgasnapontadaspa´s.
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Abstract
Eversincetheappearanceofaircraftsatthebeginningofthepastcentury,theyhavebeentransforming
the world. Their capability of travelling at speeds much greater than that of trains or ships helped the
worldbyfacilitatingeconomictradesandhelpedpeopletolearnaboutothercultures.
Theoverallperformanceofagasturbinecanbeestimatedbyknowingthemaindesignparameters,
however, this is quite challenging due to the limited data that the engine manufacturer releases to the
general public. Although a turbine manufacturer usually provides data about the turbine interface, the
datarequiredtoestimatethethermodynamiccycleofaparticulargasturbineremainshidden. Amodel
ofthatenginecapableofestimatingthatdatamustthenbecreated.
Inthisthesis,aperformancemodeloftheCFM56-3enginehasbeendevelopedusingthemodelling
software GasTurb. The chosen engine was the CFM56-3 due to the facts that it is one of the world’s
mostusedaircraftenginesandthatTAPM&EEngineShopiscertifiedtomaintainit. Themodelisfirst
created for its design point, where its geometry is defined. The off-design performance of the engine
is then modelled using data from TAP M&E test bed. The model is useful to predict the data that the
enginemanufacturersdonotreveal.
ThebestapplicationofthisworkistheanalysisoftheconditionofCFM56-3engines. Withsometest
beddatafromaparticularengine,themodelmightdiagnosetheproblemsofthatsameengine.
The thesis places major emphasis on the development and validation of the engine model, as well
asitsuseinTAPM&EEngineShop. ThedevelopedmodelallowsTAPM&Etoanalysetheperformance
ofthegasturbineaswellastocomparetheperformanceofanyCFM56-3enginetotheperformanceof
themodelinordertoestimatecomponentsdegradation.
ThemainbenefittoTAPM&Ebyusingtheperformancemodelisthepossibilityofperformingselec-
tiverepairs,allowingtosaveworkhoursandreducingrepaircosts.
Keywords:
Gasturbine,Thermodynamics,Performancemodel,GasTurb,Degradationeffects,
Repaircosts,Tipclearance.
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