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Structural study of an Intercase for a 3 spool engine
2003 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

The objective for this master thesis was to investigate and evaluate the intermediate compressor case (ICC / Intercase) for the Rolls Royce engine Trent 500. In May 2001 Volvo Aero Corporation and Rolls-Royce signed an agreement regarding the development of the T600 Intercase and the T900 Intercase. At the same time Volvo also signed a contract including the manufacturing of the T500 Intercase, and a transfer plan for the T500 Intercase design responsibility. The T900 Intercase project consists of design, analysis, manufacturing, procurement and product support. The Trent 900 engine has large similarities to the Trent 500 engine. The core from the T900 is 10% larger than T500. The major difference between T500 and T900 is the engine mount system. The different type of engine mount configuration gives different load paths, and therefore the T500 Intercase is of great interest to investigate. The Intercase forms a major structural element of the engine and has been designed using experience from previous Rolls Royce engines, especially Trent 700 that has a similar installation. The front engine mount and the load path trough the core structure via the engine mount is one of the most important design issues. The intercase aerodynamically connects the rear of the intermediate pressure compressor with the high pressure compressor and so provide the gas path between them as well as the respective mounting features. The Intercase also houses the three main shafts bearings, the bevel gears and shafts necessary to provide power from the high pressure system to drive the accessory gearbox. The investigation has covered the different flight load cases mechanical affection on the Intercase. For the 92 different flight load cases, calculations have been performed regarding the affection of forces and moments on the component different boundaries. It was impossible to find a certain flight load case that exposes the Intercase for the most severe loading, There is however some flight load cases that, besides causing extreme values in one boundary, contributes with high values of forces and moments in the other boundaries. Flight load case 1010 and 1011 are such flight load reference. In the end of the development process of the component, the FE model, which have be used for the mechanical analysis must be correlated against rig test data from a physical component. A major part in this thesis, has the been evaluation of the rig-rating test performed by Roll Royce. A comparable FE analysis of the intercase was performed in ANSYS, in order to investigate how well the FE model correlates with rig test data. The result from the FE analysis in ANSYS showed the same characteristics as Rolls Royce analysis, but the model that was used in this thesis was approximately 4% stiffer than the original Rolls Royce model. In the Trent 900 project, the design and rig analysis showed that flight load case 3021 (LC3021) had a very big influence on the front engine mount and the surrounding area. This result motivated an similar analysis on the intercase for Trent 500. The analysis of flight load case 3021 did not affect the engine mount and the surrounding area in that large extent as for the Trent 900. The result from the comparison of fan blade off loads between T900 and T500 shows that T900 in general is subjected for higher loads and moments during a FBO event. This, due to the heavier fan blade, which generates a higher kinetic energy. This thesis is confidential

Place, publisher, year, edition, pages
2003.
Keyword [en]
Technology, Intercase
Keyword [sv]
Teknik
Identifiers
URN: urn:nbn:se:ltu:diva-45872ISRN: LTU-EX--03/028--SELocal ID: 38690d52-dff4-4d3f-909a-e3f11bbc19fdOAI: oai:DiVA.org:ltu-45872DiVA: diva2:1019171
Subject / course
Student thesis, at least 30 credits
Educational program
Mechanical Engineering, master's level
Examiners
Note
Validerat; 20101217 (root)Available from: 2016-10-04 Created: 2016-10-04Bibliographically approved

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