Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - HILOGEAR (High load gear and bearings materials)

Teaser

The HILOGEAR project supports the aims to mature differentiating technologies and processes that could be introduced in the innovative drive system module for the UHPE (Ultra High Propulsion Efficiency Engine) demonstrator. The Ultra High Bypass Ratio technology achieved with...

Summary

The HILOGEAR project supports the aims to mature differentiating technologies and processes that could be introduced in the innovative drive system module for the UHPE (Ultra High Propulsion Efficiency Engine) demonstrator.
The Ultra High Bypass Ratio technology achieved with the geared turbofan concept, that decouples fan and turbine speeds by means of an Integral Drive System (IDS), is an innovative architecture that can enable significant reduction in fuel burn, noise and emissions.

Since classical aerospace materials, although performant, do not exhibit all the necessary technical characteristics to fulfil both bearings and gears strength needs for their application in the UHPE power gearbox, innovative materials and heat treatments have to be investigated.

In order to enable the introduction of such innovative materials/heat treatments in the UHPE power gearbox an extensive experimental activity is required aimed to verify the performances of bearings and gears in operating conditions representative of those on the new engines (i.e. high load and high temperature).

The project HILOGEAR is structured in a management and dissemination work package and in four main technical work packages aimed to:
select the most promising steel materials and related surface treatments for their application on bearings and gears
design the test articles (i.e. the samples gears and bearings) and the test rigs required for the tests execution
identify optimal test plans to achieve robust and reliable results minimizing the testing time and the number of test articles
procure the test articles and the test rigs
execute a complete characterization of the gears and bearings performances, even at very high temperature (up to 200°C and for bearings in contaminated conditions).

Work performed

The main results achieved during the present reporting period are:
- Selection of materials and heat treatment to be tested
- Test plan definition for gears and bearings test campaigns
- Completion of the following design activities:
Upgrade of PC test rig for tests at high torque level
Upgrade of L17 test rig for tests on bearings in hot oil conditions
Test article (bearings, gears for bending tests, both for STBF and PC test rig, gears for scuffing tests on PC rig)
- Launching of the following design activity:
Upgrade of STBF test rig for tests on gears in hot conditions
- Completion of the following procurement activity:
L17 test rig
- Launching of the procurement activities for the following test rigs:
PC
STBF
- Launching of manufacturing activities for gears and bearings.

Final results

The project HILOGEAR responds to the main requirement regarding gearbox system optimization for bearing integration and associated components such as gears.
The main objective is to demonstrate new and innovative technologies that could be introduced in the innovative drive system module for the UHPE (Ultra High Propulsion Efficiency Engine) demonstrator.
The project could have an economic impact on the European industry by:
reducing engine fuel consumption
increasing safety
reducing engine emissions
improving propulsive efficiency
reducing operating costs
increasing the competitiveness of the European aviation industry.

Furthermore, carrying out the research project at a European level, with know-how and experiences being shared, will contribute to the growth and competitiveness of the industry.
The project could also have an impact on the Consortium by:
consolidating the role of both the Partners in the field of experimental research on bearings and gears for advanced applications; the project, in continuity to other already started research activities in the same field, could allow to strengthen existing know-how and to further confirm the excellence of Partners in this area of study
giving the opportunity to reinforce the collaboration between FAG Aerospace and AM Testing in this field of research.

Website & more info

More info: http://www.amtesting.it/.