Innovative technologies to ensure the creation of aircraft engines

 

The key to having the status of an aviation power is the ability to develop and produce our own modern aircraft engines and aircraft. Out of more than 190 countries of the world, only four, which have the most highly developed technological and design base, are capable of this: the USA, Great Britain, France and Russia. China, India, Iran and a number of other countries are fiercely fighting for membership in this narrow club.

Anton Salonika,

Aviation engine building does not just produce technically complex products: the creation of a gas turbine engine is recognized as one of the outstanding scientific and technical breakthroughs of the 20th century, along with space exploration, nuclear energy and the invention of the Internet. Competition in high-tech developments such as aircraft engines is a powerful driver for finding and applying innovative approaches. Their study is one of the key tasks of science.

In the process of creating an engine, it is necessary to solve many complex problems at the junction of various fields of knowledge: from predicting the optimal appearance and forming a set of technologies that are mandatory for implementation on an engine to methods for testing and debugging it.

Technologies, methods, practical and fundamental solutions that appear and are carefully studied while working on the engine of the future, become a scientific and technical reserve. This backlog determines the success of a promising product, removes the risks of problems during its development, and avoids delays in entering pilot and then mass production.

New generation – new solutions

For more than 80 years of development of jet aviation, five generations of aircraft gas turbine engines have been created with a radical improvement in their performance. The creation of modern engines, with the constant tightening of requirements for their efficiency, weight and size characteristics.

reliability, expansion of the range of operating modes, etc., requires the development and implementation of new breakthrough technologies, materials, design solutions. In many ways, it is advanced technologies that determine the compliance of the engine with international requirements and market demand.

For over 90 years, CIAM has been accumulating and implementing new knowledge, competencies, and testing capabilities that contribute to the gradual emergence of high-tech products with a unique set of technologies and characteristics, allow bringing technologies to a high level of perfection and readiness, facilitating the transition from research to experimental design work.

CIAM began to develop methods for computer-aided design of aircraft gas turbine engines on its own initiative back in the late 1970s. They made a breakthrough in solving the problems of engine design.

Later it became known that the first programs of a similar purpose appeared in the United States around the same years, and they were conducted by the military. In Soviet times, the Siam system of programs was transferred to the Design Bureau and educational institutions in one volume or another.

CIAM pays great attention to the development of modern supercomputer technologies and tools for mathematical modeling of processes occurring in aircraft engines. An important task is to reduce the time for finishing and certification of the engine, as well as to increase the likelihood of obtaining the required engine characteristics during its testing and operation.

To solve these and related tasks, including for related enterprises, a Supercomputer Center for Collective Use with a total capacity of over 500 Teraflops was created on the basis of the Institute.

The greatest contribution from the introduction of digital twin technology is possible at the stage of product development, where its key advantages are laid.

CIAM’s own digital products make it possible to carry out calculations in the field of gas dynamics, combustion, strength, deformed body mechanics, etc., with optimal design of work processes and optimization of compressors, turbines, combustion chambers, inlet and outlet devices, etc.

In the general case, the main task of mathematical modeling is to specify the design of the product in the design process and to predict the characteristics of the engine, its systems.

assemblies, parts and assembly units under test and operation conditions. Also, recently, mathematical modeling tools have been actively used to analyze the results of testing experimental engines, including those on CIAM test benches, and technological processes used in the manufacture of engines (additive technologies, casting, product assembly, etc.).

Computing software systems of the institute have a high degree of accuracy and allow a number of virtual experiments to be carried out.  parts. No virtual simulation can replace real tests, it only supports and complements them. As part of the cooperation agreement concluded between the organizations, work is underway to create digital twins of gas turbine engines (for example, AI-222-25) and power plants based on them.

CIAM also creates demonstrators of digital twins of aircraft engines as part of other applied research. The work is based on the achievements of the Institute in the field of turbojet and small-sized gas turbine engines, as well as hybrid power plants. The purpose of the ongoing work is the development, testing and analysis of the potential of technology for digital twins of aircraft engines.