544-04 - Engine Construction
544-04 - Engine Construction
Engine Construction
CHAPTER 4
ENGINE CONSTRUCTION
ATA 72
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OBJECTIVES
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OVERVIEW
• LPC booster
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ENGINE MODULES
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The five single-race bearings are located in three bearing • Takes thrust loads of the HPC
compartments. Ball, oil
3 • Provides axial and radial support for front
dampened
of HPC
• The front bearing compartment, located at the center of the
intermediate case, houses bearing nos. 1–3. Bearing nos. 1 and
3 provide axial location support. Bearing No. 3 centers by a
• Provides radial support for rear of HPC
series of spring rods. 4 Roller
shaft
• The center bearing compartment, located in the
Diffuser/Combustor Case, houses the No. 4 Bearing.
Roller, oil • Provides radial support for rear of LPT
5
• The rear bearing compartment, located in the Turbine Exhaust dampened shaft
Case (TEC), houses the No. 5 Bearing.
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BEARING COMPARTMENTS
No. 1 Bearing
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BEARING COMPARTMENTS
No. 2 Bearing
No. 3 Bearing
The No. 3 Bearing is a split inner race ball bearing. The outer race
is secured to the No. 3 Bearing housing by a bolted flange. The
bearing housing is centered by 18 spring rods. Any radial
movement is dampened by oil pressure fed to an annulus around
the bearing outer race. The No. 3 Bearing provides axial and radial
location for the HPC rotor and also supports the internal drive gear.
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The No. 4 center bearing compartment houses the No. 4 Bearing. No. 4 Bearing
The compartment is located in a high temperature and pressure The No. 4 Bearing is a roller bearing that provides radial support to
environment at the center of the combustion section. the rear of the HPC shaft. The inner race has shoulders that guide
the rollers in the race. The outer race, installed in the No.4 Bearing
The compartment is protected from radiated heat by a heat shield support assembly, is machined elliptically so the bearing rollers
and an insulating supply of cooling air. This supply of cooled Stage cannot skid.
12 air, called buffer air, enters the space between the chamber and
first heat shield.
The buffer air is then exhausted from the cooling spaces close to
the upstream side of the carbon seals, creating an area of cooler air
from which the sealing function is obtained. This results in an
acceptable air temperature flowing across the face of the carbon
seals into the bearing compartment.
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Air used for internal cooling and sealing is taken from the LPC • Seals hydraulic seal between the LP/HP shaft
Stage 2.5 and HPC stages 6 (early A1 only), 8, 10, and 12. The fan HPC 8 in the front bearing compartment and the single
bypass provides external cooling air. carbon seal of the No. 5 Bearing compartment
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ENGINE MODULES
The engine module design allows for fast, efficient module changes No. Module Name
with minimum down time.
31 Fan
Modular construction has the advantages listed below.
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ENGINE MODULES
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Fan
Purpose: A rubber de-icing tip is bonded to the front of the inlet cone. If ice
begins to form on the rubber tip, it is thrown slightly out of balance
The fan module compresses air which flows into the engine through and begins to vibrate. The vibration causes the ice to be shed from
the nacelle intake cowl and core gaspaths. the inlet cone.
Location: The fairing provides an aerodynamic flow over the annulus fillers
and into the LPC.
The fan module is located in the front of the engine, contained
within the fan case. Operation:
Description: The LPC fan pressurizes air, which flows into the engine through
the nacelle intake cowl.
Twenty-two hollow fan blades are retained in the fan disk radially by
dovetail roots and axially by front and rear retaining rings. Twenty- The larger part of the compressed air goes through the fan duct,
two annulus fillers are installed between adjacent blades, forming a which provides the primary part of the engine thrust. The smaller
platform between each blade. These fillers form the fan inner part is compressed again when it goes through the LP and HP
annulus. A rubber seal is bonded to each side of the annulus fillers compressor stages.
to prevent air leakage between each blade and filler.
The inlet cone and fairing smooth the airflow into the fan. The fairing
is made of metal.
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FAN MODULE
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LPC/Intermediate Case
Purpose: The fan case is installed on the mounting pads on each outer strut
end of the intermediate structure (fan frame) with bolts.
The LPC/intermediate case module houses the front bearing
compartment, internal gearbox, and the LPC system to form part of The intermediate case module includes an internal gearbox that
the bypass ducting. contains a driven gear assembly.
Location:
This module is located in the front of the engine between the fan
module and the HP module.
Description:
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ENGINE MODULES
Internal Gearbox
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INTERNAL GEARBOX
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ENGINE MODULES The disk for stages 1.5, 2, 2.3 and 2.5 is a welded titanium
assembly that contains axial dovetail slots for the attachment of the
LPC/Intermediate Case (Cont.) four stages of rotor blades.
LPC/Booster Rotor blades for stages 1.5, 2, 2.3 and 2.5 are made of titanium and
are mounted into the dovetail slots of their respective disks.
Purpose:
Stator vanes for stages 1.5, 2 and 2.3 are made of titanium.
The LPC/booster compresses the air received from the fan module The vanes are bonded to inner rings by a silicone rubber compound
and delivers it at a suitable pressure level to the HPC. and secured to the LPC case by bolts.
Location: Stator vanes for stage 2.5 is made of aluminum and are secured to
an inner ring by bolts and bonded to an outer ring by a silicone
The LPC/booster is located in the center of the intermediate case rubber compound.
structure (fan frame).
Operation:
Description:
Air is delivered into the LPC by the fan module. The air then passes
The LPC/booster consists of the following. through each rotor and stator stage and is compressed at a suitable
pressure before it is delivered to the HPC.
• Rotor blades and disk for stages 1.5, 2, 2.3, and 2.5
NOTE
• LPC front and rear cases
The V2500-A1 has an LPC/booster with three stages (1.5, 2 and
• Stator vanes for stages 1.5, 2 and 2.3 2.5). The V2500-A5 has four stages (1.5, 2, 2.3 and 2.5).
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Purpose: • rear inner and outer case which forms the bleed
The High Pressure Compressor (HPC) supplies the required amount • manifolds and contains the fixed stators.
of pressurized air for all combustion and aircraft needs. It continues to
increase the pressure of the air supplied by the LPC. HPC stages are numbered 3-12.
Location: Operation:
The HPC is located between the intermediate case module and the The compressed air from the LPC goes into the HPC through the
diffuser/combustor assembly. Variable Inlet Guide Vanes (VIGVs).
Description: The angular position of the VIGVs and Variable Guide Vanes
(VGVs) is automatically adjusted to give the air flow the correct
The HPC is a 10-stage axial flow compressor made up of the direction through the compressor.
following:
As the air goes through the compressor, each stage compresses it
• drum rotor assembly more. The pressurized air is then delivered to the combustion
chamber.
• front case which contains variable stator vanes
Air is ducted from the HPC stages 7-10 to supply air for aircraft
o 5 vanes – A1 engine services. Additionally, more air is bled off at stages 7 and 10 to
improve engine starting and to prevent compressor surge under
o 4 vanes – A5 engine certain operating conditions.
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ENGINE MODULES
HPC (Cont.)
Rotor Assembly
• HPC shaft
The five sub-assemblies are bolted together to make the rotor. Stages
3 to 5 compressor blades are attached in axial dovetail slots. Stages 6
to 12 compressor blades are installed in slots around the
circumference of the disks through an axial loading slot.
The two rotor drums are bolted together with a vortex reducer installed
between the 8th and 9th stages. The vortex reducer straightens the
Stage 8 air flow, which passes to the center of the engine for the
internal cooling and sealing.
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ENGINE MODULES
HPC (Cont.)
HPC Blades
Four lock blades are installed on each disk, two on each side of the
loading slot, and are secured by two lock nuts and two jackscrews
per circumferential stage.
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The diffuser and combustor group has four primary functions listed • No. 4 Bearing compartment.
below.
The inner and outer liner are manufactured from sheet metal with
• Straighten the flow of air from the HPC 100 separate ceramic coated liner segments attached to their inner
surface (50 tiles on each liner). The tiles can be independently
• Reduce the velocity of the air to get the best speed and replaced during engine overhaul.
pressure for combustion Operation:
• Mix fuel with the air and supply ignition to make fuel burn 1. Air velocity is decreased in the diffuser case, converting the
• Hold the No. 4 Bearing in position speed energy into pressure.
Location: 2. Fuel is mixed with the air in the combustion chamber and
then burned.
The diffuser and combustor module is located between the HPC
module and the HPT module. 3. The hot expanding gases exiting the combustion chamber
are directed back toward the turbine NGV assembly.
Description:
The diffuser and combustor module includes:
• diffuser case assembly
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DIFFUSER/COMBUSTOR SYSTEM
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ENGINE MODULES
The diameter of the diffuser section is larger at the rear than at the
front. This diameter difference decreases the speed of the air and
changes the velocity energy into increased pressure.
The diffuser case has 20 mounting pads, where the fuel injectors
are installed, and two mounting pads where the igniter plugs are
installed. The diffuser case also includes five mounting pads for the
combustion chamber outer alignment pins.
Outlet guide vanes, bolted at the front of the diffuser, straighten the
air coming from the HPC. The air enters the diffuser portion of the
diffuser case prior to entering the combustion chamber.
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ENGINE MODULES
The outer liner is secured by five locating pins which pass through
the diffuser casing. The combustion chamber outer liner assembly
has 20 fuel nozzle guides.
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Turbine Nozzle Guide Vane (NGV) Assembly The vanes are attached to the Stage 1 HPT cooling duct assembly
with bolts. Each hollow vane has internal baffles and cooling holes
Purpose: in the airfoil. Vane airfoils also have a heat-resistant coating.
The Turbine Nozzle Guide Vane (NGV) Assembly delivers the The 1st Stage HPT cooling duct is installed on the rear-inner flange
exiting gases from the combustion chamber at the right speed and of the diffuser case.
pressure to the 1st Stage HPT blades. When assembled with the outer combustion chamber liner
assembly, the combustion chamber inner liner creates a chamber
Location: for burning the mixture of fuel and air.
The Turbine NGV Assembly is located between the rear of the Operation:
diffuser case and the front of the HPT. The ring of guide vanes creates a series of nozzles which increase
the velocity of the gases from the combustion chamber. The vanes
Description: point the gases at the optimum angle onto the Stage 1 turbine
blades.
Primary parts of the NGV assembly include:
The internal vane baffles and airfoil cooling holes permit cool air
• Stage 1 HPT vane cluster assemblies from the diffuser case to go through the vane and over the external
airfoil to decrease metal temperature. Sheet metal seals between
• Stage 1 HPT cooling duct assembly adjacent vane platforms decrease leakage of the cool air.
The Stage 1 HPT cooling duct assembly carries HPC discharge air
• Combustion chamber inner liner from the diffuser case, and sends it through the metered nozzle
known as the Tangential Outboard Injector (TOBI) duct. The air is
used to cool the front face of the Stage 1 turbine rotor and Stage 1
turbine blades.
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ENGINE MODULES
HPT (Cont.)
Operation:
The Stage 1 HPT blades are cooled by the HPC discharge air
which flows through the Stage 1 HPT cooling duct assembly. The
Stage 2 vane clusters are cooled by Stage 10 compressor air that
flows in through the center of the vanes.
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Purpose: The LPT rotor is installed in the LPT case where it is in alignment
with the LPT stators. The LPT case is made from high-heat-
The Low Pressure Turbine (LPT) supplies the necessary power to resistant nickel alloy and is a one-part, welded assembly.
turn the LPC and fan.
The five LPT disks are made from high-heat-resistant nickel alloy
Location: and are axially installed and assembled together with nuts and
bolts.
The turbine is located aft of the HPT at the rear of the engine.
The LPT blades are also made from nickel alloy and are attached to
the disks by fir-tree roots. The blades are held in axial position on
Description:
the disk by the rotating air seals (knife edge). The rotating air seals
Primary parts of the LPT module include the following. are in line with stationary abradable seals installed on the LPT
stator vanes.
• LPT five-stage rotor
The LPT shaft is attached to the rotor by 20 nuts and bolts on the
• LPT five-stage stator vanes 6th stage disk.
• Air seals
Operation:
• LPT case
The hot, expanding gases blow through the five stages of the LPT.
• Inner and outer duct
The remaining energy from the combustion gases is extracted to
• LPT shaft provide the necessary power to turn the LPC through the LPT shaft.
• TEC
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ENGINE MODULES
LPT (Cont.)
The TEC provides support for the No. 5 Bearing and mounting
provisions for the Combined Nozzle Assembly (CNA), exhaust plug,
and rear mount.
The TEC assembly contains the LP rotor rear (No. 5) bearing and
support structure. The loads are transmitted to the outer case by
struts.
The TEC has mounts for the airframe-supplied tail cone and the
CNA. This case also includes the engine rear mount and rear
ground handling mount points.
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The AGB support is a casting that houses the lay shaft and rigidly
connects the angle gearbox to the main gearbox.
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ENGINE MODULES
Operation:
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