Collaborative Aircraft Engine Preliminary Design using a Virtual Engine Platform, Part B: Application

Abstract

Digitalization is of growing importance for industries and research institutions as it simplifies and accelerates product development. By that it also offers the ability to reduce risks and costs. Among others, also the aircraft engine sector is facing such a shift of paradigm, entailing a huge potential to support the preliminary design workflow of projected next generation engine concepts. For that purpose the German Aerospace Center (DLR) has started the development of the virtual engine platform GTlab (Gas Turbine Laboratory). It offers a high degree of usability and flexibility with its modular architecture comprising standardized interfaces and thus allows a simple integration of arbitrary user-defined tools. At the heart of the present paper is the application of GTlab in a realistic example of an ultra high bypass-ratio (BPR $\approx 16$) aircraft engine with an anticipated state of the art technology of 2028. The design workflow starts with a 0D thermodynamic performance model and continues with 1D and 2D mid-fidelity preliminary aerodynamic and structural design tools. In this context, challenges are highlighted that were encountered in the course of the process chains and during data handling processes between different fidelity-levels. The mid-fidelity preliminary component designs are carried out by various departments of the DLR and comprise the turbo-components as well as the combustor and structural parts. By that, also the iterative procedure is highlighted, since the initial performance model is updated everytime variations are encountered in the aerodynamic component designs. Also the assessment of fan noise is integrated into the preliminary engine design procedure summing up the multi-disciplinary design loop for the evaluation of future engine concepts.