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Reflections on 50 years in R&D

Reflections on 50 years in R&D. Professor Phil Ruffles March 8 th 2011. RB211 and Trent Family. Variants -9 Engines sold and on Order RB211 -3760,Trent -2060 sold,2600 on order Aircraft RB211-L1011,B747,B757, B 767 Tu 204 Trent - A 330 A340 A350

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Reflections on 50 years in R&D

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  1. Reflections on 50 years in R&D Professor Phil Ruffles March 8th 2011

  2. RB211 and Trent Family • Variants -9 • Engines sold and on Order RB211 -3760,Trent -2060 sold,2600 on order • Aircraft RB211-L1011,B747,B757, B 767 Tu 204 Trent - A 330 A340 A350 A 380 B777 B787 • 71 Trent Operators • Revenue 40bn to date,35bn New engines on order. Aftermarket is additional

  3. The Launch – 29 March 1968

  4. RB211 Advantages of three shafts • Picture and Chart which summarises the benefits of 3 shaft engines

  5. RB211-06 • Designed for market leadership through technology • 33,260 lb thrust in 1966 • -06 was unable to meet increasing demand for thrust during aircraft development • Subsequently redesigned for 40,600lb from April to October in 1968 to become -22C • Uprated to 42,000lb (-22B) to compensate for weight growth

  6. RB211-Scale of advance Weight 8861lb RB211-22 (1972) 85.5in.dia. Conway RCo43 (1965) 45in.dia. Weight 4855lb • Performance advance • Thrust +95% • Cruise sfc -21% • Noise -19PNdB • Turbine entry temp. +150ºC • Pressure ratio 17 > 25 • Airflow x 3.7

  7. RB211-22 The Hyfil fan • The Hyfil fan offered a 300 lb weight and two per cent fuel consumption benefit • High risk of Hyfil was recognised so a Titanium alloy alternative was designed in parallel • as early as 1969 Hyfil blades were experiencing integrity problems • replacement with Titanium blades allowed continued testing • The Hyfil blade was replaced by the Titanium blade in Spring 1970

  8. RB211-The review of early milestones • 34 development engines were built, compared with today’s usual six or seven • 36 flight engines were sent to Lockheed, compared with today’s usual seven or eight RB211-06 detailed design commenced at 33260lbs thrust RB211-22 order received at 40600lbs thrust First run of -06 engine First run of -22 engine First flight of RB211 in VC10 First flight of L1011 Type approval obtained for 42000lbs at ISA+3, 40600lbs at ISA+15 L1011 obtains type approval – airline service starts Type approval obtained for 42000 lbf at ISA+15 (-22B) Mid 1967 Mar 1968 Aug 1968 Jan 1970 Mar 1970 Nov 1970 Feb 1972 Apr 1972 Feb 1973

  9. RB211-06 Realising 40,000lb thrust • RB211-06, Engine 5 – Test Report (Jan 1969): • Seizure of LP spool during initial attempts to start engine • Strip revealed distorted blades, severe foul with seal segments • Turbine module from Engine 3 fitted to resume testing • After 19hrs 40mins, several Hyfil fan blades were found damaged • Hyfil assembly removed and Titanium assembly fitted to resume testing • Surge at 36,000 lbf after 21hrs 34mins (day temperature: -7°C) • Engine rejected from test due to seized HP spool • Strip examination revealed HP turbine blade foul with seal segments • Thermal deterioration of the flame tube had also occurred • Best performance to date! • RB211-06, Engine 7 (March 1969): • Engine achieved 40,000lbf but surged and seized on run-down due to HP turbine blade failure

  10. RB211-06 Realising 40,000lb thrust ‘The Evidence’ !

  11. Engine overweight Poor performance ofcompressors and turbines Temperature traverse Fan bladeintegrity RB211 Early development problems LP blade profilechanges Deletion of composites and strengthening of engine structure HP turbine bladecooling/fatigue(IPNGV excitation) IP NGVperformance Operability Combustion chamberand NGV cooling, cracking and collapse

  12. Rolls-Royce Receivership-February 4th 1971 • Engine 10011, fitted with a package of performance modifications, returned best performance to date on evening of Feb 3rd 1971 • The SFC shortfall was approx 8% with thrust close to 40,000lb • This demonstrated the engine’s potential and had a major bearing on the events that followed • The receiver allocated 12 development engines compared with the previous 18 - this required a clear focus on priorities • Contract with Lockheed was re-negotiated with technical spec eased • HP turbine blade was fixed, turbine sealing improved and further performance improvements made • 14 months after bankruptcy the engine entered service at 40,600lbs, 41/2 months late, derated and overweight! • 12 months later thrust was fully recovered and SFC target met.

  13. -22 total engine-caused removals HP compressorsurge Fan disc Rate per 1,000 hours Combustion liner life(800 hours initially) Surge/compressor damage Fan disc RB211 Early service problems Other reasons 0 ’72 1973 1974 HP turbine life(800 hours initially) Turbine blade/combustion liner deterioration Accessory reliability HP compressorstators LP locationbearing

  14. Boeing 767 RB211-524 and RB211-535 Boeing 747 Lockheed L-1011 -535F5 Tupolev Tu 204 Boeing 757 Thrust – lb x 1000 70 (pkg 3) -524G/HT -524G/H 60 -524D4 -524C -524D4-B -524B 50 -524B4-B Improved -22B -535E4 40 -22B -535C

  15. RB211-22B/-524/-535 and Trent HP turbine blades 1979 RB211-22B/535C Multi-pass cast DS bladeHP feedExtensive film cooling1660K 1983 RB211 535E4 Second generation multi-pass cast DS blade1680K 1972-75 RB211-22B Extruded bladesLP feed, cut back trailing edge Suction and trailing edge cooling HP feed to leading edge Interlock 1545K -1550K 1995 Trent 800Multi-passSingle crystal Root damper HPNGV shapingParallel shroud40 NGVs1840K 1987-96 RB211-524 Strategy 2C-2.5CModified interlockMulti-passSingle crystal36 NGVs1730K-1751K 1977 RB211-524EquiaxedHP feed racetrack 36 NGVs1660K

  16. Rolls-Royce Changing pace of technology 1980-1990 Technology introduction IT power and capability RB211 524G/H V2500 RB211 535 Early use of CFD, FEA etc – development of turbine key systems Emergence use of modelling/analysis tools, e.g. TACITUS Widespread us of key systems across all components 90’s 80’s

  17. Improving Method Quality Rolls-Royce Modelling Capability1980 to 1986 Transient dynamic response Impractical or impossible 10 9 Whole engine modelling (FE) 8 Rotor blade vibration analysis 7 Analysis time 6 Disc temperature prediction Time to influence design 5 4 Disc LCF lifing Benefit from vector processor 3 Analysis of 14 aerofoils at six operating points (Inc OGV in 3D) 2 V2500 Plan B 1 0 1981 1985 1982 1984 1986 1983 Date (year)

  18. Rolls-Royce Computer Simulation • Computer Simulation has changed the way Engineering is carried out • 1960’s 1st Computers used • 1970’s 1st Turbine design system(1976) • 1980’s Mechanical Analysis concurrent with design. • 1990’s Faster, greater complexity, more iterations Digital Pre-assembly(Trent 800) • 2000’s Simulation validation via test then used for subsequent certification • 2010 Whole engine modelling & Fan Blade-Off simulation

  19. RB211-535, V2500, RB211-524 improvement programmes Attempts at performance improvement programmes through technology introduction provided mixed successes due to technology management and process difficulties

  20. Derwent – The new product introduction process Stage 1 Preliminary Concept Definition Audit gates Stage 1 Exit review Stage 2 Full Concept Definition Stage 2 Exit review Stage 3 Product Realisation • Critical design review • Design verification review • Production readiness review Stage 4 Production Production process check Stage 5 Service Support In-service review Stage 6 Disposal

  21. Integrated team and product structure IPT structure Product & Functional structure Chief Engineer Whole System (Product) Etc Chief Design Engineer Chief Devt. Engineer Sub-system Sub-system Team leader of Sub-system Team leader of Sub-system Component Component Team leader of Component Team leader of Component Team leader of Component Team leader of Component Component Component

  22. Rolls-Royce Capability Acquisition • Requirements: • Airframers • Operators New Product Planning Full Concept Definition Product Realisation Service Support Production Disposal Solutions • Facilities • People/skills • Supply Chain • Infrastructure New Capability Realisation R&T Strategy Planning • Technology Validation • Generic • Project specific Research and Technology Programme Strategic Research Applied Research UNIVERSITY TECHNOLOGY CENTRES Global Academic Network

  23. Rolls-Royce Technology Acquisition • Prior to mid 1970’s technology acquisition was determined by functions, largely with a research focus • High Temperature Demonstrator Unit 1st run in 1972 • Structured Advanced engineering programmes launched in 1976 including Demonstrator engines • University Technology Centres launched in 1990 • Technology Strategy linked to Corporate and Product strategy from 1995 onwards • Technology programmes key to success of Trent Engine family and growth of Company in other sectors

  24. Strategic research Validation Applied research Increasing cost/Reducing uncertainty/Reducing time to market Research and technology management Wide Chord Fan MMC Blisk Maturity Levels 3D Compressor Blading High Temp. Demo. Unit Fuel Cells Technology Categories Titanium Disc Fuel Cells Pacing Base Emerging Key Relative to competition: Lead/Neutral/Lag

  25. The Trent Family EIS 2011 EIS 2007 EIS 1996 EIS 2013 Trent XWB 84,000lb Trent 1000 74,000lb Trent 800 95,000lb Trent 900 80,000lb 110 • 2060 engines delivered • 2600 orders backlog • (December 2009) Fan diameter 97.5 EIS 1995 EIS 2002 Trent 500 56,000lb Trent 700 72,000lb 86.5 RB211-524G/H-T 60,000lb

  26. Trent 1000 – High technology at low risk Soluble core manufacturing of HPT blade Active anti icing Advanced LPT design IP power off-take Optimized lightweight fan system More electric Accessories and Engine Health Monitoring

  27. Developing our Engineering Talent Engineering Directors Chief Engineers Fellows Technical Managers Associate Fellows Recruits Some External Losses Movement out of Engineering Specialists Recruits Project Managers Technical Leadership Project Leadership Graduate Level Recruits & Apprentices

  28. Product Development –Keys to Success • Competitive Product Concepts • Technology acquired ahead of product development • Stage Gate Product introduction process • Formal gate reviews • Risk assessment and management • Integrated Product Teams • Robust product requirements • Work package management • Clearly defined deliverables • The best digital tools inc verification • Well trained and motivated people

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