Attachment0005TDS14OCT15.pdf

Source Selection Information

See FAR 3.104 1B

Appendix A Technical Data Supplement for Sub-factors 1 and 2

1. SCOPE

This appendix provides supplemental information for data to be submitted under this engine RFP.

It defines content for Sub-factor 1, Engine Design and Performance, and Sub-factor 2, Component Design. Data submitted shall document the engine design configuration, performance, and design procedures used for preliminary design. The data requirements addressed in this appendix are not comprehensive; therefore, it is the Offeror’s responsibility to submit data that supports their overall proposal.

2. APPLICABLE DOCUMENTS

2.1. General - A list of all applicable documents is provided in the ITE Specification Development Document (SDD). Unless otherwise indicated, copies of the specifications, standards, and handbooks are available from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.

2.2. Non-Government publications.

Unless otherwise specified, the issues of the documents that are DoD adopted are those listed in the issue of the DoDISS cited in the solicitation.

SOCIETY OF TRIBOLOGISTS AND LUBRICATION ENGINEERS (STLE)

SP-34 Life Factors for Rolling Bearings

(Copies of this document are available online at http://www.stle.org/, or from the Society of Tribologists and Lubrication Engineers, 840 Busse Highway, Park Ridge, IL 60068- 2376.)

3. DEFINITIONS

3.1. Acronyms

3.1.1. ABMA American Bearing Manufacturers Association

3.1.2. AGMA American Gear Manufacturers Association

3.1.3. CDP Component Development Plan

3.1.4. DoD Department of Defense

3.1.5. DoDISS DoD Index of Specifications and Standards

3.1.6. EMS Engine Monitoring System

3.1.7. FAR Fuel/Air Ratio

3.1.8. FEA Finite Element Analysis

3.1.9. FOD Foreign Object Damage

3.1.10. GGT Gas Generator Turbine

3.1.11. HCF High Cycle Fatigue

3.1.12. HP High Pressure

See FAR 3.104 2B

3.1.13. IP Intermediate Pressure

3.1.14. LCF Low Cycle Fatigue

3.1.15. LP Low Pressure

3.1.16. NATO North Atlantic Treaty Organization

3.1.17. NOAA National Oceanic and Atmospheric Administration

3.1.18. PFR Preliminary Flight Rating

3.1.19. PT Power Turbine

3.1.20. QT Qualification Test

3.1.21. RFP Request for Proposal

3.1.22. RFQ Request for Quote

3.1.23. SAE Society of Automotive Engineers

3.1.24. SLS Sea Level, Static

3.1.25. SM Stall Margin

3.1.26. STLE Society of Tribologists and Lubrication Engineers

3.1.27. 2D Two Dimensional

3.1.28. 3D Three Dimensional

3.2. Definitions

3.2.1. Cold Atmospheric Conditions - Cold atmospheric conditions are as defined in the engine specification.

3.2.2. Combustor Inlet - The exit plane of the compression system diffuser.

3.2.3. Combustor Pattern Factor

avg = thermodynamic average max = maximum temperature measured by any probe

3.2.4. Combustor Total Pressure Loss

3.2.5. Compressor Efficiency - The ratio of the work required in an isentropic compression process to that required in the actual process.

See FAR 3.104 3B

3.2.6. Hot Atmospheric Conditions - Hot atmospheric conditions are as defined in the engine specification.

3.2.7. Maximum Allowable Transient Rotor Speed - The MATS is as defined in the engine specification.

3.2.8. Maximum Fuel Consumption Guaranteed - The fuel consumption that has been calculated by a thermodynamic cycle analysis and increased by a production margin factor.

3.2.9. Minimum Delivered Shaft Power Guaranteed - The delivered shaft power that has been calculated by a thermodynamic cycle analysis and decreased by a production margin factor.

3.2.10. Nominal Performance - The performance associated with the statistically average production engine.

3.2.11. Production Margin - A factor applied to fuel consumption and delivered shaft power that accounts for performance variations associated with the production of a large number of engines. This factor is normally determined empirically from historical data of similar type and size gas turbine engines.

3.2.12. Stall Margin

SM

Pr Wa

Pr Wa 100%

Pr Wa

Pr is the compressor pressure ratio

Wa is the compressor corrected airflow

(All at a constant corrected speed.)

3.2.13. Standard Atmospheric Conditions - Standard atmospheric conditions are the values of air properties (density, temperature and pressure) given in NOAA-S/T 76-1562.

The standard humidity is zero vapor pressure. All heights shall be geopotential altitudes.

3.2.14. Standard Day - Standard day is defined as 15C (59F) ambient.

3.2.15. Turbine Efficiency - The ratio of the work available in the actual expansion process to that available in an isentropic expansion process.

3.2.16. Turbine Inlet - The inlet plane at the first stage nozzle vane row of the turbine (engine station number 4).

See FAR 3.104 4B

3.2.17. Station Identification - The engine station number system shall conform to AS755.

The power turbine inlet station shall be 4.5.

3.3. Symbols - Except as specified below, symbols shall be as specified in AS755.

Symbol Description Units

CRP Contingency rated power kW (hp)

FI Flight idle (power) kW (hp)

GI Ground idle (power) kW (hp)

IRP Intermediate rated power kW (hp)

MATS Maximum allowable transient rotor speed rpm

MCP Maximum continuous power kW (hp)

MRP Maximum rated power kW (hp)

NG Gas generator rotor speed rpm

NH High pressure gas generator rotor speed rpm NI Intermediate pressure gas generator rotor speed rpm NL Low pressure gas generator rotor speed rpm NP Power turbine rotor speed rpm NSD Delivered (Output) shaft speed rpm NST Starter shaft speed rpm P3 Compressor exit/combustor inlet total pressure kPa (ksi) P4 Combustor exit/gas generator turbine inlet total pressure kPa (ksi) T3 Compressor exit/combustor inlet total temperature ºC (ºF) T4 Combustor exit/gas generator turbine inlet total temperature ºC (ºF) T4.1 Gas generator turbine rotor inlet total temperature ºC (ºF)

Pitching velocity about the center of gravity rad/sec of the engine

Pitching acceleration about the center of rad/sec2 gravity of the engine

Yawing velocity about the center of gravity rad/sec of the engine

Yawing acceleration about the center of rad/sec2 gravity of the engine

See FAR 3.104 5B

4. GENERAL REQUIREMENTS

4.1. Content - The engine proposal data shall:

4.1.1. Thoroughly document the engine configuration, performance and operating capabilities, and the design methods employed.

4.1.2. In a component or engine functional group discussion, contain:

4.1.2.1. A description of the design and its capability.

4.1.2.2. A description of the analytical and empirical design methods employed with the results.

4.1.2.3. Include data figures and tables that accurately define the characteristics of engine components, materials, etc., with headings, legends, and axis labels, which allow easy and accurate interpretation.

See FAR 3.104 6B

5. DETAIL REQUIREMENTS

5.1. Content - The design data shall address the areas described below. The description is given not to be inclusive, but to indicate the type and minimum level of detail required.

5.2. Engine Configuration - The decisions considered in selecting the overall engine configuration shall be explained. The mechanical arrangement and overall dimensions shall be defined. Schematics shall be furnished in which physically identifiable components are labeled for both exterior and cutaway views. A scalable engine cross-section drawing shall be included. Engine maintainability and survivability features shall be addressed. A parts listing including part number, description and material shall be provided. A group weight statement (see Table I), including center of gravity locations relative to a defined reference point for the engine and its major components, a detailed weight breakdown, engine installation features, and general operating procedures shall be included. An engine station designation IAW AS755 shall be defined and presented, including an engine cross-section with station numbers. The station designation system shall be used consistently throughout the report/proposal. A table and an engine cross-section presenting the number of airfoils per stage shall be provided (including stators, rotors, impellers, etc.).

5.3. Engine Performance - Cycle analyses and trade-off studies performed to establish cycle pressure ratio, gas temperatures, and engine airflow rate shall be explained such that the reasons for selection of the design cycle parameters are clear. The overall engine performance and the component data necessary for performance calculation shall be defined as shown in Table II for conditions at SLS standard day and at all other design points identified in the engine specification. Details of the cycle, including pressures, temperatures, and flow rates (fuel, primary air and secondary air), shall indicate amounts entering or leaving the cycle which are used for overall engine performance analyses.

These details shall be provided as parameter tabulations and an engine schematic to precisely define the parameters. The schematic shall specify locations and directions of all flow streams. Substantiating data shall be included with the specific component sections, but sufficient data shall be supplied here to define the production margin utilized.

5.4. Engine Operational Capabilities - The engine’s overall operational capabilities shall be defined. Description of capability, defined limit and design parameters shall be included, which cover such areas as: vibration environment, torsional stability, temperature limits, altitude limits, starting criteria, acceleration/deceleration times, heat rejection, infrared radiation, attitude, windmilling, electromagnetic interference, fuels and oils, mechanical limits and noise.

5.5. Engine Modules/Functional Groups - Each area shall be completely defined as to its aero/fluid dynamics, thermodynamics, mechanical and functional design. Substantiating data, including component test results, as well as engine test results shall be included to verify that the engine conforms to design criteria and that design calculations and analyses are correct.

See FAR 3.104 7B

5.5.1. Compressor - A narrative description of the compressor module and applicable components, both static and rotating, shall be presented supported by drawings and with critical dimensions, physical data such as detailed in table III, and compressor performance maps such as illustrated in figure 1. Typical components include shrouds, cases, impellers, disks, airfoils, diffusers, deswirlers, frames (front and mid), and also variable geometry features such as variable stator vanes and flow fences.

The narrative description shall include definitions of terms used. The drawings shall include airfoil profiles as a function of span and shall also include profile dimensions.

Velocity triangle data along constant streamlines and airfoil geometry at tip, mid-span, and root shall be presented. Graphical representation would be the preferred method for the velocity triangle data. The nomenclature for the velocity triangles shall be identified. Other results to be presented include:

Compressor stage plots of air angle variation, static pressure rise, axial velocity, and diffusion variation through the compressor.

Compressor rotor exit total pressure, total temperature, absolute Mach number, and absolute flow angle with respect to axial, as a function of airfoil span from hub to tip.

Centrifugal compressor diffuser inlet Mach number, inlet blockage, pressure recovery, and exit Mach number.

The cooling aspects of the compressor, documented by schematics describing the cooling schemes and details of the heat transfer analyses (steady-state and transient). This data shall include cooling air temperatures and pressures, heat transfer coefficients used for the thermal analyses, and predicted temperature profiles, for critical components.

Acceleration bleed valve, inducer vent, bleed air extraction and anti-ice flow rates, temperatures, and pressures shall be defined.

5.5.1.1. Design Methodology - All analytical and empirical methods used in the design shall be presented. For the aero/thermodynamic design, the analytical and empirical methods employed in design of the airfoil surfaces and flowpath shall be described, including methods of calculating velocity distributions on airfoil surfaces and iteration of airfoil geometry computations. Empirical design procedures, based on test data from similar hardware, shall be described.

Assumptions and simplifications inherent in the empirical design procedures shall be described. Methods for balancing the rotor shaft configuration shall be addressed. Methods for predicting transient and steady-state clearances shall be addressed. All assumptions, simplifications, and parameters shall be listed and described for these methods, including relevant equations and sample calculations. For example, loss assumptions shall be provided with sample calculations. Units shall be provided for the calculations.

See FAR 3.104 8B

5.5.1.2. Structural Integrity - The structural integrity of the compressor components, both static and rotating, shall be analytically substantiated to verify compliance with design life requirements. All potential failure modes/mechanisms shall be addressed (e.g. HCF, LCF, crack propagation life, creep/stress rupture, oxidation, corrosion, overspeed, containment capability, maneuver loading, gyroscopic loading, impact loading, FOD, bird strike, pressure loading, etc.).

See 5.6 for details regarding the analyses required. A summary of development/production experience for any new/innovative materials and processes used in the compressor design shall be provided.

5.5.2. Combustor - A narrative description of the combustor module shall be presented and supported by drawings with major dimensions of the following sub-elements, as a minimum: liner (include zone lengths), swirlers, injectors, cooling devices and features, cases, shrouds, plenums, and attachment/locating devices. Flow areas shall be included in the description. Table IV shall be completed. Plots of combustion efficiency versus overall FAR with lean blowout, lightoff, GI, 65%, 80%, and 100% MCP, IRP, MRP, CRP, and rich blowout noted. Combustor performance, durability, and related features such as the following shall be presented: exit temperature profile, pattern factor, altitude lightoff envelope, fuel injector performance over the operating range, liner temperature prediction and cooling characteristics, inlet conditions, fabrication procedures and sequence, smoke and non-visible emissions, multi-fuel capability, location of vibratory resonance conditions relative to the operating range, materials, and cost tradeoffs.

5.5.2.1. Design Methodology - The analytical and empirical methods employed to design the combustor shall be described. The description shall include factors considered in selecting the basic combustor and fuel injector type, sizing the primary, secondary, and dilution zones, defining airflow split, predicting exit temperature distribution, defining pressure drop, estimating injector and delivery system heating, and predicting smoke and non-visible emissions.

Assumptions and simplifications inherent in design procedures shall be stated.

Results of the analyses shall be presented, including scaling parameters, residence time, loading parameter, reference Mach number and area, pressure loss breakdown, and airflow distribution. All reference parameters used in the analysis and design shall be clearly defined. Units shall be provided for the calculations.

5.5.2.2. Structural Integrity - A detailed description of mechanical design procedures shall be presented, including heat transfer analyses with resultant metal temperature distributions, maximum metal temperature, thermal growth, pressure vessel stresses, thermal stresses, creep buckling life, LCF life, corrosion, oxidation life, and vibratory analyses. For the life analyses, paragraph

5.6 gives specifics as to the extent of work to be done. Results of these analyses shall be compared with steady-state and cyclic design life requirements.

5.5.3. Turbine - A narrative description of the turbine module and applicable components, both static and rotating, shall be presented and supported by drawings, including all

See FAR 3.104 9B dimensions, and any required schematics depicting the turbine design. Typical components include airfoils, disks, sealplates, cases, frames, shrouds, spacers, radial turbines, etc. The turbine aero/thermodynamics design criteria, as specified in Table V, shall be presented to substantiate the turbine design. A turbine map shall be submitted for each turbine (LP, HP, PT, etc.) in the format per attached Figure 2. The detailed airfoil design specified shall be substantiated by tabulated airfoil profiles and test results of similar airfoil profiles. Airfoil profiles shall be shown graphically, as well as by surface pressure, and Mach number diagrams for the nozzle and rotor at root, mid-span, and tip locations. The turbine thermodynamic requirements, such as flow rate, turbine inlet temperature, turbine inlet pressure, turbine exhaust pressure, overall pressure ratio, overall turbine efficiency, the individual stage efficiencies, pressure ratios, and the shaft speeds shall be presented per Table V. All losses shall be calculated and defined, and the sample analytical calculations provided. The efficiency tabulation for each turbine stage shall include losses associated with tip leakage, bearing, and mechanical losses, cooling air discharge effect, pumping, and disk windage. Turbine performance characteristics shall be submitted and shall be defined by equivalent specific work versus equivalent mass flowspeed parameters.

The effects of variation in cooling airflow rates and rotor airfoil tip clearance on performance shall be shown. Other results to be presented include:

The stage work, reaction, all velocities, temperatures and pressures between airfoil rows, Mach numbers, airfoil turning angles, dimensions, and mass flow rates.

The annulus height variation between turbine stages and the effects of this variation.

The cooling aspects of the turbine, documented by schematics describing the cooling schemes and details of the heat transfer analyses (steady-state and transient). This data shall include cooling air temperatures and pressures, heat transfer coefficients used for the thermal analyses, and predicted temperature profiles, for critical components.

The shaft rotational speeds selected to achieve the compressor inlet Mach number.

5.5.3.1. Design Methodology - The structural design of the turbine module, to include the nozzle and rotor sections and all other applicable components, shall be provided along with the calculations and methods employed. All analytical and empirical methods used in the design shall be presented. For the aerodynamic design, the analytical and empirical methods employed in design of the airfoil surfaces and flowpath shall be described, including methods of calculating velocity distributions on airfoil surfaces and iteration of airfoil geometry computations. Empirical design procedures, based on test data from similar hardware, shall be described. Assumptions and simplifications inherent in the empirical design procedures shall be described. Methods for balancing the rotor shaft configuration shall be addressed. Methods for predicting transient

See FAR 3.104 10B and steady-state clearances shall be addressed. All assumptions, simplifications, and parameters shall be listed and described for these methods, including relevant equations and sample calculations. Units shall be provided for the calculations.

5.5.3.2. Structural Integrity - The structural integrity of the turbine components, both static and rotating, shall be established analytically to verify compliance with design life requirements. All potential failure modes/mechanisms shall be addressed (e.g., HCF, LCF, crack propagation life, creep/stress rupture, oxidation, corrosion, overspeed, containment capability, maneuver loading, gyroscopic loading, impact loading, FOD, bird strike, pressure loading).

Paragraph 5.6 gives specifics as to the extent of work to be done. A summary of development/production experience for any new/innovative materials and processes used in the turbine design shall be provided. Operating clearances shall be addressed.

5.5.4. Controls and Accessories

5.5.4.1. System Level - A complete, detailed description of the engine control system shall be provided. The control philosophy (such as isochronous techniques and utilization of proportional, integral and differential feedback) shall be described. The functional decomposition of system requirements to the various system components, the redundancy philosophy, the system inputs and outputs, a description of the selected control modes, and the operation of the system from engine starting through shutdown shall be provided. The description shall include a discussion of how the design reduces the pilot workload in controlling the engine and how the control system increases aircraft safety. The control system safety discussion shall include a detailed, system level, failure effects and corrective action analysis.

5.5.4.1.1. Monitoring/Diagnostic Systems - For condition monitoring, diagnostic systems, and EMS, the description shall include the appropriate information as required above plus the interface requirements and considerations including any special airframe instrumentation or readout devices needed. If the monitoring/diagnostic system is contained solely within the control system, then the appropriate information for hardware and software shall be included.

5.5.4.1.1.1. Engine Monitoring System - If an EMS is to be used, all component lifing algorithms shall be presented. The EMS shall also incorporate sufficient resolution to accurately define component life usage throughout the operational envelope and at the maximum transient capabilities of the engine.

5.5.4.1.1.2. Engine Monitoring System Validation - Not required for PDR contract.

See FAR 3.104 11B

5.5.4.1.2. Schematics - Schematics of the control system, the fuel system, and the electrical system shall be presented and shall indicate any necessary fuel and electrical interface connections between the engine, control, and the airframe.

5.5.4.2. System Components - The system component design requirements and the detailed designs (including sensors and actuators) shall be described. This description shall include the factors considered during the design process relative to flow sizing, weight, performance, endurance, reliability, maintainability, system safety, etc. For electrical systems and components, the presentation shall include electromagnetic characteristics, compatibility considerations, and electrical power requirements. The various tradeoffs of these parameters, which are considered to be advantageous for cost or other reasons, shall be documented. Properties of materials selected for components and pertinent data relative to pressure and thermal stresses, LCF life, oxidation/corrosion resistance, wear resistance, etc., shall be given.

5.5.4.2.1. Component Environmental Control System - The component environmental control system, if required to meet component-limiting temperatures, shall be described.

5.5.4.3. Electronic Control Unit - If a digital electronic control unit is utilized, a complete, detailed description of the computer architecture shall be provided.

This description shall include the aspects of chosen microelectronic processor technology, the internal data and control bus architectures, the memory management techniques, the software execution timing management techniques, the hardware and software integration approach for input/output circuitry, redundancy, and the built-in-test and failure accommodation philosophy. The control unit cooling requirements, growth potential for electronic components, mounting location and justification (if off-engine), shall be presented. A complete description of the control unit power supply, including philosophy of design efficiency, compatibility to military power transients and electromagnetic vulnerability, shall be provided.

5.5.4.3.1. Mechanical Design - The electronic hardware mechanical design shall be completely described and shall include details on circuit board design and manufacturing technology, interconnection circuitry, thermal transfer techniques, electromagnetic interference design considerations, and chassis design. A description of electronic component screening processes and component obsolescence control program shall be provided.

5.5.4.4. Software - If a digital electronic control is utilized, the design, development and validation of the control unit software shall be described. This description shall include the aspects of the chosen microelectronic processor technology, the philosophy of kernel/boot up operating system software, the structure, integration and execution of application software, the approach of foreground/background timing philosophy and programming language

See FAR 3.104 12B approach. Agreed upon modern, quality techniques and standards shall be used in the development of software. Details of the software development approach (i.e. state machine diagrams, object oriented programming, “waterfall” model, etc.), the software development environment, requirements traceability, configuration management and quality assurance/verification process shall be included.

5.5.4.4.1. Control Logic Strategy/Theory - Control logic strategy and control theory shall be presented to include control logic block diagrams. The various limiting provisions, including acceleration and deceleration fuel schedules shall be defined as well as others required for the selected control modes. Any analytical and empirical methods used during the design process shall be presented along with the assumptions and rationale used in arriving at the software design. This presentation shall include, but not be limited to, a discussion of the control system dynamics and any system stability studies or analyses of compatibility with rotor systems that are relevant to the engine design and development. A detailed description of the capability of the engine control system to be readily optimized for stability and response over a wide range of aircraft drive system parameters (i.e., inertias, spring constants and damping coefficients), rotor types and configurations shall be provided.

5.5.4.5. Fuel Systems/Components - For fuel systems and components, the presentation shall include information relative to fuel contamination requirements, design considerations, test results, and other pertinent information such as lubrication utilized, electrical characteristics, etc. Specific information for electro-motive components used for the regulation/metering of fuel and for feedback information shall be provided.

5.5.4.6. Engine Airflow Components - For components which are exposed to engine airflow, the presentation shall include information relative to air contamination requirements, design considerations, test results, and any other pertinent information such as lubrication, electrical characteristics, etc.

5.5.4.7. Ignition System Components - The ignition system and its power source shall be described including the rating, in terms of stored energy level and delivered energy level to each ignitor, in joules per spark and frequency of spark.

The points in the starting envelope where minimum stored and delivered energy levels to each ignitor occur shall also be defined.

5.5.5. Mechanical Components - A complete description of the mechanical systems of the engine shall be given. This includes bearings, gears, seals, shafts, and the lubrication system. Mechanical component dimensional and operating parameters shall be listed in tabular form (see Table VI). An explanation shall be provided detailing why each component will meet or exceed the specification requirements. If applicable, the results from rig and engine tests shall be given to substantiate the design of mechanical components.

See FAR 3.104 13B

5.5.5.1. Bearings - Describe each bearing design and the rationale for selection of each bearing type. Discuss methods of calculating B10 life, heat generation, static capacity, radial load, and inner ring hoop stress. Discuss analysis and planned testing to determine the tendency of the bearing to skid under operating conditions. Load versus speed graphs shall be prepared. The bearing system description shall address unbalance and maneuver load responses. Provide maximum misalignment and describe ring anti-rotation features. Mainshaft bearing B10 life shall be predicted considering duty cycle life and maneuver load spectrums (see engine specification). Accessory gearbox bearing B10 life shall be predicted using maximum loads and temperature at MCP. Lubricant properties used shall be those of MIL-PRF-7808 and MIL-PRF-23699 oils at maximum inlet oil temperature allowed as specified in the engine specification.

In determining lubrication factors, use properties of lubricants at maximum operating race temperatures listed in table VI. Provide all bearing life factors used. The Government will evaluate bearing life based on life factors as specified in SP-34. Other material factors may be used if thorough documentation is provided. Documentation shall include published articles and verifiable test results. Current ABMA standards shall be used in bearing design.

Deviations from these standards must be fully explained. Designs shall consider operation under contaminated conditions. Predicted design life shall factor in typical levels of contamination expected in military environments.

5.5.5.2. Gears - Describe each gear design and the rationale for selection of each type of gear. Discuss methods of calculating surface fatigue and bending life, heat generation, scoring risk, and overload capability. Provide method and type of lubrication to be used. Explain rationale for material selection. Gear web and flange critical resonance frequencies shall be determined and plotted on critical speed interference diagrams (Campbell diagrams). Explain why any resonant frequencies in the engine operating speed range will not be detrimental to engine life. Torsional analysis of the total gear train system shall be furnished. Gear case housings shall be analyzed to determine deflections to ensure good wear patterns throughout the load spectrum. Current AGMA standards shall be used in gear design. Deviations from these standards shall be fully explained. All design factors used shall be explained. Gear fatigue life for accessory drive gears shall be predicted using maximum loads and temperatures at MCP, with consideration of starts per hour as stated in the engine specification. Gear fatigue life for main drive reduction gearing shall be based on the highest load in the operating range. Lubricant properties used shall be those of MIL-PRF-7808 and MIL-PRF-23699 at the maximum oil inlet temperature allowed as specified in the engine specification. Freewheeling clutches shall be analyzed in both the drive and freewheeling mode. In the drive mode, surface compressive stresses (Hertz contact stresses) of races, sprags, and rollers shall be determined as well as hoop stresses in the races. Positions of sprags and rollers at maximum load shall be determined.

5.5.5.3. Lubrication Seals - Seal design shall be discussed. The rationale for selection of seal type shall be explained. Describe location and environment of

See FAR 3.104 14B all elastomeric seals/o-rings. Provide operating characteristics of material used and its compatibility with lubricants MIL-PRF-7808, MIL-PRF-23699 and DOD-L-85734. Provide rationale for selection of material for each seal.

Describe method for determining maximum leakage rates for oil and air. Give predicted life, assuming maximum temperatures and greatest unbalance condition, for operation at MCP.

5.5.5.4. Shafting - The bearing and shafting system description shall address rotor critical speeds, unbalance, and maneuver load response. The stability threshold shall be determined and provided. Critical speed interference diagrams (Campbell diagrams) shall be provided showing the results of the critical speed analysis and testing. A plot of vibration frequencies versus bearing stiffness shall be provided. Explain methods of calculating shaft stresses and corrected endurance limit. Give factor of safety used. Provide and explain stress concentration factors used. Life shall be predicted considering duty cycle life and maneuver load spectrums (see engine specification). Detailed dimensions of all splines shall be provided, along with maximum applied loads and corresponding stresses. Rotating group (including shafting) and static structure deflections shall be included in the determination of running clearances.

5.5.5.5. Lubrication System - Detailed studies shall be made to provide the basis for an engine lubrication and ancillary systems detail schematic. The schematic shall reflect steady-state and transient oil flow rates, heat transfer rates, and soakback temperatures. Also included on the schematic shall be steady-state and transient temperatures and pressures recorded at various engine stations, i.e.

before and after rotating disks, bearings, sump inlet, sump outlet, before and after oil coolers, etc. Provide cool down rates of bearings and oil after engine shutdown. Discuss lubrication system regulation and placement of pressure and temperature indicators. Describe oil pumps and list pump capacities at steady-state and transient conditions (altitude, temperature, etc.). Describe oil filters, including absolute rating and beta ratio. Describe oil filter bypass system and impending bypass indication capability. Describe oil coolers, including heat transfer data and pressure drop across element. If air-oil coolers are used, describe methods used to ensure that air cooling will be maintained in contaminated air environments. Provide calculation methods used in oil cooler sizing. Describe the oil tank, including capacity and internal/external features.

Describe the debris monitoring emergency lubrication systems. Provide capture efficiency and detection capability for all chip detectors. Provide flow rates and duration of flow for emergency lubrication system. Describe air-oil separation method. Describe sump scavenge system for various flight attitudes and scavenge ratios.

5.5.5.6. Inlet and Exhaust - Description of the inlet and exhaust is primarily dependent on the configuration of the engine. For those engines equipped with special function items such as inlet particle separators or infrared radiation suppressors, the details of these component designs shall be defined to include pressures, temperatures, primary and secondary flow rates, efficiencies, losses, See FAR 3.104 15B etc. Table VII shall be completed. Design methods shall also be presented. For the inlet, temperature measuring sensor location and details of anti-icing shall be included. Inlet distortion, both pressure and temperature, shall be discussed.

5.5.5.7. Section Deleted

5.5.5.8. Anti-Ice System - A narrative description of the anti-icing system shall be provided. Particular emphasis shall be placed on controlling hardware, such as air valves, within the system. This narrative shall be supported by schematics of the system with major dimensions and schematics of controlling hardware in as much detail as possible. A discussion of trade-off studies conducted in the design of the system shall also be presented. Complete technical data on output of the system and system affect on engine performance is required. The affect of anti-icing system operation in a non-icing environment shall be defined. If the design includes a removable inlet particle separator, changes to the anti-ice system configuration and performance due to separator removal shall be described.

5.5.5.9. Secondary Airflow System - A narrative description of the secondary airflow system shall be provided. Particular emphasis shall be placed on the airflow path from its source(s) through its metering devices to its eventual re-entry into the main air stream or overboard. This narrative shall be supported by schematics of the system with flow circuit diagrams depicting the locations and magnitudes of the airflow contributions through the entire system.

Complete technical data to include pressures, temperatures and flow rates of the system at various locations of inflow and outflow, and system affect on engine performance is required.

5.5.5.10. Materials - The material properties and allowables that the engine design is based upon shall be provided along with the substantiating data and statistical analyses used to generate these design allowables. This data shall encompass the temperature, stress, and strain range for each component and shall include the effects of such variables as stress concentration factor, coating, section size, product form, processes, etc. Average and allowable material property curves shall be included. Substantiation shall be provided for any process that influences the average and allowable material properties. If materials and processes are not yet fully developed and/or characterized, a plan shall be submitted that details how those processes and materials will be substantiated.

The plan shall ensure that the materials and processes are fully characterized by PDR to ensure entrance criteria are satisfied. A materials drawing of the engine shall be furnished in addition to a detailed materials breakdown in the format of table VIII.

5.6. Life Prediction - A detailed discussion of the methods used to predict life and of the results of these predictions shall be presented. Life predictions shall be based on the requirements of this section and the Specification Development Document (SDD). A summary table detailing the life predictions shall be presented in the form of Table IX

See FAR 3.104 16B for the engine specific agreed upon structural design point(s). Life predictions shall detail the analytical techniques and methodologies used to determine component life including all assumptions made during the course of the analysis. Life predictions shall be determined and presented for each potential failure mode to which the particular part is exposed, such as creep/stress rupture, corrosion, erosion, burst, containment, HCF, and LCF. A graphical representation of the structural design missions used in the analyses shall be presented. The life discussions shall include, but shall not be limited to, consideration of the following items:

Temperatures used with assumed temperature profiles and any temperature margins assumed to account for fuel control error, instrumentation error, deterioration, etc.

Types of loading considered and all assumptions utilized to establish the applicable stress and temperature distributions for life estimates.

All component critical locations, including associated failure modes, stress levels, metal temperatures, critical modes, excitation sources, etc.

An assessment of blade tolerance to FOD and/or erosion.

5.7. Survivability and Vulnerability - An explanation of how ballistic vulnerability considerations have impacted the proposed engine design shall be presented. This explanation shall include how these considerations will interface with other design functions throughout the program. The benefits and penalties associated with incorporating specific survivability design features into the engine shall be discussed. A preliminary failure mode and damage effects analysis and ballistic vulnerable area analysis of the proposed engine in the format described in Section 6 shall be provided.

The physical description of the engine shall be in sufficient detail to permit the Government to conduct a ballistic vulnerable area analysis. Full-size installation drawings showing front, rear, top, bottom, and both sides as well as a full-sized inboard profile shall be provided.

5.8. Component Development Plans - Not required for PDR contract.

5.9. Engine Development Plan - Not required for PDR contract.

See FAR 3.104 17B

6. VULNERABLE AREA/FAILURE MODES AND DAMAGE EFFECTS ANALYSES

6.1. General - A vulnerable area analysis and a failure modes and damage effects analysis of the engine, including critical components and subsystems, shall be performed.

6.2. Failure Mode and Damage Effects Analysis - An analysis of the engine shall be conducted to determine engine performance degradation as a function of damage to each component, inclusive of secondary effects such as fires, explosions, disk failures, leaking fluids, etc. The analysis shall include definition of a maximum allowable overboard airflow rate (caused by combustor case rupture, for example), above which the “K” kill criteria defined in 6.3.1 will be applicable. For applicable components, the analysis will differentiate between light and heavy damage effects associated with the range of specified threats. The results of this analysis shall be presented in the form of Table X.

6.3. Ballistic Vulnerability Estimates - The vulnerability estimate developed and a single-shot vulnerable area analysis shall be conducted for all critical subsystems and components from front, left side, right side, rear and bottom views. An estimated lower hemisphere average vulnerable area (Av) shall be calculated by adding the vulnerable area of the front, left and right sides, rear and bottom vulnerable areas and dividing the total by five. Single-shot vulnerable area (Av) of a component is defined as the component projected area (Ap) times the probability that a hit on that area causes sufficient damage to kill that component (Pk/h) which then produces a kill on the engine (Av = ApPk/h).

6.3.1. Kill Criteria - The kill criteria which will be used for these estimates is as follows:

“K” – Immediate (15 Sec) loss of at least 60% MCP

“A” – Loss of at least 60% MCP within 5 minutes

“B” – Loss of at least 60% MCP within 30 minutes

6.3.2. Threat Levels - The threat levels that shall be considered in these estimates include, but are not limited to, impacts by 7.62 mm and 12.7 mm API-type projectiles at a striking velocity of 2500 feet per second. The results of these estimates shall be presented in the form of Table XI.

See FAR 3.104 18B

TABLE I Engine Group Weight Statement.

Model Number: _______________________

Center of Gravity Reference Point: _______________________ mm in mm in mm in

INLET/IPS SECTION*

LP COMPRESSOR SECTION

Rotors

Stators

Shafts or Drums

Casing

Frames

Diffuser

Misc.

IP COMPRESSOR SECTION

Rotors

Stators

Shafts or Drums

Casing

Frames

Diffuser

Misc.

HP COMPRESSOR SECTION

Rotors

Stators

Shafts or Drums

Casing

Frames

Diffuser

Misc.

HP GAS GENERATOR TURBINE SECTION

Rotors

Stators

Casing

Frames

Diffuser

Misc.

SECTION KG LB

CENTER OF GRAVITY

X Y Z

*Itemized breakdown of major components.

See FAR 3.104 19B

TABLE I. Engine Group Weight Statement - Continued.

IP GAS GENERATOR TURBINE SECTION

Rotors Stators Casing

Frames Diffuser Misc.

LP GAS GENERATOR TURBINE SECTION

Rotors Stators Casing Frames Diffuser

Misc.

POWER TURBINE SECTION

Rotors Stators

Casing Frames Diffuser Misc.

COMBUSTION SECTION

Burners Burner Liners Shrouds Casing Shaft Housing

Misc.

EXHAUST SECTION

Tailpipe (Diffuser) Noise Suppressor

Misc.

SHAFTS AND BEARINGS

SECTION KG LB

See FAR 3.104 20B

TABLE I. Engine Group Weight Statement - Continued.

LUBRICATION SYSTEM

Pumps Tanks

Misc.

IGNITION SYSTEM

COOLING SYSTEM

WATER INJECTION

FUEL SYSTEM (Including Fuel Control)

ANTI-ICING

ACCESSORY DRIVES

TOTAL (weight or engine center of gravity)

MANUFACTURING VARIATION

MANUFACTURERS DRY WEIGHT

SECTION KG LB

See FAR 3.104 21B

TABLE II. Engine Performance Verification.

Units Design Point

CRP MRP IRP MCP

80%

MCP

65%

MCP

50%

MCP

30%

MCP

10%

MCP

GI

km ft

(2) Mach Number -kPa psia

ºC

ºF kg/s lbm/s

(6) Overall Pressure Ratio (Ps/Pt) -

ºC

ºF

ºC

ºF kW hp kg/h lbm/h kg/kW-h lbm/h/hp kW hp kg/h lbm/h kg/kW-h lbm/h/hp

N lbf

E ng in e

O ut pu t P er fo rm an ce S um m ar y

(9) Nominal Delivered Power

(10) Nominal Fuel Flow

(11) Nominal Specific Fuel Consumption

(12) Spec Delivered Power

(13) Spec Fuel Flow

(14) Spec Specific Fuel Consumption

(15) Total Jet Thrust

C yc le S um m ar y

(5) Inlet Corrected Airflow

(7) Burner Outlet Temperature

(8) Rotor Inlet Temperature

Operating Point

E ng in e

In le t

C on di tio ns

(1) Altitude

(3) Inlet Pressure

(4) Inlet Temperature

See FAR 3.104 22B

TABLE II. Engine Performance Verification - Continued.

Design Point

CRP MRP IRP MCP

80%

MCP

65%

MCP

50%

MCP

30%

MCP

10%

MCP

GI

kg/s lbm/s

ºC

ºF kPa psi kg/s lbm/s

(20) Number of Stages -

(21) Overall Pressure Ratio (Pt/Pt) -

(22) Polytropic Efficiency %

(23) Adiabatic Efficiency %

(24) Corrected Speed rpm

(25) Variable Geometry Setting -kg/s lbm/s

(27) Leakage Bleed Lost to Cycle %

(28) Discharge Duct Pressure Loss %

(29) Low Pressure Shaft rpm

(30) High Pressure Shaft rpm

(31) Power Turbine Shaft rpm

(32) Overall Pressure Ratio (Pt/Pt) -

(33) Polytropic Efficiency %

(34) Adiabatic Efficiency %

(35) Corrected Speed rpm

(36) Variable Geometry Setting -kg/s lbm/s

(38) Leakage Bleed Lost to Cycle %

(39) Customer Bleed %

ºC

ºF

B oo st er if a pp lic ab le

(26) Inlet Corrected Airflow

A ct ua l

Sh af t

R

PM

L ow

P re ss ur e C om pr es so r

(37) Inlet Corrected Airflow

(40) Customer Bleed Temperature

Engine Component Performance

In le t/I nl et P ar tic

Se pa ra to r

(16) Inlet Airflow

(17) Temperature Rise

(18) Pressure Drop

(19) Scavenge Airflow

See FAR 3.104 23B

Design Point

CRP MRP IRP MCP

80%

MCP

65%

MCP

50%

MCP

30%

MCP

10%

MCP

GI

kPa psia

(42) Discharge Duct Pressure Loss %

ºC

ºF kJ/kg

Btu/lbm kg/s/m2 lbm/s/ft2 m/s ft/s

(47) Constant Speed Stall Margin %

(49) Meridional Mach Number at Rotor Exit -radians degrees

(51) Stator Inlet to Rotor Exit Area Ratio -

(52) Inlet Hub to T ip Radius -mm in

(55) Pressure Ratio, Axial (Pt/Pt) -

(56) Pressure Ratio, Centrifugal (Ps/Pt) -

(57) Overall Pressure Ratio (Pt/Pt) -

(58) Overall Polytropic Efficiency %

(59) Overall Adiabatic Efficiency % kg/s lbm/s

(61) Corrected Speed rpm

(62) Turbine Cooling Flow %

(54) T ip Clearance

H ig h Pr es su re C om pr es so r

(60) Inlet Corrected Airflow

(53) Ratio of Rotor Exit to Inlet Radii (Meridional Line)

(50) Inlet Guide Vane Metal Angle

Engine Component Performance

L ow

P re ss ur e C om pr es so r (C on tin ue d)

(41) Customer Bleed Pressure

(43) Exit Temperature

(44) Enthalpy Change

(45) Corrected Flow per Unit Annulus Area

(46) Corrected First Stage Rotor T ip Speed

(48) Rotor Exit Meridional Loading

(2GJ*DH/U2²)

See FAR 3.104 24B

Design Point

CRP MRP IRP MCP

80%

MCP

65%

MCP

50%

MCP

30%

MCP

10%

MCP

GI

ºC

ºF kPa psia

(65) Leakage Lost to Cycle %

(66) Customer Bleed %

ºC

ºF kPa psia

(69) Discharge Duct Pressure Loss % kg/s/m2 lbm/s/ft2

(72) Meridional Mach Number at Rotor Exit -radians degrees

(74) Stator Inlet to Rotor Exit Area Ratio -

(75) Inlet Hub to T ip Radius -mm in m/s ft/s

(79) Constant Speed Stall Margin %

(77) T ip Clearance

(78) Corrected First Stage Rotor T ip Speed

(76) Ratio of Rotor Exit to Inlet Radii (Meridional Line)

(73) Inlet Guide Vane Metal Angle

Engine Component Performance

H ig h Pr es su re C om pr es so r (C on tin ue d)

(63) Cooling Air Temperature

(64) Cooling Air Pressure

(67) Customer Air Temperature

(68) Customer Air Pressure Loss

(70) Corrected Flow Per Unit Annulus Area

(71) Rotor Exit Meridional Loading

(2GJ*DH/U2²)

See FAR 3.104 25B

Design Point

CRP MRP IRP MCP

80%

MCP

65%

MCP

50%

MCP

30%

MCP

10%

MCP

GI

kg/s lbm/s

(81) Pressure Drop %

ºC

ºF

(83) Pattern Factor -kJ/kg

Btu/lbm

(85) Efficiency %

(86) Fuel/Air Ratio -

ºC

ºF

W/m³-kPa

Btu/h-ft³-atm kg/s lbm/s kg/s lbm/s

ºC

ºF kPa psia

(93) Cooled Adiabatic Efficiency %

(94) Expansion Ratio -

(95) Total Cooling Flow Requirements %

(96) 1st Vane Cooling Flow Requirements %

(97) 1st Blade Cooling Flow Requirements %

(98) 2nd Vane Cooling Flow Requirements %

(99) 2nd Blade Cooling Flow Requirements % kW hp

(101) Leakage %

H ig h Pr es su re T ur bi ne

(90) Rotor Entry Corrected Airflow

(91) Rotor Entry Temperature

(92) Rotor Entry Pressure

(100) Power Extraction

Engine Component Performance

C om bu st or

(80) Inlet Corrected Airflow

(82) Outlet Temperature

(84) Lower Heating Value of Fuel

(87) Temperature Rise

(88) Heat Release Rate

(89) Exit Airflow

See FAR 3.104 26B

Design Point

CRP MRP IRP MCP

80%

MCP

65%

MCP

50%

MCP

30%

MCP

10%

MCP

GI

kJ/kg

Btu/lbm

ºC

ºF kg/s lbm/s

(105) Interstage Duct Pressure Loss %

(106) Corrected Speed rpm kJ/kg-K

Btu/lbm-ºR kg-K1/2/s-kPa lbm-ºR1/2/s-psi

(110) Number of Stages (NSTG) -degrees radians

(113) Exit Pitch Line Axial Mach Number* -

K

ºR kPa psia

(116) Turbine Stator Inlet Fuel/Air Ratio* -

(119) Radius Ratio of Rotor Exit -mm in

*Design Point Only

(120) T ip Clearance

(118) Pitch Line Radius Ratio (Rotor Exit to Inlet)*

(115) Turbine Stator Inlet Total Pressure*

(117) Nozzle Efficiency (Ratio of Exit Actual to Ideal Kinetic Energy)*

(112) Exit Pitch Line Swirl Angle* (Positive when Opposite to Direction of Rotation)

(114) Turbine Stator Inlet Total Temperature*

(111) Average Turbine Pitch Line Loading* i.e., PSID = (DHQT/(2

(U/T )²/ J)/NSTG)

(108) Specific Work Output Divided by Inlet Temperature*, DHQT

(109) Turbine Inlet Flow Function* i.e., (TFF = W Tt1/2/Pt)

Array of 1st Stage Nozzle Area Ratios (Max of 6)

Engine Component Performance H ig h

Pr es su re

T ur bi ne

C on tin ue d)

(102) Enthalpy Change

(103) Exit Temperature

(104) Exit Corrected Airflow

(107)

See FAR 3.104 27B

TABLE II. Engine Performance Verification - Continued

Design Point

CRP MRP IRP MCP

80%

MCP

65%

MCP

50%

MCP

30%

MCP

10%

MCP

GI

kg/s lbm/s

ºC

ºF kPa psia

(124) Cooled Adiabatic Efficiency %

(125) Expansion Ratio -

(126) Total Cooling Flow Requirements %

(127) 1st Vane Cooling Flow Requirements %

(128) 1st Blade Cooling Flow Requirements %

(129) 2nd Vane Cooling Flow Requirements %

(130) 2nd Blade Cooling Flow Requirements % kW hp

(132) Leakage % kJ/kg

Btu/lbm

ºC

ºF kg/s lbm/s

(136) Interstage Duct Pressure Loss %

(137) Corrected Speed rpm kJ/kg-K

Btu/lbm-ºR kg-K1/2/s-kPa lbm-ºR1/2/s-psi

(141) Number of Stages (NSTG) -

*Design Point Only

(139) Specific Work Output Divided by Inlet Temperature*, DHQT

(140) Turbine Inlet Flow Function* i.e., (TFF = W Tt/Pt)

(138) Array of 1st Stage Nozzle Area Ratios (Max of 6)

Exit Temperature

(135) Exit Airflow

Engine Component Performance L ow P re ss ur e

T ur bi ne

(121) Rotor Entry…