Inside HAL's HTFE-25 Turbofan Engine (25 kN thrust Hindustan Turbo Fan Engine)

[Chanakya's_Chant]

Inside HAL's HTFE-25 Turbofan Engine (25 kN thrust Hindustan Turbo Fan Engine)​

The inaugural run of the core of 25 kN indigenous Aero Engine (Hindustan Turbo Fan Engine – HTFE 25), was successfully completed in the presence of Defence Minister, Mr. Manohar Parrikar at HAL’s Engine Division here today. He also launched the design and development project of Hindustan Turbo Shaft Engine (HTSE-1200) which can be used for helicopters.

Aero Engine Research & Design Centre (AERDC), HAL, Bengaluru had taken up the Design and Development of a 25 kN thrust class turbofan engine for Basic Military Trainer Aircraft. HAL used its internal resources with an aim of producing indigenously designed and developed aero engines in a time frame of six years beginning from 2013. In the first phase of the programme, the design of the full engine and manufacture and testing of the technology demonstrator of the core engine are covered. In the subsequent phases the manufacture and testing of the full engine will follow.

The HTSE-1200 can be used for helicopters of 3.5 ton class in the single engine configuration (e.g. LUH) and for 5 to 8 ton class in twin engine configuration (e.g. ALH, LCH). The engine develops a power of 1200 kW at sea level and can operate up to an altitude of 7 km. This project too is undertaken by HAL with its internal resources with an aim of developing the capability of indigenous design and development of turboshaft engines.

Mr. Parrikar also mentioned the on-going HTT-40 trainer program of HAL and said the company is almost there with final activities going on in full swing at its hangars in Bengaluru.

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Source:- Media Releases

 

[Chanakya's_Chant]

Development of Medium Thrust Class Turbofan Engine – HTFE25​

by Devanathan, AERDC, HAL

Presenter emphasizes on two points:

• Time should be the first priority.
• Role of SME is of paramount importance.

Four technical aspects covered:

• Multi-disciplinary approach for design
• Systems Engineering Simulation/Concept
• Digital Manufacturing
• Testing

• Currently (Aug-2015) manufacturing core of the engine and soon to be tested.
• Planned concept is to develop core engine first and then develop full engine based on the platform it would be fitted to.
• Emphasize on MD design iterations with quick iteration churning.
• Secondary flows: First 3D simulations to capture flow characteristics and then use 1D models calibrated using the 3D simulations. 1D for unsteady simulations. Verification sing existing engine data done as a whole.
• Idle = 70% rpm
• 3D printing technology adapted right from concept stage. Main idea behind this was to reduce lead time to manufacture critical components in order to reduce risk of program. (Since only CAD input need to be changed to change component produced).
• Casting to be replaced by 3D printing while forging, sheet metal processes retained.
• Nozzle GV 3D printed with Inconel material – intricate cooling passages with additional which would not be possible with conventional techniques are easily made with 3D printing.
• CC part- (flame tube section), Turbine blades, HPC all stator vane sectors, HPC tandem stator, gear box parts,

Pros of 3D printing:

• Practically zero lead time for implementing design change in manufacturing
• Full Freedom to designer
• Possibility of lot of weight reduction by having internal cavities at non-critical locations.

Slides:

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Q&A:

Q: Why fan under loaded and HPC overloaded (looking at PR)?

A: Only core is being focused on right now. Fan/LPT design will change based on platform requirement.

Q: Surge margin for HPC targeted?

A: Not fixed. Normally its 14-19%.

Q: Which material for Turbine blades?

A: FOr IJT, TIT=1455K, so Inconel718 used. For AJT, something else can be used.

Q: What about Compressor?

A: Forged Titanium. And machined as blisks. Laser welding. First 4 stg = Ti, Last = Inconel718. HPC bolted – like in Al-55. First priority is to get Turbines and gearbox tested and validated (Other parts well within capability). Once this is done, core testing will go on for high altitude test etc, in parallel two (platform specific?) prototypes will be built.

Q: Why build 25kN engine when HAL license mfg same thrust class engines (adour-871 et al). Why not make Al-55 replacement?

A: Initially 20kN was proposed. Since Al-55 is ~17kN, a 20kN would have been good for IJT MK2. But the higher authorities went with 25kN. Wrt adour871 advantage in technology (smaller size, PR 11 vs 20, ~600mm vs ~450mm Turbine dia – huge turbine operating at lower rpm for Adour) , weight and size. So This engine while replacing Adour would give better performance. This engine can be used for Jagaur (which has 28kN engine) as well. Just need to change mounting points (and perhaps LP module?). Its very easy to adjust the design to various thrust levels by changing materials etc. Analysis already done. With similar core 35-40kN is achievable easily. SFC for this engine 0.72, better than older engines.

Source:- A Quantum of Mind | wondering in the twelth dimension…

 

[GURU DUTT]

in short all that yers of research on kaveri dint go in wane and i hope HAL achieves target of 35-40-45 Kn thrust from same engine with a few tweaks would do wonders for owr aerospace industry

 

[Ankit Kumar]

Q: Why build 25kN engine when HAL license mfg same thrust class engines (adour-871 et al). Why not make Al-55 replacement?

A: Initially 20kN was proposed. Since Al-55 is ~17kN, a 20kN would have been good for IJT MK2. But the higher authorities went with 25kN. Wrt adour871 advantage in technology (smaller size, PR 11 vs 20, ~600mm vs ~450mm Turbine dia – huge turbine operating at lower rpm for Adour) , weight and size. So This engine while replacing Adour would give better performance. This engine can be used for Jagaur (which has 28kN engine) as well. Just need to change mounting points (and perhaps LP module?). Its very easy to adjust the design to various thrust levels by changing materials etc. Analysis already done. With similar core 35-40kN is achievable easily. SFC for this engine 0.72, better than older engines.

Source:- A Quantum of Mind | wondering in the twelth dimension…

Sir please elaborate about the engines named here and their applications in Indian Airforce.
Thanks

 

[Chanakya's_Chant]

Sir please elaborate about the engines named here and their applications in Indian Airforce.
Thanks

(I) ADOUR MK 811 - Jaguar aircraft is powered by two Adour MK 804 / MK 811 engines with 27 kN thrust. MK 811 engines are manufactured since 1981 under licence from RR/TM [ Rolls Royce Turbomeca ].

Adour MK 804 engines are also overhauled and repaired under the above licence.

Adour engine is a bypass jet engine of modular construction. The Adour has two-stage low pressure and five-stage high pressure axial flow compressors which are driven by separate, single-stage high pressure and low pressure turbines connected through co-axial shafts, with the low pressure shaft passing through the high pressure shaft.

But these will be replaced by Honeywell F125's of 28 kN thrust instead in the DARIN III upgrade.

(II) NPO Saturn AL-55I - In August 2005, the Russian export organization known as Rosoboronexport and India's Hindustan Aeronautics Limited (HAL) signed an agreement for the licensed production of up to 1,000 AL-55I engines. The agreement includes a firm order for 250 engines to be manufactured at HAL facilities in India, to power both HAL HJT-36 trainer and HAL HJT 39 combat trainer aircraft.

HTFE-25 can be both used in Jaguar as well as HJT-36 trainer and HAL HJT 39 combat trainer aircraft but chances are it might not be used on any of the platforms since Honeywell F125 have been contracted for Jaguars and HJT-36 - HAL HJT 39 (still in design phase) are at the helm of the IAF which is not convinced with their performances and might not order them in good numbers.

 

[#hydra#]

(I) ADOUR MK 811 - Jaguar aircraft is powered by two Adour MK 804 / MK 811 engines with 27 kN thrust. MK 811 engines are manufactured since 1981 under licence from RR/TM [ Rolls Royce Turbomeca ].

Adour MK 804 engines are also overhauled and repaired under the above licence.

Adour engine is a bypass jet engine of modular construction. The Adour has two-stage low pressure and five-stage high pressure axial flow compressors which are driven by separate, single-stage high pressure and low pressure turbines connected through co-axial shafts, with the low pressure shaft passing through the high pressure shaft.

But these will be replaced by Honeywell F125's of 28 kN thrust instead in the DARIN III upgrade.

(II) NPO Saturn AL-55I - In August 2005, the Russian export organization known as Rosoboronexport and India's Hindustan Aeronautics Limited (HAL) signed an agreement for the licensed production of up to 1,000 AL-55I engines. The agreement includes a firm order for 250 engines to be manufactured at HAL facilities in India, to power both HAL HJT-36 trainer and HAL HJT 39 combat trainer aircraft.

HTFE-25 can be both used in Jaguar as well as HJT-36 trainer and HAL HJT 39 combat trainer aircraft but chances are it might not be used on any of the platforms since Honeywell F125 have been contracted for Jaguars and HJT-36 - HAL HJT 39 (still in design phase) are at the helm of the IAF which is not convinced with their performances and might not order them in good numbers.

Is it possible to use this in our cruise missiles,I mean nirbhay.

 

[rational]

@#hydra# sure but then cruise missile will be of a size of an adult African elephant

 

[Death In Fire]

To

Is it possible to use this in our cruise missiles,I mean nirbhay.

Way too big and powerful for a cruise missile.

 

[#hydra#]

To

Way too big and powerful for a cruise missile.

OK... Do u have any information on indigenous engine for nirbhay (PIC & spec)

 

[sharma1111]

Manik engine for cruise missile is 5 KN engine

 

[Chanakya's_Chant]

Is it possible to use this in our cruise missiles,I mean nirbhay.

No, it is too big, heavy and too powerful to be used in any cruise missile. Instead Manak mini turbofan will be used in Nirbhay - Manik is an expendable 450 Kgf thrust class Gas Turbine engine. Small turbofan prototypes are performing well. Tested at full throttle. Flight trials 1.5 years away. It has a thrust of 3.73 kN.

The engine that will power Nirbhay cruise missile & other stuff in future: India's Manak mini turbofan. ​