Machining of the Fan Abradable Seal and its Impact on Thrust, Performance and Reliability of Aero Engines

Aviation embodies a dynamic sector marked by a continual pursuit of progress, where the integration of innovative technologies and the refinement of more efficient techniques directly contribute to advancing the aeronautical industry. Companies operating within this realm are unwavering in their dedication to delivering increasingly reliable engines, emphasizing critical factors such as safety, quality, and mechanical efficiency. Strict adherence to performance parameters in the test cell to the engine approval process is imperative, aligning with the standards set by discerning customers and regulatory bodies. Maintenance, Repair, and Overhaul (MRO) companies sometimes face problems related to engine performance during tests in the overhaul process. This highlighted the need for a study on improvements in the process related to thrust parameters. This study analyzes the match grinding process between the abradable seal and the fan blades and shows how to ensure the engines meet the required thrust limits for approval. The dimensional relationship between these components serves as a machining reference, intending to achieve minimal clearance. This strategic approach optimizes the utilization of airflow responsible for thrust, thereby enhancing engine performance, efficiency, and reliability. The methodological approach involves a case study of the match grinding process, including an analysis of a sample of engines with results collected before and after applying the process. The study indicates that the reduction in surface roughness and control of minimum clearance result in a more efficient utilization of airflow. This leads to reduced turbulence and parasitic airflow, culminating in a significant 71% improvement in thrust for the evaluated engines compared to pre-process results. The proposed process allows repair stations to produce engines of high quality, reducing rejection risks in testing and rework. The results obtained in this study validate the efficacy of the match grinding process as a strategic initiative for improving the thrust performance of aeronautical engines.

Keywords: Abradable seal, Match grinding, Thrust, Turbofan performance and reliability.