Machining of HPT Shrouds and the Impact on Air Flow, EGT Margin, Aero-engine Performance and Reliability

This study explores the dynamic landscape of the aviation industry, which is continually propelled forward by the emergence of innovative technologies and the refinement of more efficient techniques. This perpetual evolution significantly shapes the aerospace sector, where companies are unwaveringly committed to elevating their engines' safety, quality, and mechanical efficiency. Within this commitment, engine approval in the test cell demands adherence to stringent performance parameters set by clients and regulatory bodies. Maintenance, Repair, and Overhaul (MRO) companies commonly face problems with lower-than-expected Exhaust Gas Temperature (EGT) margins, underscoring the critical necessity to enhance processes related to this vital parameter. Concurrently, the study aims to show how to extend the engine's life cycle and augment its overall performance. The methodological approach encompasses a case study of the Scallop grinding process alongside the match grinding process, incorporating an analysis of results before and after implementation. The collected data shows that applying the proposed process yielded improved airflow and direction, coupled with adequate control of the minimum clearance. Consequently, a more efficient and increased airflow is characterized by a higher proportion of air in the air/fuel mixture and a larger volume of air passing through the turbine. As a result, a substantial enhancement in the EGT margin is observed. In conclusion, this method offers significant potential for optimizing Aero-engine Performance and Reliability. It contributes to the knowledge of process and aero engine maintenance, can aid safety professionals, and its implications can extend to industries where safety and reliability are paramount.

Keywords: Scallop grinding, Match grinding, EGT margin, Turbofan.