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Abstract
Contra Rotating Open Rotor is currently named as one technology offering potential solutions for the next aircraft generation.
Indeed the rise in fuel price and the increasing concern for environment impact have renewed its interest. The idea of using
twin propellers rotating in opposite direction is not original; it has been studied from the beginning of airplane. But the high
level of noise coupled with this design has limited its expansion. So, this paper first investigates the background which lead
to architecture considers by the aerospace industry. Thus the requirement of always bigger By Pass Ratio turbofan engine is
reaching some limits which implied a comeback to propeller which allows better propulsive efficiency and higher effective By
Pass. From this remark, this paper highlights some breakthroughs undergo by the aerospace world which should make CROR
feasible. Of particular interest is noise, which is the central challenge of this technology delaying its apparition. Thus this paper
discusses different architecture concludes on an architecture with gear driver in pusher configuration with a forward blade
swept design, and 7x8 blades. This architecture seems to be the most promising design considering noise and performance
requirement and should be able to cope with legislation hardening.
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38th Engine Systems Symposium - March 2013 ESS-38-89
J. Enconniere / Contra-Rotating Open Rotor Propulsion System
visaged to use CROR engine for short range aircraft ,ie the 2.2. Propellers
successor of Airbus A320 or Boeing 737.
This paper is interested in the different architecture of Propellers had been the only kind of propulsion existing
CROR, ie their achievable performances regarding current until the first jet engines in the thirties before Turbofan took
turbofan engines. Then it will be considered all conundrums the lead. Propellers allow higher propulsive efficiency than
raised by this technology as noise, certification and integra- turbofan so why are they not in used on civil aircraft when
tion, which would certainly go with new airframe design. fuel consumption is one of the main considerations. There
are few reasons. Firstly propellers are relatively noisy re-
2. Birth of Open Rotor. garding ducted turbofan. Secondly, propellers are consid-
ered to be like the ”old fashion”, something freely turning
Before considering CROR, an description of principles of doesn’t make people comfortable. And Mach number and
jet engine is required. We can define two engine global ef- altitude achievable for aircrafts driven by propellers were
ficiencies. The thermal efficiency defins as ratio of output lower than that for a jet engine or a turbofan. This remark is
power to the input energy given by fuel combustion. For no more relevant with advanced high speed propeller achiev-
our topic the output power is the one transferring to the air- ing higher flight velocity. Moreover, the air coming out of a
flow. The propulsive efficiency corresponds to the ratio of rotor is spinning and as trust is proportional to the axial ve-
the thrust to the power given by the engine to the airflow. locity only, a part of the momentum is pushing the aircraft
The thermal efficiency is function of core pressure, tem- whereas the other is waste in the swirl (visible in fig.2). The
perature and components’ efficiencies. airframe also have to adapt to this because it creates a torque.
Focusing on the propulsive efficiency, it is possible to de-
fine it as the following equation [7]:
2
ηprop = Vjet
(1)
1+ Vaircraf t
As previously explained, to increase the propulsive effi- In addition to this waste in energy, the only solution to
ciency, high mass flow is necessary; this is the basic concept deal high power levels is to increase either the propeller di-
of Turbofan engines. For Turbofan engine it is considered ameter or the rotational speed,[6][8]. These two solutions
two mass flows, the hot one which goes through the core en- induce a rise in relative Mach number thus imply the pres-
gine and the cold one going through the bypass. In the fig.1 ence of transonic or even supersonic zone on blades. Shock
is shown propulsive efficiency and fan pressure ratio func- waves would occur at blade tip, decaying the efficiency, in-
tion of the ratio of bypass flow to hot flow. creasing noise emissions. Higher diameter also induces trou-
ble for integration on airframe. Considering the problem of
high level of Mach number, new shapes of blade have been
design. It will be discussed in part 4.1.2. Nevertheless, it
does not prevent the requirement of extremely big rotor.
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38th Engine Systems Symposium - March 2013 ESS-38-89
J. Enconniere / Contra-Rotating Open Rotor Propulsion System
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38th Engine Systems Symposium - March 2013 ESS-38-89
J. Enconniere / Contra-Rotating Open Rotor Propulsion System
4. Challenges.
4.1. Acoustic.
4.1.1. Sources.
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38th Engine Systems Symposium - March 2013 ESS-38-89
J. Enconniere / Contra-Rotating Open Rotor Propulsion System
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38th Engine Systems Symposium - March 2013 ESS-38-89
J. Enconniere / Contra-Rotating Open Rotor Propulsion System
Fig. 14: prospective lower emission and lower cruise Mach number
configuration.
Fig. 12: Forward CROR design [8]. As CROR is a new technology it has to be certified before
any entry into service. Because the absence of casing, rotor
blades have to show an extremely low risk of failure. And
tion becomes crucial. Engine builder have to cooperate if there is any failure, the aircraft have to be able to land.
closely with Airframers to develop an optimised configura- Then the engine has to be operable and reliable at any step
tion for both performance and acoustic point of view. In- of a typical flight (take off, climb, cruise, and landing). One
deed, CROR architecture is by definition unducted and its of the challenges here is the operability at low power. In-
design implies elongate propellers. deed, CROR concepts have smaller gas generator size than
equivalent Turbofan but the demand in electric energy for the
aircraft remains the same. One other challenge is the design
of the gear box which is a new system on board. It doesnt
have to impede on reliable and efficiency of the main engine
to keep it as durable, safe and efficient as any other engine.
Nevertheless, system of gear box should not be completely
new. Indeed Ultra HBP ratio turbofan engine should be born
before CROR integrating one gear box to drive the fan. The
difference will be the fact that the gear box will have two
outputs instead of one for CROR. The pitch control mech-
anism also has to be integrated and has to be as simple and
reliable as possible.
Actually, the certification process consists on determining
if every component which are already reliable when takes
Fig. 13: Integration studied by Snecma [6]. separately creates an overall system still reliable and safe.
And the problem is that it is a new system thus the way to
Numbers of engine integration are considered (see fig.13). determine if the system is relevant does not exist yet as the
The current typical airframe architecture is considered with system. So a new methodology to assess CROR is necessary
a puller configuration CROR under wing or a pusher CROR and has to be created in parallel of the conception.
over wing. These architectures have the advantage of re-
semblance with existing airframe thus making certification 5. Conclusion.
6
38th Engine Systems Symposium - March 2013 ESS-38-89
J. Enconniere / Contra-Rotating Open Rotor Propulsion System
This paper is interested in the process leading to the Con- 14 prospective lower emission and lower cruise
tra Rotating Open Rotor concept. It starts from a limita- Mach number configuration. . . . . . . . . . 6
tion found in the research of always higher By Pass Ratio on
Turbofan engine. Drawbacks related to the presence of cas- References
ing implied the return to propeller technology but not simple
[1] E. S. Hendricks and M. T. Tong Performance and Weight
propellers: CROR. This configuration allows aircraft pow- Estimates for an Advanced Open Rotor Engine, 48th
ered by propeller to reach same altitudes and cruise Mach AIAA/ASME/SAE/ASEE Joint Propulsion Conference & Ex-
number as airframe with Turbofans. Besides Propellers have hibit, 30 July - 01 August 2012, Atlanta, Georgia
always been more efficient than Turbofan, CRORs have an [2] F. Julian, Snecma Veut Faire Voler un Open Rotor, Air & Cos-
even higher efficiency than propellers. All of this reunite mos, n2321, p30-31, july 13, 2012.
should allow up to a 30% reduction in CO2 emission. [3] H. Barbier Clean Sky Newsletter n2, december 2010.
As CROR technology is relatively new, a number config- [4] J. Excell Rolls-Royce technology chief Ric Parker,
uration have been proposed and evaluated to determine pros www.theengineer.co.uk, june 5, 2009.
[5] M. Goulain SAGE-ITD, CLEAN SKY Info Day, Toulouse, Feb,
and cons of each one. The position of rotor can be at the
1, 2011.
front (puller) like a typical propeller or behind the gas gen- [6] L. M’Bengue Toward Acare 2020: Innovative Engine Architec-
erator (Pusher), gas generator no different from the one on tures to Achieve the Environmental Goals ?, 27th Congres of
a Turbofan. From recent studies, the pusher design seems the Aeronautical Sciences, Snecma SAFRAN Group, 2010.
more efficient, quieter and lighter than the puller design. [7] P. Pilidis & J.R Palmer Gas Turbine Theory and Performance,
Another discussion is the driver of the rotors. Two possi- Cranfield University, 2012.
bilities exist: Direct drive and Geared drive. Direct drive is [8] S. Rochhausen Investigation of Two-Stage Open Rotor Features
the simplest, Turbines and Rotors operates at same speed, affecting Noise and Performance, Cranfield University, MSc
but it means that neither turbine nor rotor operate at their Thesis, 2009.
[9] Plane Propellers Revolve in Opposite Directions,Popular Sci-
optimum design, inducing loss in efficiency and additional
ence, November 1931.
weight. Therefore the geared engine has been considered al- ——————————————————————–
lowing either the high-speed turbine or rotors to operate at
their optimum speed with an optimal speed ratio of nearly 7.
Thus from what have been said before, we can conclude
on what should look like a CROR in the future. It is a pusher
design, with geared drive configuration. Blades should be
highly swept, in forward configuration with a relatively high
number of blades. The second row should have one more
blade than the first row, so lets say a 7x8 configuration.
This design seems to be the most promising in term of per-
formance and noise emission. Besides, CROR engine will
much likely go with new airframe design where engine will
be mounted at the rear fuselage. Moreover the implementa-
tion of a new method of certification in parallel of the con-
ception of CROR is required. SAGE 1 and 2 of CLEAN
SKY paternship will incorporate all this to show the feasi-
bility of CROR engine for future aircraft.
CROR design proves to be the breakthrough which will
enable aircraft to cope with regulation always more severe
regarding fuel emission and noise. It wont be surprising to
see an aircraft flying with Open Rotors to power it in the next
decade.
6. *
List of Figures
1 Propulsive efficiency an Fan Pressure Ratio
function of BPR [6]. . . . . . . . . . . . . . 2
2 single propeller swirl effect [6]. . . . . . . . 2
3 Propulsive efficiency function of flight Mach
number [6]. . . . . . . . . . . . . . . . . . 3
4 Puller configuration proposed by Rolls
Royce [4]. . . . . . . . . . . . . . . . . . . 3
5 GE demonstrator. . . . . . . . . . . . . . . 3
6 P&W demonstrator. . . . . . . . . . . . . . 3
7 Direct Drive configuration. . . . . . . . . . 4
8 Rolls Royce SAGE 1 project [5]. . . . . . . 4
9 SAGE 2 architecture [5]. . . . . . . . . . . 5
10 Mach number reduction by sweeping a
wing[8]. . . . . . . . . . . . . . . . . . . . 5
11 Phase cancellation [8]. . . . . . . . . . . . . 6
12 Forward CROR design [8]. . . . . . . . . . 6
13 Integration studied by Snecma [6]. . . . . . 6