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UEC`s enterprise in Rybinsk has mastered a through 3D technology of aircraft engine units design and production

Site news 24.05.2017

Innopolis, May 24, 2017

A through 3D technology of aircraft engine parts and units design and production has been implemented and mastered at NPO Saturn PJSC's Design Office (a part of United Engine Corporation (JSC), a Rostec State Corporation company). Its application considerably increases the efficiency of design and development activities and reduces associated risks and expenses.
This year, UEC is one of the sponsors of the conference "Digital Industry of Industrial Russia-2017" which is carried out from May 24 to 26, 2017 in Innopolis (Tatarstan). Corporation representatives take part in the business program of the conference. 
NPO Saturn is specialized in the design and development, production and after-market support of gas turbine engines for military and commercial aviation, power generation and gas compression, maritime propulsion units. NPO Saturn produces SaM146 engines (together with Safran Aircraft Engines) for the civil Sukhoi Superjet 100 aircraft, D-30KP engines for transport aviation, small-size GTD and etc.
The through 3D design and production technology implies the following: creation of a 3D mathematical model for a part/unit, spatial aeromechanical design, issue of 3D design documentation (digital mock-up, assemblability), tooling design according to 3D models, production as per 3D models, 3D inspection using special control measuring units and, if necessary, calculations of the actual geometry of a part. The outcome of the work is high quality of produced parts which allows requirements of technical specifications to be met at the first attempt for the whole range of operating modes.
"The designing of a gas turbine engine requires solving many tasks covering different disciplines:  thermal physics, design strength, materials science, manufacturability, management and etc., - says Roman Khramin, NPO Saturn PJSC General Designer.  - Conducting independent examinations and development within each discipline with no regard for interrelation, as well as the unavailability of a close prototype at the initial step may lead to the general non-conformance of the obtained engineering solution to all the requirements specified for the engine. The importance and the growing need in the through design and production approach is evident. In the countries playing the leading role in the creation of advanced aircraft and aerospace systems, large-scale activities within complex tasks have been implemented quite a long time".
"Mastering the through 3D design and production technology with the application of advanced CAD/CAM/CAE systems allows NPO Saturn to cute expenses for the creation of high-tech products, to upgrade their quality and reliability, to reduce the number of test cycles and the time of bringing products to market, - says Mikhail Polyakov, NPO Saturn PJSC acting IT Director. - The use of the through 3D technology became possible due to the application of the corporate information system covering all the functional scopes of the enterprise. The IT-system is built on modern IT-infrastructure which has recourses for high efficient calculations".
The supercomputer center "Saturn-100" created at NPO Saturn represents a single cluster of the high efficient computing resources AL-100 and SPAK. It is used for complex, time-consuming and resource-intensive calculations. The total peak performance of the SPAK data processing modular center (special-purpose hardware and software system) is 114.5 Tflops, the total RAM is 14.5 TByte, the total number of processors of the computing field is 204, the overall number of cores is 2808. The data processing center AL-100 previously put in service (the total peak performance is 14.3 Tflops) was acknowledged in 2008 to be a supercomputer with the highest performance in the industry of Russia and the Commonwealth of Independent States.  With the much more powerful supercomputer SPAK, specialists can perform 3D calculations exceeding the tasks solved by AL-100 in terms of dimension: calculations with eddy-resolving turbulence models, non-stationary calculations of acoustic characteristics of the fan, calculations of combustion in the combustion chamber with detailed models of chemical kinetics, adjoined tasks of gas dynamics in non-stationary set-up, tasks of multi-objective and probabilistic optimization. 
"For comparison: if on a PC we can perform only the simplest calculations with one physical model (i.e. either only mechanical or only thermal calculations) and use the simplest models of physical processes, then AL-100 allowed us to move to more complicated calculations, for example, gas dynamic and thermal calculations, says Artem Badernikov, Head of Heat Exchange and Combustion Team, Systems Engineering Analysis Design Department, NPO Saturn PJSC. –Thus, we obtain the correct thermal state of parts. However, we still deal with simple models.  When SPAK appeared, we switched over to coupled non-stationary calculations with complex models of physical processes".  
In prospect, Saturn's IT-potential will ramp up, in particular, there is a plan to install new more efficient computing equipment. The work on the partial replacement of the software by domestic analogues is in progress.

Research and production association Saturn [NPO Saturn] (PJSC) is an engine-manufacturing company specialized in the design and development, production and after-market support of gas turbine engines for military and commercial aviation, power generation and gas compression as well as for ships and vessels. "NPO Saturn is a United Engine Corporation company". It is located in Rybinsk (Yaroslavl region).

United Engine Corporation (JSC) (a Rostec State Corporation company) is an integrated organization specialized in the design and development, serial production and after-market support of engines for military and commercial aviation, space programs, the Navy as well as for the oil and gas industry and power generation. One of UEC’s prioritized fields of activity is the implementation of comprehensive programs of development of the industry’s companies by introducing new technologies meeting the world-class standards.

Rostec State Corporation is a Russian corporation established in 2007 in order to facilitate the development, manufacturing and export of high-technology industrial products of military and commercial application. The corporation comprises 700 companies, which form 11 defense-industrial and 3 civil industry holdings as well as 80 direct control companies. Rostec’s subsidiaries are located in 60 regions of Russia and deliver their products to over 70 countries worldwide. The Rostec portfolio spans such renowned brands as AVTOVAZ, KAMAZ, Kalashnikov Concern, Russian Helicopters, VSMPO-AVISMA, and others. Rostec' s consolidated revenue reached 1 trillion 266 billion rubles in 2016. Rostec's consolidated net revenue reached 88 billion rubles, and EBITDA reached 269 billion rubles in 2016. The corporation's average salary in 2016 amounted 44 000 rubles. Following Rostec's new strategy, the major objective of the Corporation is to ensure the technological advantage of Russia at the competitive world markets. The implementation of a new technological wave and digitalization of Russian economics is one of Rostec's tasks.


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