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Aircraft Turbine Engine Development 131 The 12 development engines are each built to accommodate the unique requirements of a particular type of test. This plan does not account for any spare hardware assets, which can be a significant contributor to development costs. The number of flight test engines (not included here) would be determined by the needs of the aircraft flight test team. Ground-test engines are typically not transferred to the flight test program due to specialized instrumentation needs and the unquantifiable wear accumulated during ground test. Component testing is conducted first in the test program and is es- sentially used as a risk reduction measure to indicate whether a pro- posed design is feasible. Component testing is conducted on a rig, or “slave” engine, to evaluate and verify the individual component’s performance and mechanical integrity and to assess material stresses and vibration modes. Typically, the fan, compressors, turbines, and combustor are tested on a rig, while an augmentor is tested on a slave engine. The 12 development engines contained in this notional plan are al- located for different testing purposes. Aeromechanical testing is used to evaluate the stresses and vibration modes of engine turbo machin- ery (fan, compressor, and turbine blades) and the functionality of other components, such as the combustor, augmentor, and nozzle. Initial aeromechanical assessments are conducted on a rig, then in an expressly instrumented engine in a sea-level test cell, and then under worst-case conditions in an altitude test cell. The instrumentation takes static and dynamic measurements of rotor speeds, inlet conditions, pressures, temperatures, and airflow to evaluate both static and dynamic stresses. If static stresses fall within design limits and the measured low-cycle fatigue stresses allow components to meet the required design life, the engine meets the success criteria for this testing. Sea-level development testing is conducted early in the development test plan. The engine is tested in a sea-level test cell (i.e., sea-level pressures, temperatures, and operating conditions). Sea-level testing begins at ambient inlet pressure and temperature and later includes elevated inlet pressure and temperature conditions to simulate ef- fects due to the Mach number. Sea-level development testing is used to evaluate engine steady-state performance (thrust, SFC), transient performance (starting, accelerating and decelerating, augmentorPDF Image | Military Jet Engine Acquisition Technology Basics and Cost-Estimating Methodology
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