ROLLS-ROYCE ULTRAFAN ENGINE PROJECT

Rolls-Royce has started building the world’s largest airplane engine, the UltraFan, at their dedicated facility in Derby UK.  The engine is the first step towards the airplane industries’ transition to more sustainable fuels and will redefine sustainable travel in future.

 

The engine has a fan diameter of 140 inches and is the basis for the UltraFan family of engines. They will be able to power both narrow-body and wide-body aircraft in the future and deliver 25% better fuel efficiency compared to the first generation Trent engine.

 

The development of the engine has been supported by both the UK and German governments.

 

The HYDRO UK team are proud to be helping with the development of the tooling for the construction of the UltraFan demonstrator engine module. This will be completed by the end of 2021.

 

What does the key engineering features of the engine include?

  • A new, proven, Advance 3 core architecture, combined with our ALECSys (Advanced Low Emissions Combustion System) lean-burn combustion system, to deliver maximum fuel-burn efficiency and low emissions.
  • Carbon titanium fan blades and a composite casing that reduce weight by up to 1,500 lb. per aircraft.
  • Advanced ceramic matrix composite (CMC) components that operate more effectively in high-pressure turbine temperatures.
  • A geared design that delivers efficient power for the high-thrust, high bypass ratio engines of the future.

 


rolls-royce-UltraFan-animation-1 rolls-royce-UltraFan-animation-2

 

 

 

Who was involved in this project?

The UK Production team, Inspection team, logistics team, ESR team, Engineering team, Sales team, UK and HQ Purchase teams and Service team have all been instrumental in delivering great new UltraFan tooling to Rolls-Royce.

 

 

HYDRO-UltraFan-fan-disc-lifter-rolls-royce-tool

 

 

What are the special features of the project?

The tooling is being manufactured and finished in line with the module builds in R-R Derby and is both time and quality critical. Without our internal manufacturing, proof load, paint and finish assembly, we would never have won such a high percentage of the tooling package. HYDRO is one of six suppliers. All tooling must be manufactured or assembled in the UK due to being government funded.

 

HYDRO-UltraFan-press-support-stand-rolls-royce-tool

Every single tool has the same level of focus given to all engine tooling, with weekly delivery meetings to ensure HYDRO meets the customer’s strict demands on time and quality. The development of the engine build relies heavily on the tools being delivered just in time for the next operation.

 

This, in turn, brings additional orders as our capability grows.

 

Following a request from Rolls-Royce to expedite a tool for validation testing, Hydro UK was able to adjust priorities and manufacture, paint, test and deliver the tool on-time and on-quality to the customer’s requirements.  The tool in question is a hydraulic shown in action below.

 

HYDRO-UltraFan-fan-hydraulic-loading-kit-rolls-royce-tool

 

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