CFM AGB Hand Cranking Bearing Failure

航空发表于 2011-4-15 09:00:42

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航空发表于 2011-4-15 09:00:52

February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 1 February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 2 AGB Hand Cranking Bearing Failure February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 3 Background • Metal particles found during routine AGB/TGB MCD inspection • 4 cases to date, removed and sent to shop  888103 with 1758 TSN / 836 CSN  888149 with 1367 TSN / 793 CSN  888105 with 2191 TSN / 1549 CSN  876745 with 1136 TSN / 1086 CSN • All AGB handcranking gearshaft ball bearings « line #4 » (340-052-602-0) damaged • Other -602-0 installed in the AGB’s – IDG gearshaft ball bearing « line8 » – No damages found AGB Hand Cranking Bearing Ball bearing February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 4 Axial cracks Spalling on a 35° sector Spalling Spalling on a 55° sector AGB Hand Cranking Bearing Failed Part Investigation February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 5 Cross Section Plan Axial crack depth: 0,35 mm = 14 mils Fatigue crack =Spalling Coarse martensitic structure AGB Hand Cranking Bearing Failed Part Investigation February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 6 Spalling starting from a crack AGB Hand Cranking Bearing Failed part Investigation February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 7 Residual stresses measurement • 2 new bearings • 1 is in CFM experience • 1 is out of experience • high process dispersion AGB Hand Cranking Bearing New Part Investigation Depth(microns) -500 -400 -300 -200 -100 0 100 200 300 400 0 10 20 30 40 50 60 70 Good compression stress distribution Tensile stress distribution February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 8 Coarse microstructures + Tensile residual stresses Surface fatigue abnormal Spalling grinding AGB Hand Cranking Bearing Failure Mode Scenario Root Cause = Surface overheating during grinding operation Cracks February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 9 Root Cause • All four (4) failures occurred on bearings coming from a single batch of grinding operation • Overheating due to machine tooling shaft abnormal vibrations Corrective Actions • Manufacturing tool shaft replaced prior to the next batch • Others : Smaller batch size, destructive test added in every batch, …. AGB Hand Cranking Bearing Potential Affected Population Root cause confirmed - Batch identified Corrective actions implemented February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 10 Batch definition • The grinding batch includes 361 bearings installed on line #4, and line #8 • As this bearing (340-052-602-0) is fitted on other CFM56 models, the bearings from that batch have been installed on 80 CFM56-7B engines  4 line #4 failed in service  3 engines have the bearing on line #8 only  73 remaining engines have a bearing from the batch on the line #4 • 15 bearings have been delivered as spare parts AGB Hand Cranking Bearing Potential Affected Population February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 11 73 CFM56-7B are equipped with handcranking bearing coming from the same grinding batch Most AGB have more than 2,000 hours AGB Hand Cranking Bearing Potentially Affected Population AGB handcranking aging repartition 6 0 6 6 16 14 8 12 5 0 2 4 6 8 10 12 14 16 18 0-500 500-1000 1000-1500 1500-2000 2000-2500 2500-3000 3000-3500 3500-4000 >4000 Hours Number of AGB 1 Failure 2 Failures 1 Failure Data as of December, 2001 February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 12 • Crack propagation rate very slow, captured through regular MCD Inspection (500 hours)  No need to implement a specific inspection • Infant mortality type of failure • Plan to inspect new bearings regarding residual stress • Retrieve, all spare parts (15) from the identified Batch • Proposed to replace Bearing line #4 & line #8 at Shop Visit for engines having a suspected bearing and accumulated less than 2,500 hours  Bearing line #8 loaded two times less than line #4 AGB Hand Cranking Bearing Action Plan February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 13 AGB Hand Cranking Bearing Potentially Affected Batch Failed Part L8(Boeing) Bearing S/N L 4(Boeing) Bearing S/N AGBS/N Engine S/N TSN CSN L8(Boeing) Bearing S/N L 4(Boeing) Bearing S/N AGBS/N Engine S/N TSN CSN EB046343 WQ3520 876646 3900 2333 EB046465-8 EB046466-7 WQ3561 888103 1759 836 EB046380 EB046366 WQ3521 876649 4100 2464 EB046632-T EB046633-R WQ3576 888104 2191 1549 EB046364 EB046365 WQ3507 876651 4066 1920 EB046619-K EB046618-L WQ3569 888105 2191 1549 EB046409 EB046406 WQ3543 876662 4100 2464 EB046568-4 EB046530-W WQ3568 888107 2800 1159 EB046415 EB046353 WQ3541 876663 3054 1281 EB046621 EB046620-D WQ3570 888108 1554 1486 EB046358 EB046357 WQ3515 876672 3900 2333 EB046591-R EB046590-T WQ3592 888109 2601 2103 EB046345 EB046341 WQ3524 876674 1547 1850 EB046604 EB046605-9 WQ3591 888110 2617 1523 EB046286 EB046299 WQ3545 876675 1547 1850 EB046297 EB046298 WQ3552 888111 2617 1523 EB046288 EB046280 WQ3546 876678 3070 2170 EB046492 EB046532-U WQ3577 888112 2601 2103 EB046397 EB046276 WQ3547 876679 3176 1229 EB046577-K EB046594 WQ3594 888113 1403 1342 EB046552-T EB046495-M WQ3563 876680 3611 1237 EB046527 EB046579-H WQ3605 888116 3849 2238 EB046505-A EB046498 WQ3562 876681 3070 2170 EB046606 EB046529-5 WQ3600 888119 2433 1890 EB046497 EB046496 WQ3564 876682 1476 1834 EB046479-J EB046478-K WQ3560 888120 2937 2282 EB046293 EB046295 WQ3551 876683 2343 1632 EB046578 EB046609-5 WQ3596 888121 2937 2282 EB046453 EB046452-U WQ3558 876684 2866 1626 EB046546-7 EB046511-W WQ3584 888122 1435 1421 EB046480-C EB046481-B WQ3557 876686 1650 658 EB046518 EB046528-6 WQ3598 888123 2433 1890 EB046349 EB046347 WQ3526 876687 2365 1578 EB046635 EB046634-P WQ3588 888124 3501 2093 EB046494-N EB046561-B WQ3579 876689 2365 1578 EB046608 EB046599-6 WQ3599 888125 3501 2093 EB046362 EB046363 WQ3523 876690 3654 1330 EB046622 EB046612-U WQ3608 888131 2301 1424 February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 14 AGB Hand Cranking Bearing Potentially Affected Batch Failed Part L8(Boeing) Bearing S/N L 4(Boeing) Bearing S/N AGB S/N Engine S/N TSN CSN L8(Boeing) Bearing S/N L 4(Boeing) Bearing S/N AGB S/N Engine S/N TSN CSN EB046508 EB046489 WQ3574 876691 3734 2219 EB046595-L EB046596 WQ3573 888141 3257 1895 EB046545-8 EB046544-9 WQ3580 876692 4173 2455 EB046611-V EB046523-B WQ3593 888143 2663 1063 EB046526-8 EB046525-9 WQ3567 876693 2128 1186 EB046543-A WQ3582 888144 2663 1063 EB046472-T EB046471-U WQ3555 876694 3695 2166 EB046469-4 EB046482-A WQ3554 888147 1234 842 EB046512-V EB046507 WQ3575 876696 2666 2144 EB046565-7 EB046567-5 WQ3587 888148 17 12 EB046490 EB046509 WQ3572 876697 2666 2144 EB046517-N EB046516-P WQ3583 888149 2325 1334 EB046531-V EB046533-T WQ3581 876698 0 0 EB046638-K EB046639 WQ3590 888150 2279 1673 EB046557-L EB046556-M WQ3586 876699 3755 1840 EB046499 EB046500 WQ3565 888152 489 496 EB046327 EB046323 WQ3542 876744 1821 1535 EB046464-9 EB046477-L WQ3559 888153 2547 1086 EB046394 EB046393 WQ3525 876745 1136 1086 EB046572-R EB046586-5 WQ3607 888160 3165 1555 EB046296 EB046294 WQ3549 876746 1874 1604 EB046593-N EB046592-P WQ3595 888172 2138 1434 EB046436-P EB046637-L WQ3589 876748 1449 1232 EB046616-N EB046615-P WQ3597 888189 2641 1196 EB046374 WQ3519 877645 2315 1088 EB046574 EB046598 WQ3602 888196 0 0 EB046361 WQ3518 877648 1453 1095 EB046576 EB046600-E WQ3609 888204 3621 1296 EB046396-M EB046398 WQ3522 877660 1272 1895 EB046597-J EB046582-9 WQ3610 888228 2210 1262 EB046287 EB046407 WQ3544 877667 3495 2069 EB046584 EB046585 WQ3601 888235 13 10 EB046279 EB046281 WQ3548 877676 2343 1632 EB046284 EB046278 WQ3550 888238 3274 974 EB046468-5 EB046467-6 WQ3556 877685 4169 2451 EB094429-2 WQ5004 888534 774 506 EB046510 WQ3578 877695 3695 2166 EB046602-C EB046617 WQ3606 889130 2314 1352 EB046285 EB046277 WQ3553 888101 2506 1458 EB046587-4 EB046588-3 WQ3585 889132 2301 1424 EB046321 EB046316 WQ3566 888102 3654 1330 EB046642-A EB046640-C WQ3571 889151 17 12

kinran 发表于 2011-6-4 23:24:54

:victory: :victory:

bocome 发表于 2011-7-31 04:44:02

CFM AGB Hand Cranking Bearing Failure

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CFM AGB Hand Cranking Bearing Failure