CFM Radial Drive Shaft Failure
**** Hidden Message ***** Radial Drive<BR>Shaft Failure<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 2<BR>• 8 RDS failures on -5B model since December 2000<BR>- Engine TSN below 3000 FH<BR>- 6 IFSD’s, 2 UER’s from MCD particle findings<BR>• All engines included in the last 300 produced CFM56-5B’s<BR>Fleet experience<BR>Date ESN TSN CSN Event Findings / status EMCD /<BR>screens<BR>05/03/98 779165 5003 3613 IFSD Brg spall ; hvy damage ;no cause found No report<BR>19/12/00 779873 245 119 IFSD Brg spall ; hvy damage ;no cause found M50+RBD<BR>12/04/01 575120 436 360 IFSD Brg spall ; hvy damage ;no cause found M50+ RBD<BR>16/03/01 779972 671 454 UER IR+roller spall ; outer housing sector indic M50<BR>11/06/01 779809 2038 1183 IFSD Brg spall ; shaft damaged ; not investigated no report<BR>08/07/01 779996 256 177 IFSD 6:00 frame strut crack ; not investigated no report<BR>17/07/01 779983 1151 546 IFSD 6:00 frame strut crack ; not investigated no report<BR>Post SB 72-0407 19/11/01 575128 2726 800 UER EMCD popped out M50<BR>event<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 3<BR>Hardware description<BR>#6:00 Fan<BR>frame strut Outer housing<BR>Inner housing<BR>Radial Drive Shaft<BR>(RDS)<BR>Transfert Gearbox<BR>(TGB)<BR>Roller<BR>bearing<BR>Washer<BR>Vespel<BR>nut<BR>Inlet Gearbox<BR>(IGB)<BR>Fan frame<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 4<BR>Root Cause Analysis<BR>• Major contributor<BR>- Assembly tooling used for inner housing bonding<BR>- Tooling overtorque generates housing<BR>ovalization<BR>- Randomly distributed<BR>- Reduces clearance between housings…roller<BR>pinching<BR>- Aggravated when in same direction than normal<BR>thermal deformation of fan frame bore.<BR>- Problem induced by production line organization<BR>change initiated early 1999<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 5<BR>Root Cause Analysis<BR>Engine centerline<BR>Outer race spalling due<BR>to roller pinching<BR>Reduced roller<BR>clearance<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 6<BR>• Minor contributors<BR>- Glue change for outer housing bonding in Feb 99<BR>- Loctite 932 replaced by Loctite 638 (structural glue)<BR>- Fan frame bore ovalization<BR>- Discrepancy between both manufacturing sources, although within<BR>tolerance<BR>Root Cause Analysis<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 7<BR>Corrective Actions - Production Level<BR>• Tooling modified<BR>- Eliminates overtorquing<BR>• 100% housing ovalization check<BR>• Loctite 932 glue re-introduced<BR>- Conservative measure<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 8<BR>• Affected population defined<BR>- Engines below 5000FH<BR>- SAC: 779522 to 779899 and 575101 to 575261<BR>- DAC: 779900 to 779999 and 575900 to 575901<BR>• On-wing ECMD inspection: SB 72-0407, cat 2, Oct 2001<BR>- Pop-out indication, inspect MCD per AMM within 10 cycles<BR>• Engine induced in shop before 5000 FH<BR>- Inspection per SB 72-0409, cat 3, Nov 2001<BR>- Inner housing diameter ovalization check<BR>- Housing/bearing replacement if ovalization out of tolerance<BR>- Engine relieved from SB 72-0407<BR>Corrective Actions - Field Level :victory: :victory: CFM Radial Drive Shaft Failure
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