Boeing Components & Accessories #4 Bearing Program Status

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CFM56-7B WTT Meeting - September,25-26/2002 CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 1
#4 Bearing Program Status
Components & Accessories
CFM56-7B WTT Meeting - September,25-26/2002 CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 2
#4 bearing P/N installed on
CFM56-7B
305-355-717-0
335-352-301-0
335-352-302-0
340-167-901-0
# 4 Bearing Status
Background
HP/LP Intershaft bearing
• Constraints
 Bearing exposed at each shop
visit
 Sensitive to agressors
(handling, assembly ,
contamination…)
& manufacturing variability
• Advantages :
– Engine length reduction
– Performance retention
– Weight reduction
CFM56-7B WTT Meeting - September,25-26/2002 CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 3
CFM56-All - UER & IFSD rates , #4 bearing fail cause
IFSD
0.00
1.00
2.00
3.00
4.00
Fail per million EFH - 12 month rolling
0
100,000,000
200,000,000
Cumul effective flight
hours
UER + IFSD
"UER" 1.32 as of July02
# 4 Bearing Status
CFM56-7B WTT Meeting - September,25-26/2002 CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 4
CFM56--7B - UER & IFSD rates , #4 bearing fail cause
"UER"
IFSD
UER + IFSD
0.00
2.00
4.00
6.00
8.00
Aug-98
Feb-99
Aug-99
Feb-00
Aug-00
Feb-01
Aug-01
Feb-02
Fail per million EFH - 12 month rolling
0.88 as of July02
CFM56-7B Average Better Than Global CFM Experience
# 4 Bearing Status
CFM56-7B WTT Meeting - September,25-26/2002 CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 5
Ev# UER IFSD ESN DATE E.TSN E.CSN P/N
1 1 874125 May/01/1998 520 220 335-352-301-0
2 1 874254 Nov/01/1998 834 255 335-352-301-0
3 1 875314 Dec/30/1998 1142 409 335-352-301-0
4 1 874424 Sep/15/1999 1991 1271 305-355-717-0
5 1 875529 Oct/19/1999 1225 791 305-355-717-0
6 1 874596 Dec/14/1999 1997 650 340-167-901-0 Prod° stop 12-01 SB in progress
7 1 874219 May/27/2000 5532 1814 305-355-717-0
8 1 874669 Jul/18/2000 4844 1790 340-167-901-0 Prod° stop 12-01 SB in progress
9 1 874103 Sep/29/2000 2975 1124 305-355-717-0
10 1 874972 Nov/19/2000 3551 1687 340-167-901-0 Prod° stop 12-01 SB in progress
11 1 876424 Dec/29/2000 943 670 305-355-717-0
12 1 876403 Jan/27/2001 1422 875 305-355-717-0
13 1 876686 Mar/23/2001 824 326 340-167-901-0
14 1 874581 Aug/05/2001 6245 4662 340-167-901-0
15 1 875652 Feb/28/2002 7908 5485 340-167-901-0
16 1 876336 Mar/05/2002 6907 4068 305-355-717-0
17 1 874816 May/31/2002 5465 2042 340-167-901-0
18 1 876150 Jul/22/2002 7309 2504 340-167-901-0
CFM56-7B #4bearing events summary
Prod° stop 12-01
Prod° stop 12-01
Actions
SB in progress
SB in progress
Batch of 47 suspect parts
identified
Production stopped in 1998 SB72-180 & 72-192
SB72-328 & 72-329
• reliability and quality monitored thru failure rates and failed bearing investigations
• PN301 (retired > 1998) and PN 901 (thru2002) showed deviant failure rates
• 2 ea.PN 717 from one defective batch
• random other PN717 failures within large experience
# 4 Bearing Fleet Monitoring
CFM56-7B WTT Meeting - September,25-26/2002 CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 6
#4 Bearing P/N340-167-901-0
• Reliability and quality monitored thru failure rates and failed
bearing investigations
 P/N340-167-901-0 showed deviant failure rates (See previous
table)
 P/N 901 retirement program decided
– From Production
– From in-service engines when exposed at Shop visit
regardless of age
– SB72-0395 released September, 2002
# 4 Bearing Status
CFM56-7B WTT Meeting - September,25-26/2002 CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 7
Material Improvement
Outer race typical failure ----> improved outer race
Introducing new Outer Race material : 32 CDV 13 + nitrogen hardening
 deep nitrite material
– material structure gives high crack resistance
– high compressive stress level --> high resistance to damage propagation
(spalling) : aggression (dents, contamination) effects reduced
 successful tests
– typically damaged samples
 better resistance than M50 to spalling propagation evidenced
– large engine tests program satisfactorily achieved
 Implemented on production engines August, 2002
 Field implementation SB72-352 October, 2002
32CDV13 Implemented to improve outer race reliability
# 4 Bearing Status
CFM56-7B WTT Meeting - September,25-26/2002 CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 8
#4 brg vibration screening
• Tool 856A2679 developed to measure roller passing frequency
 Based on development test bearing failure experience
– Tested with intentionally pitted bearing -- refined signature
 To allow to early detect damaged bearing
H (N2-N1)
Tool 856A2679
HP N2
BP N1
#4R detection
message
Accelerometer 1
Accelerometer 2
856A2679G0x
Tool available for installation in
CFM56 shop test facilities
#4 brg Vibration Screening
# 4 Bearing Status
CFM56-7B WTT Meeting - September,25-26/2002 CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 9
• Test cell and on-wing runs system - tool 856A2679-
accumulating experience
– CFM Production facilities and overhaul cells equipped
– Less than 1% « delinquent » expected (experience)
– Continuous working together efforts with shops to refine
criteria
• Screening procedure being implemented in the ESM for all
CFM56 engine models
• In February, 2003 ESM revision
#4 bearing Vibrations Survey Initiative To Help Capture
Damaged Bearing
#4 brg vibration screening (cont’d)
CFM56-7B WTT Meeting - September,25-26/2002 CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 10
Summary
• CFM56-7B experience better than CFM experience
• Material Improvement
• 32 CDV13 material
• higher outer race reliability
• new bearing introduction expected 4 Qr 2002 for CFM56-7B
• P/N -901 Shop Plan Defined, and issued
• SB72-0395 issued in September, 2002
• Damage Survey System
• #4 bearing vibration survey initiative for outer Race damages
• CFM tool available for test cell runs
• Implementation started
• Screening procedure to be implemented in Feb, 03 ESM revision
# 4 Bearing Status

979199501

CFM56-7B TRAINING MANUAL ENGINE FAN TRIM BALANCE

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Boeing Components & Accessories #4 Bearing Program Status