CFM AGB Hand Cranking Bearing Failure

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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
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Axial cracks Spalling on a 35° sector
Spalling
Spalling on a 55° sector
AGB Hand Cranking Bearing
Failed Part Investigation
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Cross Section Plan
Axial crack depth:
0,35 mm = 14 mils
Fatigue crack =Spalling
Coarse martensitic structure
AGB Hand Cranking Bearing
Failed Part Investigation
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Spalling starting from a crack
AGB Hand Cranking Bearing
Failed part Investigation
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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
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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
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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
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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
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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
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• 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
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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
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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

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CFM AGB Hand Cranking Bearing Failure