Research on the Calculation Method of Oil Consumption for Commercial Turbofan Engines Durability Test

The whole-engine durability test for commercial aircraft engines represents a comprehensive assessment of the lifespan of all engine components, characterized by its extended duration and rigorous operating conditions. This test assumes a pivotal role in securing airworthiness certification for aircraft engines. Throughout the durability test, engine maintenance is often concurrently executed, with a significant consideration being the need for oil replenishment due to oil consumption, which impacts the determination of the service interval for the test, serving as a critical criterion for successfully completing the final durability assessment. In this study, we aim to contribute to the development of service interval guidelines for ground durability tests of commercial turbofan engines through extensive research and intricate calculations. Our research team meticulously analyzed the airworthiness requirements governing service intervals for comprehensive engine durability testing. Employing the radial basis function neural network method, we constructed a robust physical mechanism model to depict the intricate relationship between oil consumption and oil temperature. This model, developed based on dynamic volume distribution within the engine oil system, serves as a crucial tool. Additionally, we introduced a novel calculation method to estimate oil consumption during durability tests. To validate this method, we meticulously compared its outcomes with real-world operational data before and after full engine tests. Our proposed calculation method proved highly reliable in determining the engine’s oil consumption rate and the frequency of replenishment required for ground tests. These results not only offer invaluable insights for establishing service intervals in certification tests but also serve as critical pass criteria in full engine durability tests. Ultimately, this research ensures that long-term tests, such as endurance tests and first service inspections, align with stringent airworthiness regulations, bolstering the safety and reliability of commercial aircraft engines.