Kaveri Engine K9 & K10
The GTX-35VS Kaveri is an afterburning turbofan project developed by the Gas Turbine Research Establishment (GTRE) Bengaluru. It is a low bypass twin spool turbo fan engine of 80 kN thrust class. Kaveri is a technologically complex power plant. It is a two spool, bypass turbofan engine having three stages of transonic low pressure compressor driven by a single stage low pressure turbine. The core engine consists of a six stage transonic compressor driven by single stage cooled high pressure turbine. Its three stage transonic fan, designed for good stall margin handles an air mass flow of 78 kg and develops a pressure combustion chamber line ratio of 3:4. Kaveri engine has been designed to achieve a fan pressure ratio of 4:1 and overall pressure ratio of 27:1. These pressure parameters are claimed to be good enough to support the super cruise manoeuvres of an advanced combat aircraft.
The CCS has first sanctioned the project in 1989. Till date 9 full prototype engines and 4 core engines have been built. 3217 hours of engine testing have been conducted till date including altitude tests & Flying Test Bed trials. So, far Rs 2105 crore fund has been allocated for Kaveri Engine program.
GTRE's Kaveri effort may have failed to yield a usable fighter-class low-bypass afterburning turbofan but its core is being developed further and is quite usable and the learnings have been significant. The Kaveri project was later divided into two categories: K9+ and K 10. K9+ Program is to prove concept of complete design and gain hand-on experience of aircraft engine integration and flight trials to cover a defined truncated flight envelope prior to the launch of production version of K10 Standard engine. The K10 Program is going to be a joint venture (JV) partnership with a foreign engine manufacturer Safran or Rolls-Royce to develop entirely new engine. K10 program engine will be final production standard Kaveri engine and will have less weight and more reheat thrust along with certain other changes to meet the original design intent.
Issues with Kaveri Engine fixed
As per reports, the problems of Kaveri engine have been solved and only high-altitude tests are remaining. One of the major issues with the Kaveri engine was the flutter of fan blades. Flutter was related to all the blades used in the engine. Various methods have been deployed to successfully resolve the flutter issue. Other issues with Kaveri engine related to fan, HP Compressor, LP Turbine, combustor, after burner and screech issue has also been resolved.
India’s dependence on Russian Test Bed
GTRE is ready with the engine and its eagerly waiting for simulated high altitude tests. Designers working on the Kaveri Dry engine explained that simulated tests basically simulate high altitude conditions on the ground. Once the Kaveri Dry engine clears these simulated high altitude tests, GTRE will position the engine in the flying test bed (FTB), which is a modified Ilyushin (Il)-76 fixed-wing, four-engine turbofan aircraft. The Kaveri Dry engine will replace one of the Il-76's four engines in the FTB.
Russia-Ukraine conflict delays testing
As per the initial plan, the GTRE has planned to complete all testing by 2024-25 and commence limited series production by 2025-26. The production agency is likely to be HAL. However, India’s dependence on Russia for conducting simulated high-altitude tests and flight test bed testing are causing a further delay to the flight-testing of the Kaveri dry engine. In the midst of on-going Russia-Ukraine conflict, the simulated high altitude flight test will take longer than expected which was already delayed due to COVID-19 pandemic. For several years now, DRDO have been pushing for the acquisition of an Il-76 aircraft which will be used purely as an aero engine flight test bed. A single test bed will cost around $500 million which will include the aircraft with structural modification, airworthy certification, pilot training, sensors and test equipment.
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