Experimental development of Adaptive Cycle Micro-Turbofan Engine (ACE)
| This talk presents the design, development, and validation of an adaptive cycle micro-turbofan engine, converted from a baseline micro-turbojet (AMT Nike), for application in unmanned aerial systems. Addressing the performance limitations of micro-turbojets—particularly their inefficiency during low-speed and take-off conditions—this work explores a propulsion architecture capable of adapting to different flight regimes.
Following a mission-driven literature review, the methodology includes detailed thermodynamic, aerodynamic, and mechanical analysis of the adaptive engine concept. Key components such as a custom-designed gearbox, a newly developed fan, and a variable bypass nozzle are introduced. Core engine behavior is assessed using experimental data and component maps derived from CFD studies. Design-point and off-design performance simulations were conducted using a Python-based thermodynamic modeling tool developed in-house. These simulations guided the selection of optimal fan parameters and gearbox ratios and enabled performance comparison with conventional configurations. The mechanical design phase covered the structural layout, stress analysis, thermal fit design, and additive manufacturing strategies. Custom assembly and alignment techniques were implemented to ensure mechanical precision and operational reliability. An experimental test bench was developed using a real-time control system (dSPACE), National Instruments hardware, and a custom Simulink-LabVIEW software environment. Initial tests investigated engine startup behavior, sensor performance, and IDLE regime stability. The results demonstrate significant improvements in thrust and fuel efficiency using the adaptive configuration. The talk concludes with practical insights from the assembly and testing process, and recommendations for future engine iterations and control system enhancements. |
