• SILVERcREST PROGRAM

    8off used in engine

    demonstrates how Smiths, with close partnership with a major OEM (Safran AE), effectively Smiths delivers complex project management through all stages of development to achieve what the customer requires, and on time

  • Silvercrest program

    Fan-casing fully machined

  • silvercrest program

    Exploded view of finished details

Case Study

Silvercrest Fan Casing

From early development to mass production.

In close partnership with major OEM, Safran AE, we effectively deliver complex project management through all stages of development to achieve what our customer requires, and on time.

First Stage NPI 2010

Within the business we have a gated process route to follow for all enquiries:

Gate Process

  1. Enquiry received – decision to bid Y/N
  2. RFQ bid
  3. Contract Review
  4. Pre-Design Review (testing etc.)
  5. Final Design Review
  6. Pass to Production
  7. Support aftermarket


Enquiry received – decision to bid Y/N

RFQ bid

Contract Review

Special Processes (Check)
  • 1st Process: grit blast / size constraints / automatic process / conform IAW customer specifications and procedures. (Safran approved company)
  • 2nd Process: composite manufacture and bonding. NADCAP approved / suitability and capability / composite design capability and testing. (Not a customer approved company at RFQ stage)
  • Work with contractor to achieve approval

Pre-Design Review

Design Concept of Fan Casing

  • Nomex core
  • Glass prepreg
  • Filler material Minnesota

The composite structure keeps the engine blades contained within the engine structure in the event of fan blade outage

Cartridge to Fan Casing Fitment Review

Composite Design Consideration
  • Consulted with customer to develop and establish the best possible design
  • 1st Design was agreed (mould tools + tooling produced) cartridges accepted (tested / strength concern)
  • 2nd Design changes (mould tools remade) – approx. 28 different designs of fan casing designs
  • Form fit and function were critical, so that the cartridge could be installed in the fan casing
  • The affected segment could be removed easily in the event of cartridge damage

 

Choice of Composite Materials
  • Composite material was chosen
  • On review a different type was preferred.
  • The close connection between Subcon & Smiths and the customer were very important to ensure the correct result was achieved

Final Design Review

Metallic Fan Casing Design and Manufacture
Design for Manufacture
  • Throughout customer design, Smiths were closely involved with methods, suggesting what could be machined and at what costs
Project Management
  • Effective project management throughout the manufacture Industrialisation, including the control of tooling and fixturing
  • Project plans continually provided to the customer for project review

Fan Casing History I

Design Phase Type ‘A’
2010 to 2015
  • Smiths produced 28 different fan casing designs involving a process of effectively controlling and managing many different design changes
  • We considered 2 different cartridge designs, and had to purchase a Quantum CMM machine to completely inspect the fan casing in one operation
  • Our Quality Department controlled and produce all the DVI’s and controlling documentation.
  • In 2014, Smiths were awarded by Safran in recognition of their ability to effectively manage the complexity of introducing all the different designs required against all adversity
October 2015
  • Customer announcement of the temporary postponement of the Silvercrest program
  • However with a collaborative approach between Smiths and the customer the new design was quickly established, and work resumed by December 2015, enabling the customer to restart the program again

In 2014, Smiths were awarded by Safran in recognition of their ability to effectively manage the complexity of introducing all the different designs required against all adversity.

Fan Casing History II

New Design Type ‘B’
  • Smiths had a tight timescale to achieve FETT (First Engine To Test) for the customer, including a major redesign of the Fan casing and also another new composite cartridge design
  • This was managed and produced in extremely tight timescales.
  • FETT fan casing was produced and delivered on time – progress now continues.

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