Proposal

University of Engineering and Technology
Lahore
Final Year Project

Bsc. Automotiuve Engineering
Project Proposal
Design and Optimization of Micro Turbojet Engine
2020-au-14 Muhammad Arslan (Group Leader)

2020-au-12 Mubashir Hussain
2020-au-21 Muhammad Faizan Noshahi
Supervisor
Mr. Tahir Asif
Automotive Engineering Centre

Abstract:
The goal of this major qualifying project is to design, optimize and manufacture a small
gas turbine engine. Designing will include the whole engine each and every component in the
solidworks. The components which we will optimize their design are shroud, axial compressor,
fuel diffuser and nozzle. The manufacture components will include: axial turbine, stator, diffuser,
compressor inlet, shaft, outer casing, combustion chamber, fuel distributer, exhaust nozzle, and
inlet flange. We will review literature regarding gas turbine engine components, design each
component, and manufactured them accordingly. We will then assemble our engine and plan for
testing.
Introduction:
The gas turbine engine is a machine that, according to the thermodynamic Brayton Cycle, does
work by harnessing energy from a working fluid and converting the energy into a useable form.
Various types of gas turbines are designed to perform a range of tasks but all operate on similar
principles. Air enters the engine, is compressed, mixed with fuel, combusted, and then expanded
through a rotating turbine. Common applications of modern gas turbines include: producing
auxiliary power for ground or aircraft systems, propelling military aircraft at supersonic speeds,
and driving the rotor system of helicopters (Macisaac & Langton, 2011). Due to the extreme
temperatures and high rotational speeds experienced by engine components, design and
construction of a gas turbine demands accuracy, informed material selection, knowledge of
thermodynamics, and the ability to model and machine metal components. As material processing
techniques advanced, it became possible to manufacture gas turbine engines small enough to
power radio controlled (RC) airplanes.
Modern gas turbines for full size aircraft generally utilize
axial compressors and turbines with multiple stages of blades. These multi-stage components
increase efficiency, pressure ratios, and performance characteristics (Shreckling, 1992). However,
RC jet modelers found that small engines can be reasonably efficient and powerful with single
stage compressor and turbine stages. A centrifugal compressor matched to an axial turbine has
become a common design among RC jet enthusiasts. With this simplification, along with
advancements in CNC machining and 3D modeling, it is possible to manufacture a complete
miniature gas turbine with a relatively small investment. Although miniature gas turbines are now
available for sale from a number of manufacturers, the secrets of design and construction are still
somewhat hidden from the end customer. Accurate analysis of performance is elusive even with
the utilization of modern software, and an iterative design process offers the soundest path toward
new engine development (Stricker, 1998). However, a number of publications are available that
instruct the ambitious RC jet enthusiast on how to manufacture an engine with amateur means.
The goal of this project is to call on the literature available regarding small gas turbines in order
to design and manufacture an engine that is self-sustaining. In order to expedite the design process,
efficiency and thrust production are not prioritized. Due to budget and time restrictions we are
unable to complete multiple iterations of a new engine. Therefore, we rely on engine designs
currently developed to aid in the design of our major components. Subjects such as new airfoil
design for turbine blades, nozzle efficiency, and combustor efficiency can be the subject of years
of research and investment. For this reason, we drew on industry standards and recommendations
of modelers to design some of our components. We realized early that two crucial components,
the centrifugal compressor and ball bearings, would be impossible to design and manufacture
given the time frame. We made the decision to purchase these components in order to make our
project more feasible given the restrictions. This project culminated in the manufacture of twelve
major components.
• Compressor inlet shroud
• Diffuser
• Power transmitting shaft
• Shaft housing
• Annular Combustion chamber
• Fuel distributer
• Stator
• Stator/turbine housing
• Axial Turbine
• Exhaust nozzle
• Outer casing
• Inlet flange
Each component listed above was first modeled with SOLIDWORKS software and then
manufactured. Throughout the experience, our team furthered our design and manufacturing skills
through manual and CNC milling and turning, TIG welding, sheet metal forming, and regular
engineering troubleshooting.
Research gap:
Micro jet engines represent an interesting area of research in the field of propulsion. These engines
are small-scale, gas turbine engines designed for a variety of applications, such as unmanned aerial
vehicles (UAVs), micro air vehicles (MAVs), and certain military and civilian applications. While
significant progress has been made in this area, there are still several research gaps that could
benefit from further investigation:
Efficiency and performance optimization: Micro jet engines often face challenges in achieving
high levels of efficiency and performance due to their small size and limited resources. Research
is needed to explore novel designs, materials, and manufacturing techniques that can improve the
overall efficiency and thrust-to-weight ratio of micro jet engines.
Combustion and emissions control: Achieving efficient combustion in micro jet engines while
minimizing harmful emissions is a complex task. Research is required to develop advanced
combustion technologies and explore alternative fuels that can improve the environmental impact
of micro jet engines.
Methodology:
Methodology will include following steps:
Designing in Solidworks:
First if all complete jet engine will be designed and then assembled in solidworks with drawings
for manufacturing.
CFD and Thermal analysis in Ansys Workbench:
Then we will conduct CFD of compressor and turbine and thermal analysis of combustion chamber
also combustion analysis in ansys workbench.
Research Gap:
Efficiency and performance optimization
To increase efficiency and performance optimization we will focus on some main components like
compressor. Compressor design predicts the efficiency and performance of a gas turbine. It all
depends on up to how much pressure air is compressed with increased mass flow. For this we will
make iterations on the design of shroud and impeller based on CFD results to propose optimized
and highly efficient design of compressor shroud and impeller. Also they both will be
manufactured by 3d printing to reduce cost.
Combustion and emissions control
To cover this we will do CFD and combustion analysis on combustion chamber and fuel
distributor. Then with iteration in design we will try to enhance combustion by changing fuel
nozzle designs and diameters. Also by flow over the combustion chamber. Emissions will be also
reduced by using different fuels and biodiesel with best design of combustion chamber and after
burner.
Manufacturing:
Afterward we will go for manufacturing most of the parts will be CNC machined.
TimeLine Cost and Resources:
We have two semester for this project so each semester consists of 16 weeks a total of 32 weeks
so work is divided as follows:
 Week 1-4: Basic learning of theories, drawings, understanding working of different parts
like compressor, combustor, turbine, fuel distributors.
 Week 5-9: Designing in Solidworks
 Week 10-15: Analysis in Ansys workbench
 Week 16-19: Optimization and redesigning
 Week 20-22: Design revisions with drawings
 Week 23-30: Manufacturing
 Week 31-32: Testing
Main resources are CNC machines, TIG welding some sheet metal machines for combustor and
high end computing system for designing and analysis.
References:
Aviation. (2015, June 23). Aviation. Retrieved from Stack Exchange:
https://aviation.stackexchange.com/questions/16177/what-are-thedifferences-between-a-
helicopter-engine-turboshaft-and-an-aircraf
Benini, E., & Giacometti, S. (2007). Design, Manufacturing and Operation of a Small Turbojet-
engine for Research Purposes. Applied Energy, 1102-1116.
Britannica, E. (2018). Afterburner. Retrieved from Enyclopedia Britannica:
https://www.britannica.com/technology/afterburner-mechanicalengineering
Garret. (2017). Compressor Maps. Retrieved from Honeywell Garret:

https://www.turbobygarrett.com/turbobygarrett/compressor_maps
Limit Engineering. (2015). Garret Turbo Products GT4202. Retrieved from Limit Engineering:
http://www.limitengineering.com/Turbos/GT4202/GT4202.html

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University of Engineering and Technology

Final Year Project

Design and Optimization of Micro Turbojet Engine

2020-au-14 Muhammad Arslan (Group Leader)

Automotive Engineering Centre

Garret. (2017). Compressor Maps. Retrieved from Honeywell Garret:

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