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Leveraging technology for growth JSC Aviadvigatel is a leading Russian design company. For 70 years, the company has been developing civilian and military aircraft engines, industrial gas turbines and power plants. Today Aviadvigatel’s engines include the Tupolev 204, Tupolev 214, Ilyushin 96-300, Ilyushin 76MF modern aircraft and the Air Force No. 1 Ilyushin 96-300PU. The engines are batch produced by JSC Perm Engine Company, a Russian and CIS leader in aircraft and industrial engines production.

Both companies are affiliated with the United Aircraft Engine Corporation. Making the right choice Siemens PLM Software’s solutions have been used at Aviadvigatel since 1994. These systems were among the first large-scale deployments of Siemens PLM Software’s products in Russia. “We clearly realized that we needed a CAD system,” recalls Sergei Bormalev, CIO, JSC Aviadvigatel. “We understood that it was necessary both for production planning and engineering analysis support.” In the mid-80s, Aviadvigatel engineers tried 3D modeling for the first time using the early versions of domestic and imported CAD systems. Before working with Siemens PLM Software’s Russian office, Aviadvigatel had used CATIA® software and Pro/Engineer® software.

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However the functionality of these solutions was not satisfactory for the design department. In 1994, Unigraphics Solutions, Inc.’s newly opened Russian office provided Unigraphics® software to Aviadvigatel. Eventually, Unigraphics Solutions became Siemens PLM Software and the Unigraphics system became software, a digital product development suite. “We immediately noticed several NX advantages,” notes Bormalev. “First, the functionality: we required concurrent determined parameterization and modeling in any context.

NX was able to do it in contrast to other systems. Second was the excellent price-quality ratio. Third, our U.S. Strategic partner at that time also used NX (Unigraphics then). However, the greatest benefit is Siemens PLM Software’s reputation as a leading PLM supplier to the aerospace industry. Having evaluated all this, we opted for NX.”.

NX – the first steps The NX training was initially organized onsite. “Siemens PLM Software’s top experts worked with us and they provided highly efficient support,” Bormalev says. Then, in 1995 a group of engineers went to Cologne for training.

Among them were Aviadvigatel’s designers, as well as several engineers from its manufacturing operation, JSC Perm Engine Company. “It was teaching teachers,” says Bormalev. “It was an advanced course and we studied the system comprehensively. Later, these engineers transferred their skills to others.” The first project that the company implemented with NX was designing the engine’s most complicated part – a cooled turbine blade, as well as its tooling. The molds, the external and internal surfaces and the ceramic inserts were all modeled in NX.

“It was a tremendous timesaver,” says Bormalev. “Conventional production planning for this kind of part would take about nine months. With the new technology we made it in four months. It was our first major accomplishment.” Later when JSC Perm Engine considered implementing new CAD technology, this example played a key role is convincing their organization to choose NX. Switching to the new NX technology has changed many of Aviadvigatel’s workflows. The advantages of concurrent product development were obvious but at that time expensive workstations were still required.

That is why several concurrent development teams were created, as well as a computer lab for the product and its tooling designers and NC experts. “All these experts looked at the screen together, reviewed the results, evaluated manufacturability, made changes, solved ongoing issues and just communicated,” Bormalev explains. “The atmosphere was business-like but still rather informal; everybody worked for the goal. These sessions helped define how to select parts for NX modeling. Specifically, NX was used if a 3D analysis was needed, as well as when a CAD model was required by production. Today, product development is almost entirely performed with NX.”.

From turbine blade to a new engine As early as 1997 JSC Aviadvigatel was using all of the CAD capabilities of NX, from production planning and tooling design to NC programming and engineering analysis. The company also has gone from designing just cooled turbine blades to non-cooled, compressor, fan blades, combustion chambers and other components. “Today we make new engines and retrofit the old ones using NX,” Bormalev says. “For convenience, we issue tutorials on part design. Every new NX version contributes something into our workflows.” JSC Perm Engine implemented Siemens PLM Software’s solutions somewhat later in 2003. “It was very important that we didn’t start from scratch and have to reinvent the wheel,” says Bormalev. “By that time, we had gained a lot of experience and were able to help Perm Engine Company through technology transfer and training.” Both JSC Aviadvigatel and JSC Perm Engine now use NX to solve much more complicated tasks than ten years ago.