Davis, R. Benjamin | Engineering Papers

NASA NTRS2013

Implementation of Speed Variation in the Structural Dynamic Assessment of Turbomachinery Flow-Path Components

During the design of turbomachinery flow path components, the assessment of possible structural resonant conditions is critical. Higher frequency modes of these structures are frequently found to be subject to resonance, and in these cases, design criteria require a forced response analysis of the structure with the assumption that the excitation speed exactly equals the resonant frequency. The design becomes problematic if the response analysis shows a violation of the HCF criteria. One possible solution is to perform "finite-life" analysis, where Miner's rule is used to calculate the actual life in seconds in comparison to the required life. In this situation, it is beneficial to incorporate the fact that, for a variety of turbomachinery control reasons, the speed of the rotor does not actually dwell at a single value but instead dithers about a nominal mean speed and during the time that the excitation frequency is not equal to the resonant frequency, the damage accumulated by the structure is diminished significantly. Building on previous investigations into this process, we show that a steady-state assumption of the response is extremely accurate for this typical case, resulting in the ability to quickly account for speed variation in the finite-life analysis of a component which has previously had its peak dynamic stress at resonance calculated. A technique using Monte Carlo simulation is also presented which can be used when specific speed time histories are not available. The implementation of these techniques can prove critical for successful turbopump design, as the improvement in life when speed variation is considered is shown to be greater than a factor of two

Brown, Andrew M.↗

NASA NTRS2013

Implementation of Speed Variation in the Structural Dynamic Assessment of Turbomachinery Flow-Path Components

During the design of turbomachinery flow path components, the assessment of possible structural resonant conditions is critical. Higher frequency modes of these structures are frequently found to be subject to resonance, and in these cases, design criteria require a forced response analysis of the structure with the assumption that the excitation speed exactly equals the resonant frequency. The design becomes problematic if the response analysis shows a violation of the HCF criteria. One possible solution is to perform "finite-life" analysis, where Miner's rule is used to calculate the actual life in seconds in comparison to the required life. In this situation, it is beneficial to incorporate the fact that, for a variety of turbomachinery control reasons, the speed of the rotor does not actually dwell at a single value but instead dithers about a nominal mean speed and during the time that the excitation frequency is not equal to the resonant frequency, the damage accumulated by the structure is diminished significantly. Building on previous investigations into this process, we show that a steady-state assumption of the response is extremely accurate for this typical case, resulting in the ability to quickly account for speed variation in the finite-life analysis of a component which has previously had its peak dynamic stress at resonance calculated. A technique using Monte Carlo simulation is also presented which can be used when specific speed time histories are not available. The implementation of these techniques can prove critical for successful turbopump design, as the improvement in life when speed variation is considered is shown to be greater than a factor of two.

Brown, Andrew M.↗

NASA NTRS2012

Validation of Measured Damping Trends for Flight-Like Vehicle Panel/Equipment including a Range of Cable Harness Assemblies

This validation study examines the effect on vibroacoustic response resulting from the installation of cable bundles on a curved orthogrid panel. Of interest is the level of damping provided by the installation of the cable bundles and whether this damping could be potentially leveraged in launch vehicle design. The results of this test are compared with baseline acoustic response tests without cables. Damping estimates from the measured response data are made using a new software tool that leverages a finite element model of the panel in conjunction with advanced optimization techniques. While the full test series is not yet complete, the first configuration of cable bundles that was assessed effectively increased the viscous critical damping fraction of the system by as much as 0.02 in certain frequency ranges.

Smith, Andrew M.↗

NASA NTRS2010

Acoustic-Modal Testing of the Ares I Launch Abort System Attitude Control Motor Valve

The Attitude Control Motor (ACM) is being developed for use in the Launch Abort System (LAS) of NASA's Ares I launch vehicle. The ACM consists of a small solid rocket motor and eight actuated pintle valves that directionally allocate.thrust_- 1t.has-been- predicted-that significant unsteady. pressure.fluctuations.will.exist. inside the-valves during operation. The dominant frequencies of these oscillations correspond to the lowest several acoustic natural frequencies of the individual valves. An acoustic finite element model of the fluid volume inside the valve has been critical to the prediction of these frequencies and their associated mode shapes. This work describes an effort to experimentally validate the acoustic finite model of the valve with an acoustic modal test. The modal test involved instrumenting a flight-like valve with six microphones and then exciting the enclosed air with a loudspeaker. The loudspeaker was configured to deliver broadband noise at relatively high sound pressure levels. The aquired microphone signals were post-processed and compared to results generated from the acoustic finite element model. Initial comparisons between the test data and the model results revealed that additional model refinement was necessary. Specifically, the model was updated to implement a complex impedance boundary condition at the entrance to the valve supply tube. This boundary condition models the frequency-dependent impedance that an acoustic wave will encounter as it reaches the end of the supply tube. Upon invoking this boundary condition, significantly improved agreement between the test data and the model was realized.

Davis, R. Benjamin↗

NASA NTRS2010

Internal Acoustics of a Pintle Valve with Supercritical Helium Flow

Large amplitude flow unsteadiness is a common phenomenon within the high flow rate ducts and valves associated with propulsion systems. Boundary layer noise, shear layers and vortex shedding are a few of the many sources of flow oscillations. The presence of lightly damped acoustic modes can organize and amplify these sources of flow perturbation, causing undesirable loading of internal parts. The present study investigates the self-induced acoustic environment within a pintle valve subject to high Reynolds Number flow of helium gas. Experiments were conducted to measure the internal pressure oscillations of the Ares I Launch Abort System (LAS) Attitude Control Motor (ACM) valve. The AGM consists of a solid propellant gas generator with eight pintle valves attached to the aft end. The pintle valve is designed to deliver variable upstream conditions to an attache( converging diverging nozzle. In order to investigate the full range of operating conditions 28 separate tests were conducted with varying pintle position and upstream pressure. Helium gas was utilized in order to closely mimic the speed of sound of the gas generator exhaust, minimizing required scaling during data analysis. The recordec pressure measurements were interrogated to multiple ends. The development of root mean square (RMS) value! versus Reynolds Number and Pintle position are important to creating bounding unsteady load curves for valve internal parts. Spectral analysis was also performed, helping to identify power spectral densities (PSD) of acoustic natural frequencies and boundary layer noise. An interesting and unexpected result was the identification of an acoustic mode within the valve which does not respond until the valve was over 60% open. Further, the response amplitude around this mode can be as large or larger than those associated with lower frequency modes.

Fishbach, Sean R.↗

NASA NTRS2010

The Response of a Mechanical Oscillator Due to Swept and Dithered Excitation

A single degree-of-freedom oscillator subject to linearly swept and/or dithered excitation is considered. Dither refers to the variation of an excitation frequency about a given nominal, or primary, frequency. Dither in rocket engine turbopump shaft speeds can be an important consideration when analyzing the dynamic response of turbomachinery components such as turbine blades. Results indicate that the incorporation of dithered excitation into a fatigue analysis may extend the predicted fatigue life of the structure by a factor of two or more.

Davis, R. Benjamin↗

NASA NTRS2009

Acoustic-Structure Interaction in Rocket Engines: Validation Testing

While analyzing a rocket engine component, it is often necessary to account for any effects that adjacent fluids (e.g., liquid fuels or oxidizers) might have on the structural dynamics of the component. To better characterize the fully coupled fluid-structure system responses, an analytical approach that models the system as a coupled expansion of rigid wall acoustic modes and in vacuo structural modes has been proposed. The present work seeks to experimentally validate this approach. To experimentally observe well-coupled system modes, the test article and fluid cavities are designed such that the uncoupled structural frequencies are comparable to the uncoupled acoustic frequencies. The test measures the natural frequencies, mode shapes, and forced response of cylindrical test articles in contact with fluid-filled cylindrical and/or annular cavities. The test article is excited with a stinger and the fluid-loaded response is acquired using a laser-doppler vibrometer. The experimentally determined fluid-loaded natural frequencies are compared directly to the results of the analytical model. Due to the geometric configuration of the test article, the analytical model is found to be valid for natural modes with circumferential wave numbers greater than four. In the case of these modes, the natural frequencies predicted by the analytical model demonstrate excellent agreement with the experimentally determined natural frequencies.

Davis, R. Benjamin↗