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Rotor and control system loads analysis of the XV-15 with the advanced technology blades

An analysis of the rotor and control system loads of the XV-15 with the Advanced Technology Blades (XV-15/ATB) was conducted to investigate the effects of modifications designed to alleviate high collective actuator loads encountered during initial flight tests. Rotor loads predictions were correlated with flight data to establish accuracies of the methodology used in the analysis. Control system loads predictions were then examined and were also correlated with flight data. The results showed a significant reduction in 3/rev collective actuator loads of the XV-15/ATB when the control system stiffness was increased and the rotor blade chord balance and tip twist were modified.

Totah, Joseph J.↗

Investigation of the Effect of In-Plane Fiber Waviness in Composite Materials through Multiple Scales of Testing and Finite Element Modeling

Defects in materials can reduce strengths and lifetimes of manufactured parts. The number of possible defects increases with the complexity inherent in composite materials. The wind industry uses composite wind turbine blades in which the manufacturing process induces a number of defects. In order for the wind industry to continue sustainable expansion, the effects of defects must be better understood. In-plane (IP) fiber waviness is the focus of this work. The three main parts of this work include testing on the coupon level, modeling on the coupon level, and testing of beams in four-point bending (with and without defects). The coupon level testing includes partial IP waves, similar to those in manufactured parts, rather than full width IP waves. This allows investigation into complex interactions and varying failure mechanisms caused by the fiber misalignment gradient. Partial waves are also modeled to both validate testing as well as to increase robustness of a previously developed progressive damage modeling method. Lastly, a sandwich beam test specimen for testing in 4-point bending is developed to investigate the effects of fiber waviness in both tension and compression when loaded in flexure.

36 MATERIALS SCIENCE↗

Rotor Performance Predictions of a Next Generation Mars Science Helicopter

Since Ingenuity took flight and proved aerial capabilities on Mars, the horizon for rotorcraft on the Red Planet has only expanded. One proposed future Martian rotorcraft is the Mars Science Helicopter (MSH). The MSH is a hexacopter capable of carrying scientific payloads. As a part of its joint development by NASA Ames Research Center (ARC) and the Jet Propulsion Laboratory (JPL), key MSH rotor components will be tested inside the in-development Reduced Atmospheric Pressure Testing Of Rotors (RAPTOR) wind tunnel in the Planetary Aeolian Laboratory (PAL) at NASA ARC. In preparation for the test, the Comprehensive Hierarchical Aeromechanics Rotorcraft Model (CHARM) analysis was utilized to predict the aerodynamic performance for one MSH hexacopter isolated rotor. This paper provides an overview of the planned experiments involving the MSH reference blades, as well as CHARM pretest predictions of rotor performance in hover and forward flight. Additionally, the interference effects of wind tunnel walls on rotor performance will be evaluated to inform the test matrix of the upcoming test in the RAPTOR tunnel.

MHS↗

Investigation of advanced counterrotation blade configuration concepts for high speed turboprop systems. Task 5: Unsteady counterrotation ducted propfan analysis. Computer program user's manual

The primary objective of this study was the development of a time-marching three-dimensional Euler/Navier-Stokes aerodynamic analysis to predict steady and unsteady compressible transonic flows about ducted and unducted propfan propulsion systems employing multiple blade rows. The computer codes resulting from this study are referred to as ADPAC-AOACR (Advanced Ducted Propfan Analysis Codes-Angle of Attack Coupled Row). This report is intended to serve as a computer program user's manual for the ADPAC-AOACR codes developed under Task 5 of NASA Contract NAS3-25270, Unsteady Counterrotating Ducted Propfan Analysis. The ADPAC-AOACR program is based on a flexible multiple blocked grid discretization scheme permitting coupled 2-D/3-D mesh block solutions with application to a wide variety of geometries. For convenience, several standard mesh block structures are described for turbomachinery applications. Aerodynamic calculations are based on a four-stage Runge-Kutta time-marching finite volume solution technique with added numerical dissipation. Steady flow predictions are accelerated by a multigrid procedure. Numerical calculations are compared with experimental data for several test cases to demonstrate the utility of this approach for predicting the aerodynamics of modern turbomachinery configurations employing multiple blade rows.

Hall, Edward J.↗

Stereo Photogrammetry Measurements of the Position and Attitude of a Nozzle-Plume/Shock-Wave Interaction Model in the NASA Ames 9- by 7-Ft Supersonic Wind Tunnel

Stereo photogrammetry was used to measure the position and attitude of a slender body of revolution during nozzle-plume/shock-wave interaction tests in the NASA Ames 9- by 7-Ft Supersonic Wind Tunnel. The model support system was designed to allow the model to be placed at many locations in the test section relative to a pressure rail on one sidewall. It included a streamwise traverse as well as a thin blade that offset the model axis from the sting axis. With these features the support system was more flexible than usual resulting in higher-than-usual uncertainty in the position and attitude of the model. Also contributing to this uncertainty were the absence of a balance, so corrections for sting deflections could not be applied, and the wings-vertical orientation of the model, which precluded using a gravity-based accelerometer to measure pitch angle. Therefore, stereo photogrammetry was chosen to provide independent measures of the model position and orientation. This paper describes the photogrammetry system and presents selected results from the test.

supersonic↗

Quantifying mortality and injury susceptibility for two morphologically disparate fishes exposed to simulated turbine blade strike

Passage of fishes through hydropower turbines and water pumping stations may cause mortal injury as the result of exposure to blade strike impact. Laboratory trials of simulated blade strike on two morphologically distinct fishes, American eel ( Anguilla rostrata ) and bluegill sunfish ( Lepomis macrochirus ) were undertaken to assess injury and mortality rates. We hypothesized that bluegill would have comparable rates of injury and mortality to other laterally compressed fishes while anguilliform American eel would be more resistant to injury. American eel had low observed mortality rates at the highest velocity tested (13.6 m/s), but many fish were observed with vertebral fractures which we categorized as functionally dead individuals. Bluegill were more susceptible to blade strike with high rates of mortality regardless of blade thickness, velocity, or impact conditions (location, angle, or fish orientation). These data have broadened our understanding of the range of responses among entrained fishes exposed to blade strike and represent species with low (American eel) and high (bluegill) susceptibility to injury and mortality. Furthermore, our blade strike data can help inform safer turbine designs or prioritization of pumps that minimize traumatic injury and mortality of fishes during non-volitional passage through hydropower turbines or water pumping stations.

59 BASIC BIOLOGICAL SCIENCES↗

Investigation of advanced counterrotation blade configuration concepts for high speed turboprop systems. Task 5: Unsteady counterrotation ducted propfan analysis

The primary objective of this study was the development of a time-marching three-dimensional Euler/Navier-Stokes aerodynamic analysis to predict steady and unsteady compressible transonic flows about ducted and unducted propfan propulsion systems employing multiple blade rows. The computer codes resulting from this study are referred to as ADPAC-AOAR\CR (Advanced Ducted Propfan Analysis Codes-Angle of Attack Coupled Row). This document is the final report describing the theoretical basis and analytical results from the ADPAC-AOACR codes developed under task 5 of NASA Contract NAS3-25270, Unsteady Counterrotating Ducted Propfan Analysis. The ADPAC-AOACR Program is based on a flexible multiple blocked grid discretization scheme permitting coupled 2-D/3-D mesh block solutions with application to a wide variety of geometries. For convenience, several standard mesh block structures are described for turbomachinery applications. Aerodynamic calculations are based on a four-stage Runge-Kutta time-marching finite volume solution technique with added numerical dissipation. Steady flow predictions are accelerated by a multigrid procedure. Numerical calculations are compared with experimental data for several test cases to demonstrate the utility of this approach for predicting the aerodynamics of modern turbomachinery configurations employing multiple blade rows.

Hall, Edward J.↗

A comparative analysis of XV-15 tiltrotor hover test data and WOPWOP predictions incorporating the fountain effect

Acoustic measurements from a hovering full scale XV-15 tilt rotor with the advanced technology blades are presented which show the directionality of fountain effect noise. Predicted acoustic directivity results are also presented which show agreement with the measured data. The aeroacoustic code, WOPWOP, was used in conjunction with a mathematical model which simulated the fountain recirculation aerodynamic effect on the rotor blade surface pressures. The predictions were used to identify the spike character in the measured data as fountain effect associated noise. The directivity of the fountain effect noise was observed to be dominant at the rear of the aircraft with increased intensities 45 degrees below the rotor disk planes.

Rutledge, Charles K.↗

NDE of PWA 1480 single crystal turbine blade material

Cantilever bending fatigue specimens were examined by fluorescent liquid penetrant and radioactive gas penetrant (Krypton) non-destructive evaluation (NDE) methods and tested. Specimens with cast, ground, or polished surface were evaluated to study the effect of surface condition on NDE and fatigue crack initiation. Fractographic and metallurgical analyses were performed to determine the nature of crack precursors. Preliminary results show that fatigue strength was lower for specimens with cast surfaces than for specimens with machined surfaces. The liquid penetrant and gas penetrant techniques both provided indications of a large population of defects on the cast surfaces. On ground or polished specimen surfaces, the gas penetrant appeared to estimate the actual number of voids more accurately than the liquid penetrant.

Klima, Stanley J.↗

A comparative analysis of XV-15 tiltrotor hover test data and WOPWOP predictions incorporating the fountain effect

Acoustic measurements from a hovering full-scale XV-15 tiltrotor with the advanced technology blades are presented which show the directionality of fountain effect noise. Predicted activity directivity results are also presented which show agreement with the measured data. The aeroacoustic code, WOPWOP, was used in conjunction with a mathematical model which simulated the fountain/recirculation aerodynamic effect on the rotors' blade surface pressures. The predictions were used to identify the spike character in the measured data as fountain effect associated noise. The directivity of the fountain effect noise was observed to be dominant at the rear of the aircraft with increased intensities 45 degrees below the rotor disk planes.

Rutledge, Charles K.↗

Study of noise and inflow distortion sources in the NASA QF-1B fan using measured blade and vane pressures

Pressure transducers were installed on the blades and vanes of QF-1B, a transonic-tip-speed fan from the NASA Quiet Fan Program which was tested on the outdoor quiet fan test facility at NASA-Lewis. Signals from the transducers and from far field microphones were analyzed to determine sources of nonuniform inflow and noise. The nonuniform inflow was mostly unsteady with roughly equal contributions from atmospheric turbulence and rig interference. The rig interference was largest at the bottom and appeared to be generated by the support structure which was located behind the inlet lip under the fan. Interaction of this inflow distortion was the dominant source of noise at 1, 2, and 3 times blade passing frequency (BPF) at 60, 70, and 80 percent of design speed. At 90 percent speed, noise at BPF was dominated by the steady rotor field. A broadband spectrum peak centered at about 2.2 times BPF was identified as rotor/stator interaction stemming from a high frequency rotor exit flow component. The remaining broadband energy from 0.3 to 3.5 times BPF was attributed to the better known type of rotor/stator interaction associated with rotor wake turbulence.

Hanson, D. B.↗

Experimental study of three exit pressure distortions on turbine performance

A cold flow air test of the Space Shuttle Main Engine (SSME) High Pressure Fuel Turbopump (HPFTP) turbine was conducted with a circumferential pressure distortion at the turbine exit. The effects of three circumferential exit pressure distortions on turbine efficiency and pressure ratio, are presented. Circumferential and radial total pressure, total temperature, static pressure, and flow angle distributions at the turbine exit are also presented. Efficiency and total-to-total pressure ratio are shown to have a circumferential variation as high as 13.7 percent (or points of efficiency) and 7.1 percent, respectively. A slight pressure distortion was measured downstream of the first stage nozzle and the distortion increased across subsequent blade rows to a maximum downstream of the second stage rotor for all three plates. A brief discussion of the test facility, model, instrumentation, and test plan is given for completeness.

Gaddis, Stephen W.↗

Mechanism of Supercooled Water Droplet Breakup near the Leading Edge of an Airfoil

This work presents the results of an experimental study on supercooled droplet deformation and breakup near the leading edge of an airfoil. The results are compared to prior room temperature droplet deformation results to explore the effects of droplet supercooling. The experiments were conducted in the Adverse Environment Rotor Test Stand (AERTS) at The Pennsylvania State University. An airfoil model placed at the end of the rotor blades mounted onto the hub in the AERTS chamber was moved at speeds ranging between 50 and 80 m/sec. The temperature of the chamber was set at -20˚C. A monotonic droplet generator was used to produce droplets that fell from above, perpendicular to the path of the airfoil. The supercooled state of the droplets was determined by measurement of the temperature of the drops at various locations below the droplet generator exit. A temperature prediction code was also used to estimate the temperature of the droplets based on vertical velocity and the distance traveled by droplets from the droplet generator to the airfoil stagnation line. High speed imaging was employed to observe the interaction between the droplets and the airfoil. The high speed imaging provided droplet deformation information as the droplet approached the airfoil near the stagnation line. A tracking software program was used to measure the horizontal and vertical displacement of the droplet against time. It was demonstrated that to compare the effects of water supercooling on droplet deformation, the ratio of the slip velocity and the initial droplet velocity must be equal. A case with equal slip velocity to initial velocity ratios was selected for room temperature and supercooled droplet conditions. The airfoil velocity was 60 m/s and the slip velocity for both sets of data was 40 m/s. In these cases, the deformation of the weakly supercooled and warm droplets did not present different trends. The similar behavior for both environmental conditions indicates that water supercooling has no effect on particle deformation for the limited range of the weak supercooling of the droplets tested and the selected impact velocity. The assumption of a constant surface tension value was further supported by the equal trend of the Bond number obtained for supercooled and room temperature droplets.

in-flight icing↗

Comprehensive Validation of an Intermittency Transport Model for Transitional Low-Pressure Turbine Flows

A transport equation for the intermittency factor is employed to predict transitional flows under the effects of pressure gradients, freestream turbulence intensities, Reynolds number variations, flow separation and reattachment. and unsteady wake-blade interactions representing diverse operating conditions encountered in low-pressure turbines. The intermittent behaviour of the transitional flows is taken into account and incorporated into computations by modifying the eddy viscosity, Mu(sub t), with the intermittency factor, gamma. Turbulent quantities are predicted by using Menter's two-equation turbulence model (SST). The onset location of transition is obtained from correlations based on boundary-layer momentum thickness, acceleration parameter, and turbulence intensity. The intermittency factor is obtained from a transport model which can produce both the experimentally observed streamwise variation of intermittency and a realistic profile in the cross stream direction. The intermittency transport model is tested and validated against several well documented low pressure turbine experiments ranging from flat plate cases to unsteady wake-blade interaction experiments. Overall, good agreement between the experimental data and computational results is obtained illustrating the predicting capabilities of the model and the current intermittency transport modelling approach for transitional flow simulations.

Suzen, Y. B.↗

CFD Study of the J2-X LOX Two-Bladed Inducer in the Presence of a Circumferential Groove

Results are presented of a computational fluid dynamics (CFD) study done in support of water flow experiments of the J-2X Oxidizer Turbopump (OTP) 2-bladed inducer with a circumferential groove that were conducted at Marshall Space Flight Center (MSFC). Sub-scale water flow testing results indicate that the circumferential groove greatly reduces synchronous cavitation and subsequent bearing loads at a minimal performance cost, but the energy reappears as high order cavitation (HOC) that spans a relatively large frequency range. Thus, HOC may have implications for the full-scale OTP inducer in terms of reduced structural margin at higher mode frequencies. Simulations using the LOCI-Stream CFD program were conducted in order to explore the root physical cause of the HOC. It was found that the axial recirculation pattern in the circumferential groove causes high-swirl fluid to interact with the nearly-axial incoming fluid just above the inducer blades. The high-shear interface between the fluids is Kelvin-Helmholtz unstable, resulting in trains of low pressure regions or 'pearls' forming near the upstream edge of the groove. When the pressure in these regions becomes low enough and they get cut by the blade leading edge, HOC is thought to occur. Although further work is required, the numerical models indicate that the root cause of HOC is hydrodynamic. That is, the pearls are always present, even when cavitation is not. Comparisons to ongoing water flow experiments will be discussed, as well as predictions for the full-scale OTP inducer.

Coker, Robert↗

Experimental investigation of turbine blade-tip excitation forces

Results of a program to investigate the magnitude and parametric variations of rotordynamic forces which arise in high power turbines due to blade-tip leakage effects are presented. Five different unshrouded turbine configurations and one configuration shrouded with a labyrinth seal were tested with static offsets of the turbine shaft. The forces along and perpendicular to the offset were measured directly with a rotating dynometer. Exploration of casing pressure and flow velocity distributions was used to investigate the force-generating mechanisms. For unshrouded turbines, the cross-forces originate mainly from the classical Alford mechanisms while the direct forces arise mainly from a slightly skewed pressure pattern. The Alford coefficient for cross-force was found to vary between 2.4 and 4.0, while the similar direct force coefficient varied from 1.5 to 3.5. The cross-forces are found to increase substantially when the gap is reduced from 3.0 to 1.9% of blade height, probably due to viscous blade-tip effects. The forces also increase when the hub gap between stator and rotor decreases. The force coefficient decreased with operating flow coefficient. In the case of the shrouded turbine, most of the forces arise from nonuniform seal pressures. This includes about 80% for the transverse forces. The rest appears to come from uneven work extraction. Their level is about 50% higher in the shrouded case.

Martinez-Sanchez, Manuel↗

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