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NASA NTRS1988

Fluid oscillation in the Drop Tower

An interfluid meniscus oscillates within a cylindrical container when suddenly released from earth's gravity and taken into a microgravity environment. Oscillations damp out from energy dissipative mechanisms such as viscosity and interfacial friction. Damping out of the oscillations by the latter mechanism is affected by the nature of the interfacial junction between the fluid-fluid interface and the container wall. Perfluoromethylcyclohexane and isopropanol in glass were the materials used for the experiment. The wetting condition of the fluids against the wall changes at the critical wetting transition temperature. This change in wetting causes a change in the damping characteristics.

Kaukler, William F.↗

NASA NTRS2003

Production of Near-Mirror Surface Quality by Precision Grinding

Mechanical components such as gears and bearings operate with the working surfaces in intimate contact with a mating part. The performance of such components will be influenced by the quality of the working surface. In general, a smoother surface will perform better than a rougher surface since the lubrication conditions are improved. For example, surfaces with a special near-mirror quality finish of low roughness performed better than ground surfaces when tested using a block-on-ring arrangement. Bearings with near-mirror quality have been tested and analyzed; lower running torques were measured and improved fatigue life was anticipated. Experiments have been done to evaluate the performance of gears with improved, low roughness surface finishing. The measured performance improvements include an increased scuffing (scoring) load capacity by a factor of 1.6, a 30-percent reduction of gear tooth running friction, and longer fatigue lives by a factor of about four. One can also anticipate that near-mirror quality surface finishing could improve the performance of other mechanical components such as mechanical seals and heavily loaded journal bearings. Given these demonstrated benefits, capable and economical methods for the production of mechanical components with near-mirror quality surfaces are desired. One could propose the production of near-mirror quality surfaces by several methods such as abrasive polishing, chemical assisted polishing, or grinding. Production of the surfaces by grinding offers the possibility to control the macro-geometry (form), waviness, and surface texture with one process. The present study was carried out to investigate the possibility of producing near-mirror quality surfaces by grinding. The present study makes use of a specially designed grinding machine spindle to improve the surface quality relative to the quality produced when using a spindle of conventional design.

Dimofte, Florin↗

NASA NTRS2010

Two-Speed Gearbox Dynamic Simulation Predictions and Test Validation

Dynamic simulations and experimental validation tests were performed on a two-stage, two-speed gearbox as part of the drive system research activities of the NASA Fundamental Aeronautics Subsonics Rotary Wing Project. The gearbox was driven by two electromagnetic motors and had two electromagnetic, multi-disk clutches to control output speed. A dynamic model of the system was created which included a direct current electric motor with proportional-integral-derivative (PID) speed control, a two-speed gearbox with dual electromagnetically actuated clutches, and an eddy current dynamometer. A six degree-of-freedom model of the gearbox accounted for the system torsional dynamics and included gear, clutch, shaft, and load inertias as well as shaft flexibilities and a dry clutch stick-slip friction model. Experimental validation tests were performed on the gearbox in the NASA Glenn gear noise test facility. Gearbox output speed and torque as well as drive motor speed and current were compared to those from the analytical predictions. The experiments correlate very well with the predictions, thus validating the dynamic simulation methodologies.

Lewicki, David G.↗

NASA NTRS1991

Regolith-structure modeling

Early lunar missions have provided a basic understanding of the physical and strength properties of lunar regolith, which have been shown to differ from those of dry terrestrial granular soils. Lunar regolith is predominantly a fine sand of which nearly 40 percent can be characterized as silt with a particle size smaller than 100 micrometers. The top 10 to 20 cm of the regolith can be characterized as being in a loose to medium-loose state. The density of the regolith, however, rapidly increases below a depth of 20 cm. The highly irregular and angular shapes of the regolith particles tend to interlock and create relatively strong mechanical bonds that give the particulate mass substantial cohesive properties and smaller amounts of tensile strength properties. In addition, the friction angle of lunar regolith at medium to high densities is quite high and often exceeds 55 degrees. These known properties of lunar regolith have been matched in a terrestrially-manufactured analog known as Minnesota Lunar Simulant. A variety of experiments were conducted using this simulant to both verify existing information and generate new information on the physical and constitutive properties of lunar regolith. These experiments include maximum and minimum density determinations, specific mass of solids, grain-size distribution, conventional triaxial compression and extension, isotropic compression, one-dimensional compression, direct shear, and direct tension. Direct shear experiments were conducted under atmospheric and vacuum conditions. Results of the physical and strength experiments compare closely to results obtained from lunar missions. Results of simulant strength experiments performed in vacuum indicated no observable difference from results obtained in air. A test bed currently under study is one involving a regolith shield covering a first-generation human habitat module. It is understood that regolith in depths ranging from 3 to 5 meters is required for radiation shielding for habitation and workspace. The habitat module is treated as a rigid cylindrical tube with a smooth exterior. By making the cylinder rigid, a complex interaction problem is reduced to a situation where we can consider the support regolith and the shielding regolith as behaving independently of the structural properties of the cylindrical structure. Medium-dense lunar simulant was placed around a scaled model of the habitat module to provide a radiation shield. This embankment-type shield was constructed in relatively thin but fine layers by compacting, by mechanical vibratory means, layer upon layer of simulant placed adjacent to the horizontally-aligned cylinder. The slope angles were constructed at 55 degrees. The model described above was studied in a geotechnical centrifuge, which allows for the scaling of model dimensions to prototype dimensions by increasing the acceleration of gravity on the model. The deformation response can be scaled up to prototype dimensions to provide an assessment of the deformation patterns of the lunar structure. The actual process of local and/or global growth of instabilities or skip planes can also be observed.

Ko, Hon-Yim↗

NASA NTRS2018

Series Elastic Tether Management for Rappelling Rovers

The Axel rappelling rover was designed to enable access to intriguing and important science sites that lie in difﬁcult terrains that are inaccessible to conventional rovers. Extended autonomous rappelling calls for careful control of tethertension,precisemanagementoftetherspooling,andsome measure of shock tolerance. This paper covers the design and testing of a ﬁrst-generation tether management system (TMS) for Axel. The system uses a double bull-wheel capstan driven by a low-stiffness series elastic actuator (SEA) to provide tension control and decouple internal spooling tension from external tether tension. The beneﬁt of the series elastic actuator is two-fold. First, it permits closed-loop tether tension control with lower mass and power consumption than a comparable torque motor. Second, it improves the shock/drop tolerance of the rappelling system both while moving and when the system is inactive with the motors locked. Experiments on the new TMS show that this design performs well in keeping nearly constant spooling tension while rejecting large dynamic disturbances at the output. While the SEA is very effective at maintaining a given tension contribution, the additional effects of friction and the unique mechanical properties of the tether result in substantial errors in the measured output tension. Upcoming ﬁeld trials will be used to evaluate the effectiveness and sufﬁciency of this system when integrated in Axel.

Nesnas, Issa↗

NASA NTRS1990

The experimental evaluation and application of high-temperature solid lubricants

A research program is described which developes an understanding of high-temperature solid lubrication and experimental techniques through the development of a composite lubricant coating system. The knowledge gained through this research was then applied to a specific engineering challenge, the tribology of a sliding seal for hypersonic flight vehicles. The solid lubricant coating is a chromium carbide based composite combined with silver, which acts as a low temperature lubricant, and barium fluoride/calcium fluoride eutectic, which acts as a high-temperature lubricant. This composite coating provides good wear resistance and low friction for sliding contacts from room temperature to over 900 C in reducing or oxidative environments. The specific research on this coating included a composition screening using a foil gas bearing test rig and the use of thin silver films to reduce initial wear using a pin-on-disk test rig. The chemical stability of the materials used was also addressed. This research indicated that soft metallic films and materials which become soft at elevated temperatures are potentially good lubricants. The general results from the experiments with the model solid lubricant coating were then applied to a sliding seal design concept. This seal design requires that a braided ceramic fabric slide against a variety of metal counterface materials at temperatures from 25 to 850 C in an oxidative environment. A pin-on-disk tribometer was used to evaluate the tribological properties of these materials and to develop lubrication techniques. The results indicate that these seal materials must be lubricated to prevent wear and reduce friction. Thin films of silver, gold and calcium fluoride provided lubrication to the sliding materials.

Dellacorte, Christopher↗

NASA NTRS1980

Drawer drive for space shuttle vacuum canister

A sliding drawer type canister was designed to contain long duration exposure facility experiments which require vacuum storage before and after space exposure. The elastomeric seals require high closing loads which are generated through camming levers and transmitted through a spring loaded pressure plate. Lubrication was provided by various dry surface coatings. Higher than expected friction required some redesign after which the assembly functioned well and provided good sealing.

Werner, K. E.↗

NASA NTRS1990

Compensating for pneumatic distortion in pressure sensing devices

A technique of compensating for pneumatic distortion in pressure sensing devices was developed and verified. This compensation allows conventional pressure sensing technology to obtain improved unsteady pressure measurements. Pressure distortion caused by frictional attenuation and pneumatic resonance within the sensing system makes obtaining unsteady pressure measurements by conventional sensors difficult. Most distortion occurs within the pneumatic tubing which transmits pressure impulses from the aircraft's surface to the measurement transducer. To avoid pneumatic distortion, experiment designers mount the pressure sensor at the surface of the aircraft, (called in-situ mounting). In-situ transducers cannot always fit in the available space and sometimes pneumatic tubing must be run from the aircraft's surface to the pressure transducer. A technique to measure unsteady pressure data using conventional pressure sensing technology was developed. A pneumatic distortion model is reduced to a low-order, state-variable model retaining most of the dynamic characteristics of the full model. The reduced-order model is coupled with results from minimum variance estimation theory to develop an algorithm to compensate for the effects of pneumatic distortion. Both postflight and real-time algorithms are developed and evaluated using simulated and flight data.

Whitmore, Stephen A.↗

NASA NTRS2011

Pre-Finishing of SiC for Optical Applications

13 Manufacturing & Prototyping A method is based on two unique processing steps that are both based on deterministic machining processes using a single-point diamond turning (SPDT) machine. In the first step, a high-MRR (material removal rate) process is used to machine the part within several microns of the final geometry. In the second step, a low-MRR process is used to machine the part to near optical quality using a novel ductile regime machining (DRM) process. DRM is a deterministic machining process associated with conditions under high hydrostatic pressures and very small depths of cut. Under such conditions, using high negative-rake angle cutting tools, the high-pressure region near the tool corresponds to a plastic zone, where even a brittle material will behave in a ductile manner. In the high-MRR processing step, the objective is to remove material with a sufficiently high rate such that the process is economical, without inducing large-scale subsurface damage. A laser-assisted machining approach was evaluated whereby a CO2 laser was focused in advance of the cutting tool. While CVD (chemical vapor deposition) SiC was successfully machined with this approach, the cutting forces were substantially higher than cuts at room temperature under the same machining conditions. During the experiments, the expansion of the part and the tool due to the heating was carefully accounted for. The higher cutting forces are most likely due to a small reduction in the shear strength of the material compared with a larger increase in friction forces due to the thermal softening effect. The key advantage is that the hybrid machine approach has the potential to achieve optical quality without the need for a separate optical finishing step. Also, this method is scalable, so one can easily progress from machining 50-mm-diameter samples to the 250-mm-diameter mirror that NASA desires.

Rozzi, Jay↗

NASA NTRS2015

Direct Simulation of Flow over A Wall-Mounted Hump

Simulating separated flows at high Reynolds numbers using Reynolds Averaged Navier-Stokes (RANS) modeled equations remains a challenge in aeronautics. The main hindrance to progress stems from the lack of extended de- tailed data pertinent to the root cause of failure of RANS models, as well as the little progress in RANS modeling innovations in the past several decades. The goal of the current effort is to generate data for separated flow at a Reynolds numbers where conventional models are challenged. We use Direct Numerical Simulations to model turbulent flow over the wall-mounted hump configuration to investigate the physics of flow separation and boundary layer recovery, as well as provide data relevant to the modeling community. A chord-based Reynolds number of Re(sub c) = 47,500 is considered with a turbulent inflow profile of Re(sub θ) = 1,400 (θ /c = 3%). We use FDL3DI, a code that solves the compressible Navier-Stokes equations using high-order compact-difference scheme and filter, with the standard re- cycling/rescaling method of generating turbulent boundary layers as inflow to the computational domain. Two differ- ent configurations of the upper-wall are analyzed for two sets of boundary conditions (slip and no-slip). The results are compared with the available higher Re(sub c) (= 936,000, Re(sub θ) = 7,200, θ /c = 0.77%) experiment for major flow features. The simulated lower Rec allows for DNS-like mesh resolutions, and adequately wide spans. The results from these simulations show earlier separation and delayed reattachment compared to Re(sub c) = 936,000, and significantly higher skin friction in the forebody of the hump. We also find that the upper-wall shape and boundary condition influence pressure distribution over the hump, whereas skin friction is only influenced by the boundary condition.

Wall-Mounted↗

NASA NTRS2000

Experiments on the Richtmyer-Meshkov Instability of Incompressible Fluids

Richtmyer-Meshkov (R-M) instability occurs when two different density fluids are impulsively accelerated in the direction normal to their nearly planar interface. The instability causes small perturbations on the interface to grow and possibly become turbulent given the proper initial conditions. R-M instability is similar to the Rayleigh-Taylor (R-T) instability, which is generated when the two fluids undergo a constant acceleration. R-M instability is a fundamental fluid instability that is important to fields ranging from astrophysics to high-speed combustion. For example, R-M instability is currently the limiting factor in achieving a net positive yield with inertial confinement fusion. The experiments described here utilize a novel technique that circumvents many of the experimental difficulties previously limiting the study of the R-M instability. A Plexiglas tank contains two unequal density liquids and is gently oscillated horizontally to produce a controlled initial fluid interface shape. The tank is mounted to a sled on a high speed, low friction linear rail system, constraining the main motion to the vertical direction. The sled is released from an initial height and falls vertically until it bounces off of a movable spring, imparting an impulsive acceleration in the upward direction. As the sled travels up and down the rails, the spring retracts out of the way, allowing the instability to evolve in free-fall until impacting a shock absorber at the end of the rails. The impulsive acceleration provided to the system is measured by a piezoelectric accelerometer mounted on the tank, and a capacitive accelerometer measures the low-level drag of the bearings. Planar Laser-Induced Fluorescence is used for flow visualization, which uses an Argon ion laser to illuminate the flow and a CCD camera, mounted to the sled, to capture images of the interface. This experimental study investigates the instability of an interface between incompressible, miscible liquids with an initial sinusoidal perturbation. The amplitude of the disturbance during the experiment is measured and compared to theory. The results show good agreement (within 10%) with linear stability theory up to nondimensional amplitude ka = 0.7 (wavenumber x amplitude). These results hold true for an initial ka (before acceleration) of -0.7 less than ka less than -0.06, while the linear theory was developed for absolute value of ka much less than 1. In addition, a third order weakly nonlinear perturbation theory is shown to be accurate for amplitudes as large as ka = 1.3, even though the interface becomes double-valued at ka = 1.1. As time progresses, the vorticity on the interface concentrates, and the interface spirals around the alternating sign vortex centers to form a mushroom pattern. At higher Reynolds Number (based on circulation), an instability of the vortex cores has been observed. While time limitations of the apparatus prevent determination of a critical Reynolds Number, the lowest Reynolds Number this vortex instability has been observed at is 5000.

Jacobs, J.↗

NASA NTRS1987

Theory versus experiment for the rotordynamic coefficients of labyrinth gas seals. I - A two control volume model

The basic equations are derived for a two-control-volume model for compressible flow in a labyrinth seal. The recirculation velocity in the cavity is incorporated into the model for the first time. The flow is assumed to be completely turbulent and isoenergetic. The wall friction factors are determined using the Blasius formula. Jet flow theory is used for the calculation of the recirculation velocity in the cavity. Linearized zeroth- and first-order perturbation equations are developed for small motion about a centered position by an expansion in the eccentricity ratio. The zeroth-order pressure distribution is found by satisfying the leakage equation while the circumferential velocity distribution is determined by satisfying the momentum equations. The first-order equations are solved by a separation of variable solution. Integration of the resultant pressure distribution along and around the seal defines the reaction force developed by the seal and the corresponding dynamic coefficients.

Scharrer, J. K.↗

NASA NTRS1988

Microgravity two-phase fluid flow pattern modeling

When gas and liquid mixtures flow in a pipe, the distribution of the two phases may take many forms. A flow pattern, or flow regime, is the characteristic spatial distribution of the phases of flow in a pipe. Because heat transfer and pressure drop are dependent on the characteristic distribution of phases, it is necessary to describe flow patterns in an appropriate manner so that a hydrodynamic or heat transfer theory applicable to that can be chosen. A theoretical two phase flow regime transition map under a microgravity environment was developed on physical concepts. These transitions use four basic flow patterns: dispersed flow, slug flow, stratified flow, and annular flow. The forces considered are body force, surface tension force, inertial force, friction, and the force from eddy turbulent fluctuation. Three dimensionless parameters were developed. Because these transition boundaries were developed based on physical concepts, they should be applicable to flow regimes occurring in various design conditions. Because the flow pattern data from KC-135 experiments are insufficient to verify these theoretical transition lines completely, an adiabatic experiment for flow regime analysis is recommended.

Lee, Doojeong↗

NASA NTRS1978

Estimation of the sea surface's two-scale backscatter parameters

The relationship between the sea-surface normalized radar cross section and the friction velocity vector is determined using a parametric two-scale scattering model. The model parameters are found from a nonlinear maximum likelihood estimation. The estimation is based on aircraft scatterometer measurements and the sea-surface anemometer measurements collected during the JONSWAP '75 experiment. The estimates of the ten model parameters converge to realistic values that are in good agreement with the available oceanographic data. The rms discrepancy between the model and the cross section measurements is 0.7 db, which is the rms sum of a 0.3 db average measurement error and a 0.6 db modeling error.

Wentz, F. J.↗

NASA NTRS1985

Lubrication and cooling for high speed gears

The problems and failures occurring with the operation of high speed gears are discussed. The gearing losses associated with high speed gearing such as tooth mesh friction, bearing friction, churning, and windage are discussed with various ways shown to help reduce these losses and thereby improve efficiency. Several different methods of oil jet lubrication for high speed gearing are given such as into mesh, out of mesh, and radial jet lubrication. The experiments and analytical results for the various methods of oil jet lubrication are shown with the strengths and weaknesses of each method discussed. The analytical and experimental results of gear lubrication and cooling at various test conditions are presented. These results show the very definite need of improved methods of gear cooling at high speed and high load conditions.

Townsend, D. P.↗

NASA NTRS2021

Coupling of the FUN3D Unstructured Flow Solver and the LASTRAC Stability Code to Model Transition

We develop an iterative automated method to predict transition locations in boundary-layer flows by using the FUN3D solver to perform flow simulations and the LASTRAC code for linear stability computations. The coupling of FUN3D and LASTRAC allows for a robust physics-based approach to model boundary-layer transition by analyzing the growth of different instability waves and then using that information to iteratively update the resulting transition location. There is no user involvement during the iterative computations. We apply this automated method to subsonic flow over a flat plate with a sharp leading edge. The final solution has regions of laminar and turbulent flow with a transition onset location that agrees with experiments and stability-based correlations. This iterative automated method is also applied to an NLF(1)-0416 airfoil for conditions with and without a separation bubble. Along with predicting transition locations, we compare the streamwise distributions of surface-pressure and skin-friction coefficients to a transport-equation-based model. We consider a 6:1 prolate spheroid at three angles of attack, namely, five, ten, and fifteen degrees, where mixed-mode transition occurs due to both Tollmien-Schlichting and crossflow instabilities. The skin-friction contours and transition fronts at every angle of attack from our iterative automated method show good agreement with past experimental and computational results in the literature for the 6:1 prolate spheroid.

Transition↗

NASA NTRS1992

Numerical experiments with flows of elongated granules

Theory and numerical results are given for a program simulating two dimensional granular flow (1) between two infinite, counter-moving, parallel, roughened walls, and (2) for an infinitely wide slider. Each granule is simulated by a central repulsive force field ratcheted with force restitution factor to introduce dissipation. Transmission of angular momentum between particles occurs via Coulomb friction. The effect of granular hardness is explored. Gaps from 7 to 28 particle diameters are investigated, with solid fractions ranging from 0.2 to 0.9. Among features observed are: slip flow at boundaries, coagulation at high densities, and gross fluctuation in surface stress. A videotape has been prepared to demonstrate the foregoing effects.

Elrod, Harold G.↗

NASA NTRS1992

Flow prediction over a transport multi-element high-lift system and comparison with flight measurements

Accurate prediction of surface-pressure distributions, merging boundary-layers, and separated-flow regions over multi-element high-lift airfoils is required to design advanced high-lift systems for efficient subsonic transport aircraft. The availability of detailed measurements of pressure distributions and both averaged and time-dependent boundary-layer flow parameters at flight Reynolds numbers is critical to evaluate computational methods and to model the turbulence structure for closure of the flow equations. Several detailed wind-tunnel measurements at subscale Reynolds numbers were conducted to obtain detailed flow information including the Reynolds-stress component. As part of a subsonic-transport high-lift research program, flight experiments are conducted using the NASA-Langley B737-100 research aircraft to obtain detailed flow characteristics for support of computational and wind-tunnel efforts. Planned flight measurements include pressure distributions at several spanwise locations, boundary-layer transition and separation locations, surface skin friction, as well as boundary-layer profiles and Reynolds stresses in adverse pressure-gradient flow.

Vijgen, P. M. H. W.↗