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NASA NTRS2004

Unsteady Analyses of Valve Systems in Rocket Engine Testing Environments

This paper discusses simulation technology used to support the testing of rocket propulsion systems by performing high fidelity analyses of feed system components. A generalized multi-element framework has been used to perform simulations of control valve systems. This framework provides the flexibility to resolve the structural and functional complexities typically associated with valve-based high pressure feed systems that are difficult to deal with using traditional Computational Fluid Dynamics (CFD) methods. In order to validate this framework for control valve systems, results are presented for simulations of a cryogenic control valve at various plug settings and compared to both experimental data and simulation results obtained at NASA Stennis Space Center. A detailed unsteady analysis has also been performed for a pressure regulator type control valve used to support rocket engine and component testing at Stennis Space Center. The transient simulation captures the onset of a modal instability that has been observed in the operation of the valve. A discussion of the flow physics responsible for the instability and a prediction of the dominant modes associated with the fluctuations is presented.

Shipman, Jeremy↗
NASA NTRS2004

Strategy Developed for Selecting Optimal Sensors for Monitoring Engine Health

Sensor indications during rocket engine operation are the primary means of assessing engine performance and health. Effective selection and location of sensors in the operating engine environment enables accurate real-time condition monitoring and rapid engine controller response to mitigate critical fault conditions. These capabilities are crucial to ensure crew safety and mission success. Effective sensor selection also facilitates postflight condition assessment, which contributes to efficient engine maintenance and reduced operating costs. Under the Next Generation Launch Technology program, the NASA Glenn Research Center, in partnership with Rocketdyne Propulsion and Power, has developed a model-based procedure for systematically selecting an optimal sensor suite for assessing rocket engine system health. This optimization process is termed the systematic sensor selection strategy. Engine health management (EHM) systems generally employ multiple diagnostic procedures including data validation, anomaly detection, fault-isolation, and information fusion. The effectiveness of each diagnostic component is affected by the quality, availability, and compatibility of sensor data. Therefore systematic sensor selection is an enabling technology for EHM. Information in three categories is required by the systematic sensor selection strategy. The first category consists of targeted engine fault information; including the description and estimated risk-reduction factor for each identified fault. Risk-reduction factors are used to define and rank the potential merit of timely fault diagnoses. The second category is composed of candidate sensor information; including type, location, and estimated variance in normal operation. The final category includes the definition of fault scenarios characteristic of each targeted engine fault. These scenarios are defined in terms of engine model hardware parameters. Values of these parameters define engine simulations that generate expected sensor values for targeted fault scenarios. Taken together, this information provides an efficient condensation of the engineering experience and engine flow physics needed for sensor selection. The systematic sensor selection strategy is composed of three primary algorithms. The core of the selection process is a genetic algorithm that iteratively improves a defined quality measure of selected sensor suites. A merit algorithm is employed to compute the quality measure for each test sensor suite presented by the selection process. The quality measure is based on the fidelity of fault detection and the level of fault source discrimination provided by the test sensor suite. An inverse engine model, whose function is to derive hardware performance parameters from sensor data, is an integral part of the merit algorithm. The final component is a statistical evaluation algorithm that characterizes the impact of interference effects, such as control-induced sensor variation and sensor noise, on the probability of fault detection and isolation for optimal and near-optimal sensor suites.

Source record↗
NASA NTRS2004

Computation of Gust-Cascade Interaction Using the CE/SE Method

The problem 2 in Category 3 of the 4th Computational Aeroacoustic(CAA) Workshop is solved using the space-time conservation element and solution element (CE/SE) method. This problem models rotor-stator interaction in a 2D cascade. It involves complex geometries and flow physics including vortex shedding and acoustic radiation. The parallel version of the 2D nonlinear Euler solver is used with an unstructured triangular mesh to solve this problem. The Giles approach is incorporated with the CE/SE method to handle non-equal pitches of the rotor and stator. Validation on the Giles approach is performed using Problem 3.1 in the 2nd CAA Workshop. The space-time CE/SE method is a finite volume method with second-order accuracy in both space and time. The flux conservation is enforced in both space and time instead of space only. It has low numerical dissipation and dispersion errors. It uses simple non-reflecting boundary conditions and is compatible with unstructured meshes. It is simple, flexible, and generate reasonably accurate solutions. The CE/SE method has been successfully applied to solve numerous practical problems, especially aeroacoustic problems. Some preliminary numerical results of the benchmark problem 3.2 of the 4th CAA Workshop are shown. The steady-state pressure contour is plotted. The mean pressure distribution on the blade surface is compared with Turbo solution showing a good agreement. The sound pressure level versus the rotor harmonic n at the six designated positions on the blade surface, three locations at inlet plane, and three locations at the outlet plane are plotted. It can be seen that the acoustic response exists only at the excitation frequencies (n = 1,2,3). On the blade surface, the acoustic wave at n = 1 is dominant, while at the inlet and outlet planes, the sound pressure level at n = 2 becomes the largest, which is similar to the results presented. The distribution of sound pressure level at different spatial modes along the z- direction is plotted for n = 1,2,3, respectively. It shows that the spatial modes m = -32 and 22 at n = 1 exponentially decay, and the spatial modes m = 10 at n = 2, m = -42 and 12 at n = 3 propagate both upstream and downstream, which agrees with the prediction based on the linearized theory. Some oscillations are observed, which needs to be investigated further. In the final paper, the numerical results will be compared with a frequency-domain solver LINFLUX solution if it is available.

Wang, X.-Y.↗
NASA NTRS2003

National Combustion Code Validated Against Lean Direct Injection Flow Field Data

Most combustion processes have, in some way or another, a recirculating flow field. This recirculation stabilizes the reaction zone, or flame, but an unnecessarily large recirculation zone can result in high nitrogen oxide (NOx) values for combustion systems. The size of this recirculation zone is crucial to the performance of state-of-the-art, low-emissions hardware. If this is a large-scale combustion process, the flow field will probably be turbulent and, therefore, three-dimensional. This research dealt primarily with flow fields resulting from lean direct injection (LDI) concepts, as described in Research & Technology 2001. LDI is a concept that depends heavily on the design of the swirler. The LDI concept has the potential to reduce NOx values from 50 to 70 percent of current values, with good flame stability characteristics. It is cost effective and (hopefully) beneficial to do most of the design work for an LDI swirler using computer-aided design (CAD) and computer-aided engineering (CAE) tools. Computational fluid dynamics (CFD) codes are CAE tools that can calculate three-dimensional flows in complex geometries. However, CFD codes are only beginning to correctly calculate the flow fields for complex devices, and the related combustion models usually remove a large portion of the flow physics.

Iannetti, Anthony C.↗
NASA NTRS2006

Single- and Multiple-Objective Optimization with Differential Evolution and Neural Networks

Genetic and evolutionary algorithms have been applied to solve numerous problems in engineering design where they have been used primarily as optimization procedures. These methods have an advantage over conventional gradient-based search procedures became they are capable of finding global optima of multi-modal functions and searching design spaces with disjoint feasible regions. They are also robust in the presence of noisy data. Another desirable feature of these methods is that they can efficiently use distributed and parallel computing resources since multiple function evaluations (flow simulations in aerodynamics design) can be performed simultaneously and independently on ultiple processors. For these reasons genetic and evolutionary algorithms are being used more frequently in design optimization. Examples include airfoil and wing design and compressor and turbine airfoil design. They are also finding increasing use in multiple-objective and multidisciplinary optimization. This lecture will focus on an evolutionary method that is a relatively new member to the general class of evolutionary methods called differential evolution (DE). This method is easy to use and program and it requires relatively few user-specified constants. These constants are easily determined for a wide class of problems. Fine-tuning the constants will off course yield the solution to the optimization problem at hand more rapidly. DE can be efficiently implemented on parallel computers and can be used for continuous, discrete and mixed discrete/continuous optimization problems. It does not require the objective function to be continuous and is noise tolerant. DE and applications to single and multiple-objective optimization will be included in the presentation and lecture notes. A method for aerodynamic design optimization that is based on neural networks will also be included as a part of this lecture. The method offers advantages over traditional optimization methods. It is more flexible than other methods in dealing with design in the context of both steady and unsteady flows, partial and complete data sets, combined experimental and numerical data, inclusion of various constraints and rules of thumb, and other issues that characterize the aerodynamic design process. Neural networks provide a natural framework within which a succession of numerical solutions of increasing fidelity, incorporating more realistic flow physics, can be represented and utilized for optimization. Neural networks also offer an excellent framework for multiple-objective and multi-disciplinary design optimization. Simulation tools from various disciplines can be integrated within this framework and rapid trade-off studies involving one or many disciplines can be performed. The prospect of combining neural network based optimization methods and evolutionary algorithms to obtain a hybrid method with the best properties of both methods will be included in this presentation. Achieving solution diversity and accurate convergence to the exact Pareto front in multiple objective optimization usually requires a significant computational effort with evolutionary algorithms. In this lecture we will also explore the possibility of using neural networks to obtain estimates of the Pareto optimal front using non-dominated solutions generated by DE as training data. Neural network estimators have the potential advantage of reducing the number of function evaluations required to obtain solution accuracy and diversity, thus reducing cost to design.

Rai, Man Mohan↗
NASA NTRS2006

The NASA Constellation University Institutes Project: Thrust Chamber Assembly Virtual Institute

This paper documents key aspects of the Constellation University Institutes Project (CUIP) Thrust Chamber Assembly (TCA) Virtual Institute (VI). Specifically, the paper details the TCA VI organizational and functional aspects relative to providing support for Constellation Systems. The TCA VI vision is put forth and discussed in detail. The vision provides the objective and approach for improving thrust chamber assembly design methodologies by replacing the current empirical tools with verified and validated CFD codes. The vision also sets out ignition, performance, thermal environments and combustion stability as focus areas where application of these improved tools is required. Flow physics and a study of the Space Shuttle Main Engine development program are used to conclude that the injector is the key to robust TCA design. Requirements are set out in terms of fidelity, robustness and demonstrated accuracy of the design tool. Lack of demonstrated accuracy is noted as the most significant obstacle to realizing the potential of CFD to be widely used as an injector design tool. A hierarchical decomposition process is outlined to facilitate the validation process. A simulation readiness level tool used to gauge progress toward the goal is described. Finally, there is a description of the current efforts in each focus area. The background of each focus area is discussed. The state of the art in each focus area is noted along with the TCA VI research focus in the area. Brief highlights of work in the area are also included.

Tucker, P. Kevin↗
NASA NTRS2007

USM3D Unstructured Grid Solutions for CAWAPI at NASA LaRC

In support the Cranked Arrow Wing Aerodynamic Project International (CAWAPI) to improve the Technology Readiness Level of flow solvers by comparing results with measured F-16XL-1 flight data, NASA Langley employed the TetrUSS unstructured grid solver, USM3D, to obtain solutions for all seven flight conditions of interest. A newly available solver version that incorporates a number of turbulence models, including the two-equation linear and non-linear k-epsilon, was used in this study. As a first test, a choice was made to utilize only a single grid resolution with the solver for the simulation of the different flight conditions. Comparisons are presented with three turbulence models in USM3D, flight data for surface pressure, boundary-layer profiles, and skin-friction results, as well as limited predictions from other solvers. A result of these comparisons is that the USM3D solver can be used in an engineering environment to predict flow physics on a complex configuration at flight Reynolds numbers with a two-equation linear k-epsilon turbulence model.

Lamar, John E.↗
NASA NTRS2007

Flutter Analysis of the Shuttle Tile Overlay Repair Concept

The Space Shuttle tile overlay repair concept, developed at the NASA Johnson Space Center, is designed for on-orbit installation over an area of damaged tile to permit safe re-entry. The thin flexible plate is placed over the damaged area and secured to tile at discreet points around its perimeter. A series of flutter analyses were performed to determine if the onset of flutter met the required safety margins. Normal vibration modes of the panel, obtained from a simplified structural analysis of the installed concept, were combined with a series of aerodynamic analyses of increasing levels of fidelity in terms of modeling the flow physics to determine the onset of flutter. Results from these analyses indicate that it is unlikely that the overlay installed at body point 1800 will flutter during re-entry.

Bey, Kim S.↗
NASA NTRS2009

Hypersonic Viscous Flow Over Large Roughness Elements

Viscous flow over discrete or distributed surface roughness has great implications for hypersonic flight due to aerothermodynamic considerations related to laminar-turbulent transition. Current prediction capability is greatly hampered by the limited knowledge base for such flows. To help fill that gap, numerical computations are used to investigate the intricate flow physics involved. An unstructured mesh, compressible Navier-Stokes code based on the space-time conservation element, solution element (CESE) method is used to perform time-accurate Navier-Stokes calculations for two roughness shapes investigated in wind tunnel experiments at NASA Langley Research Center. It was found through 2D parametric study that at subcritical Reynolds numbers of the boundary layers, absolute instability resulting in vortex shedding downstream, is likely to weaken at supersonic free-stream conditions. On the other hand, convective instability may be the dominant mechanism for supersonic boundary layers. Three-dimensional calculations for a rectangular or cylindrical roughness element at post-shock Mach numbers of 4.1 and 6.5 also confirm that no self-sustained vortex generation is present.

Chang, Chau-Lyan↗
NASA NTRS2009

A Computational and Experimental Study of Resonators in Three Dimensions

In a previous work by the present authors, a computational and experimental investigation of the acoustic properties of two-dimensional slit resonators was carried out. The present paper reports the results of a study extending the previous work to three dimensions. This investigation has two basic objectives. The first is to validate the computed results from direct numerical simulations of the flow and acoustic fields of slit resonators in three dimensions by comparing with experimental measurements in a normal incidence impedance tube. The second objective is to study the flow physics of resonant liners responsible for sound wave dissipation. Extensive comparisons are provided between computed and measured acoustic liner properties with both discrete frequency and broadband sound sources. Good agreements are found over a wide range of frequencies and sound pressure levels. Direct numerical simulation confirms the previous finding in two dimensions that vortex shedding is the dominant dissipation mechanism at high sound pressure intensity. However, it is observed that the behavior of the shed vortices in three dimensions is quite different from those of two dimensions. In three dimensions, the shed vortices tend to evolve into ring (circular in plan form) vortices, even though the slit resonator opening from which the vortices are shed has an aspect ratio of 2.5. Under the excitation of discrete frequency sound, the shed vortices align themselves into two regularly spaced vortex trains moving away from the resonator opening in opposite directions. This is different from the chaotic shedding of vortices found in two-dimensional simulations. The effect of slit aspect ratio at a fixed porosity is briefly studied. For the range of liners considered in this investigation, it is found that the absorption coefficient of a liner increases when the open area of the single slit is subdivided into multiple, smaller slits.

Tam, C. K. W.↗
NASA NTRS2009

CFD Analysis of Nozzle Jet Plume Effects on Sonic Boom Signature

A computational fluid dynamics study is conducted to examine nozzle exhaust jet plume effects on the Sonic boom signature of a supersonic aircraft. A simplified axisymmetric nozzle geometry, representative of the nozzle on the NASA Dryden NF-15B Lift and Nozzle Change Effects on Tail Shock research airplane, is considered. The computational fluid dynamics code is validated using available wind-tunnel sonic boom experimental data. The effects of grid size, spatial order of accuracy. grid type, and flow viscosity on the accuracy of the predicted sonic boom pressure signature are quantified. Grid lines parallel to the Mach wave direction are found to give the best results. Second-order accurate upwind methods are required as a minimum for accurate sonic boom simulations. The highly underexpanded nozzle flow is found to provide significantly more reduction in the tail shock strength in the sonic boom N-wave pressure signature than perfectly expanded and overexpanded nozzle flows. A tail shock train in the sonic boom signature is observed for the highly underexpanded nozzle flow. Axisymmetric computational fluid dynamics simulations show the flow physics inside the F-15 nozzle to be nonisentropic and complex.

Bui, Trong T.↗
NASA NTRS2010

Three-Dimensional Unsteady Simulation of a Modern High Pressure Turbine Stage Using Phase Lag Periodicity: Analysis of Flow and Heat Transfer

Unsteady three-dimensional RANS simulations have been performed on a highly loaded transonic turbine stage and results are compared to steady calculations as well as experiment. A low Reynolds number k- turbulence model is employed to provide closure for the RANS system. A phase-lag boundary condition is used in the periodic direction. This allows the unsteady simulation to be performed by using only one blade from each of the two rows. The objective of this paper is to study the effect of unsteadiness on rotor heat transfer and to glean any insight into unsteady flow physics. The role of the stator wake passing on the pressure distribution at the leading edge is also studied. The simulated heat transfer and pressure results agreed favorably with experiment. The time-averaged heat transfer predicted by the unsteady simulation is higher than the heat transfer predicted by the steady simulation everywhere except at the leading edge. The shock structure formed due to stator-rotor interaction was analyzed. Heat transfer and pressure at the hub and casing were also studied. Thermal segregation was observed that leads to the heat transfer patterns predicted by steady and unsteady simulations to be different.

Shyam, Vikram↗
NASA NTRS2009

Numerical Solutions for the CAWAPI Configuration on Unstructured Grids at NASA LaRC, United States

In support of the Cranked Arrow Wing Aerodynamic Project International (CAWAPI) with its goal of improving the Technology Readiness Level of flow solvers by comparing results with measured F-16XL-1 flight data, NASA Langley employed the TetrUSS unstructured grid solver, USM3D, to obtain solutions for all seven flight conditions of interest. A newly available solver version that incorporates a number of turbulence models, including the two-equation linear and non-linear k- , was used in this study. As a first test, a choice was made to utilize only a single grid resolution with the solver for the simulation of the different flight conditions. Comparisons are presented with three turbulence models in USM3D, flight data for surface pressure, boundary-layer profiles, and skin-friction distribution, as well as limited predictions from other solvers. A result of these comparisons is that the USM3D solver can be used in an engineering environment to predict vortex-flow physics on a complex configuration at flight Reynolds numbers with a two-equation linear k- turbulence model.

Lamar, John E.↗
NASA NTRS2010

Instability of a Supersonic Boundary-Layer with Localized Roughness

A localized 3-D roughness causes boundary-layer separation and (weak) shocks. Most importantly, streamwise vortices occur which induce streamwise (low U, high T) streaks. Immersed boundary method (volume force) suitable to represent roughness element in DNS. Favorable comparison between bi-global stability theory and DNS for a "y-mode" Outlook: Understand the flow physics (investigate "z-modes" in DNS through sinuous spanwise forcing, study origin of the beat in DNS).

Marxen, Olaf↗
NASA NTRS2010

Analysis of Instabilities in Non-Axisymmetric Hypersonic Boundary Layers Over Cones

Hypersonic flows over circular cones constitute one of the most important generic configurations for fundamental aerodynamic and aerothermodynamic studies. In this paper, numerical computations are carried out for Mach 6 flows over a 7-degree half-angle cone with two different flow incidence angles and a compression cone with a large concave curvature. Instability wave and transition-related flow physics are investigated using a series of advanced stability methods ranging from conventional linear stability theory (LST) and a higher-fidelity linear and nonlinear parabolized stability equations (PSE), to the 2D eigenvalue analysis based on partial differential equations. Computed N factor distribution pertinent to various instability mechanisms over the cone surface provides initial assessments of possible transition fronts and a guide to corresponding disturbance characteristics such as frequency and azimuthal wave numbers. It is also shown that strong secondary instability that eventually leads to transition to turbulence can be simulated very efficiently using a combination of advanced stability methods described above.

Li, Fei↗
NASA NTRS2010

Inlet Flow Control and Prediction Technologies for Embedded Propulsion Systems

Fail-safe inlet flow control may enable high-speed cruise efficiency, low noise signature, and reduced fuel-burn goals for hybrid wing-body aircraft. The objectives of this program are to develop flow control and prediction methodologies for boundary-layer ingesting (BLI) inlets used in these aircraft. This report covers the second of a three year program. The approach integrates experiments and numerical simulations. Both passive and active flow-control devices were tested in a small-scale wind tunnel. Hybrid actuation approaches, combining a passive microvane and active synthetic jet, were tested in various geometric arrangements. Detailed flow measurements were taken to provide insight into the flow physics. Results of the numerical simulations were correlated against experimental data. The sensitivity of results to grid resolution and turbulence models was examined. Aerodynamic benefits from microvanes and microramps were assessed when installed in an offset BLI inlet. Benefits were quantified in terms of recovery and distortion changes. Microvanes were more effective than microramps at improving recovery and distortion.

McMillan, Michelle L.↗
NASA NTRS2011

Enhancements to TetrUSS for NASA Constellation Program

The NASA Constellation program is utilizing Computational Fluid Dynamics (CFD) predictions for generating aerodynamic databases and design loads for the Ares I, Ares I-X, and Ares V launch vehicles and for aerodynamic databases for the Orion crew exploration vehicle and its launch abort system configuration. This effort presents several challenges to applied aerodynamicists due to complex geometries and flow physics, as well as from the juxtaposition of short schedule program requirements with high fidelity CFD simulations. NASA TetrUSS codes (GridTool/VGRID/USM3D) have been making extensive contributions in this effort. This paper will provide an overview of several enhancements made to the various elements of TetrUSS suite of codes. Representative TetrUSS solutions for selected Constellation program elements will be shown. Best practices guidelines and scripting developed for generating TetrUSS solutions in a production environment will also be described.

Pandya, Mohagna J.↗
NASA NTRS2011

Aerodynamic Characterization of a Modern Launch Vehicle

A modern launch vehicle is by necessity an extremely integrated design. The accurate characterization of its aerodynamic characteristics is essential to determine design loads, to design flight control laws, and to establish performance. The NASA Ares Aerodynamics Panel has been responsible for technical planning, execution, and vetting of the aerodynamic characterization of the Ares I vehicle. An aerodynamics team supporting the Panel consists of wind tunnel engineers, computational engineers, database engineers, and other analysts that address topics such as uncertainty quantification. The team resides at three NASA centers: Langley Research Center, Marshall Space Flight Center, and Ames Research Center. The Panel has developed strategies to synergistically combine both the wind tunnel efforts and the computational efforts with the goal of validating the computations. Selected examples highlight key flow physics and, where possible, the fidelity of the comparisons between wind tunnel results and the computations. Lessons learned summarize what has been gleaned during the project and can be useful for other vehicle development projects.

Hall, Robert M.↗