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All sourcesNASA NTRSDOE OSTI
NASA NTRS2016

Wind Tunnel Interference Effects on Tilt Rotor Testing Using Computational Fluid Dynamics

Experimental techniques to measure rotorcraft aerodynamic performance are widely used. However, most of them are either unable to capture interference effects from bodies, or require an extremely large computational budget. The objective of the present research is to develop an XV-15 Tiltrotor Research Aircraft rotor model for investigation of wind tunnel wall interference using a novel Computational Fluid Dynamics (CFD) solver for rotorcraft, RotCFD. In RotCFD, a mid-fidelity Unsteady Reynolds Averaged Navier-Stokes (URANS) solver is used with an incompressible flow model and a realizable k-ε turbulence model. The rotor is, however, not modeled using a computationally expensive, unsteady viscous body-fitted grid, but is instead modeled using a blade-element model (BEM) with a momentum source approach. Various flight modes of the XV-15 isolated rotor, including hover, tilt, and airplane mode, have been simulated and correlated to existing experimental and theoretical data. The rotor model is subsequently used for wind tunnel wall interference simulations in the National Full-Scale Aerodynamics Complex (NFAC) at Ames Research Center in California. The results from the validation of the isolated rotor performance showed good correlation with experimental and theoretical data. The results were on par with known theoretical analyses. In RotCFD the setup, grid generation, and running of cases is faster than many CFD codes, which makes it a useful engineering tool. Performance predictions need not be as accurate as high-fidelity CFD codes, as long as wall effects can be properly simulated. For both test sections of the NFAC wall, interference was examined by simulating the XV-15 rotor in the test section of the wind tunnel and with an identical grid but extended boundaries in free field. Both cases were also examined with an isolated rotor or with the rotor mounted on the modeled geometry of the Tiltrotor Test Rig (TTR). A "quasi linear trim" was used to trim the thrust for the rotor to compare the power as a unique variable. Power differences between free field and wind tunnel cases were found from -7 to 0 percent in the 80- by 120-Foot Wind Tunnel and -1.6 to 4.8 percent in the 40- by 80-Foot Wind Tunnel, depending on the TTR orientation, tunnel velocity, and blade setting. The TTR will be used in 2016 to test the Bell 609 rotor in a similar fashion to the research in this report.

CFD↗
NASA NTRS2019

Correlation of Full-Scale Isolated Proprotor Performance and Loads

A full-scale isolated proprotor test is currently being conducted in the USAF National Full-Scale Aerodynamics Complex (NFAC) 40- by 80-Foot Wind Tunnel at NASA Ames. The test article is a 3-bladed research rotor derived from the right-hand rotor of the AW609; this rotor was manufactured by Bell Helicopter under contract to NASA. In this paper, this research rotor is referred to as "699". The test, nearly completed, is an integral part of the initial checkout test of the newly developed Tiltrotor Test Rig (TTR), whose purpose is to test advanced, full-scale proprotors in the NFAC. Figure 1 shows the TTR/699 installed in the 40- by 80-Foot test section. The TTR rotor axis is horizontal and the rig rotates in yaw on the wind tunnel turntable for conversion (transition) and helicopter mode testing. To date, a substantial amount of wind tunnel test data has already been acquired. The completed operational conditions include hover, airplane mode (cruise, wind tunnel airspeed V=61 to 267 knots), and the helicopter and conversion conditions (with a comprehensive sweep of the TTR yaw angle ranging, to date, from 90-deg yaw helicopter mode to 30-deg yaw conversion mode, at varying airspeeds). This 699 proprotor performance and loads correlation study uses these newly acquired wind tunnel test data. This paper represents the third analytical study, coming after two earlier analytical studies on the TTR/699; that is, a 2018 paper on pre-test predictions of 699 performance and loads, Ref. 1, and an upcoming January 2019 paper on aeroelastic stability analysis of the TTR/699 installed in the 40- by 80-Foot Wind Tunnel, Ref. 2. Reference 8 will present an overview of the entire TTR/699 test program. For completeness, Ref. 3 addresses the development and initial testing of the TTR. Background information on the TTR effort at NASA Ames can be found at the Aeromechanics website: https://rotorcraft.arc.nasa.gov/Research/Facilities/ttr.html. To the authors' knowledge, the full-scale results presented in this paper are the first of their kind. A literature survey brought up several existing correlation studies, but these were either based on small-scale test data (for example, the studies performed by the University of Maryland) or full-scale aircraft flight test data (for example, flight tests conducted by Bell Helicopter). Separately, the 2009 NASA study involving the JVX rotor is relevant (see Ref.4). The JVX is closely similar to the 699 in size and aerodynamics, and is accordingly a good reference for performance calculations. In Ref. 1 (as mentioned above), pre-test reality checks of the current analytical model were made by comparing JVX and 699 predictions in hover and forward flight (airplane mode).

Isolated Proprotor Performance↗
NASA NTRS2019

High-Speed Wind Tunnel Tests of a Full-Scale Proprotor on the Tiltrotor Test Rig

The Tiltrotor Test Rig (TTR) is a NASA project, joint with the U.S. Army and Air Force, to develop a new, large scale proprotor test system for the National Full-Scale Aerodynamics Complex (NFAC). The first wind-tunnel entry was completed in November 2018 with a modern, 26-ft diameter proprotor. The primary purpose was to complete the development of the TTR, including systems integration with the NFAC. The TTR and rotor were tested up to 273 knots in axial flow. This is the highest airspeed ever achieved by a full-scale proprotor in any wind tunnel. Extensive conversion-mode data were also acquired, and hover/climb conditions were explored. Additional testing included aerodynamic tares, motor tests, thermal tests, modal vibration tests, and other checkout activities. This paper summarizes the results of the test, including examples of the most significant data.

Wind Tunnel Tests↗
NASA NTRS2019

Aeroacoustic Measurements of the Bell 699 Rotor on the Tiltrotor Test Rig in the National Full-Scale Aerodynamics Complex 40- by 80-Foot Wind Tunnel

The Tiltrotor Test Rig (TTR) with the Bell 699 Rotor was tested in the National Full-Scale Aerodynamics Complex (NFAC) 40- by 80-Foot Wind Tunnel from 2017 to 2018. The primary goal of the test was to understand the operational capabilities of the TTR while also acquiring research data, including acoustic data. A data quality study revealed that the NFAC 40- by 80-Foot Wind Tunnel is an adequate acoustic environment to test the Bell 699 Rotor for helicopter, conversion, and airplane configurations. Representative acoustic data are presented, and selected acoustic data and corresponding test conditions are included.

Schatzman, N. L.↗
NASA NTRS2022

Wind Tunnel Performance Tests of a Full-Scale Proprotor on the Tiltrotor Test Rig

The Tiltrotor Test Rig (TTR) is a new, large-scale proprotor test system for the National Full-Scale Aerodynamics Complex (NFAC). The TTR was jointly developed by NASA, the U. S. Army and the U. S. Air Force. The first wind-tunnel entry was completed in November 2018 with a modern, 26-ft diameter proprotor. The primary purpose was to complete the development of the TTR, including systems integration with the NFAC. The TTR and rotor were tested up to 273 knots in axial flow, which is the highest airspeed ever achieved by a full-scale proprotor in any wind tunnel. The entry constitutes the first full-scale wind-tunnel test of a gimballed, coning-flexure rotor. Extensive conversion-mode data were also acquired, and hover/climb conditions were explored. Additional testing included aerodynamic tares, motor tests, thermal tests, modal vibration tests, and other checkout activities. This report summarizes the results of the test, including examples of the most significant data.

Tiltrotor Test Rig↗
NASA NTRS2016

Comparison of RTA Vibratory Loading in the 40- by 80-Foot Wind Tunnel and 80- by 120-Foot Wind Tunnel at the National Full-Scale Aerodynamics Complex

This paper presents data taken in the 80- by 120-Foot Wind Tunnel in 1992 to data taken in the 40- by 80-Foot Wind Tunnel in 2016 at the NFAC. In both sets of data, the RTA was equipped with an identical set of S-76 helicopter blades. These data sets were compared to determine the repeatability of the RTA as a testing device, and to quantify differences in 40- by 80-Foot Wind Tunnel vs. 80- by 120-Foot Wind Tunnel results. The contents include an overview of the RTA and test facility, as well as a discussion of the methodology used. Vibratory load data is presented for a variety of wind and RPM conditions in various test section configurations. Data presented in this report quantifies the repeatability of the RTA.

NFAC↗
NASA NTRS1986

Hover in-ground-effect testing of a full-scale, tilt-nacelle V/STOL model

A full-scale, tilt-nacelle V/STOL aircraft model was tested in hover at the National Full Scale Aerodynamics Complex (NFAC), NASA Ames Research Center. The model was powered by two TF-34 turbofan engines. It was tested at several ground heights and control deflections. Test technique and test setup were documented. Limited results show that: (1) a small change in control power with ground height was measured, and control power was found to be good over + or - 20 deg of horizontal vane deflection; (2) integrated fuselage undersurface pressures, when compared with the total model loads and measured thrust, defined the effect of the fountain and its related flow field on model forces and moments; and (3) there was no indication of hot gas ingestion during simulated takeoff in calm winds from wheels on deck ground height.

Eshleman, J. E.↗
NASA NTRS1986

Hover in-ground-effect testing of a full-scale, tilt-nacelle V/STOL model

A full-scale, tilt-nacelle V/STOL aircraft model was tested in hover at the National Full Scale Aerodynamics Complex (NFAC), NASA Ames Research Center. The model was powered by two TF-34 turbofan engines. It was tested at several ground heights and control deflections. Test technique and test setup were documented. Limited results show that (1) a small change in control power with ground height was measured, and control power was found to be good over + or - 20 deg of horizontal vane deflection; (2) integrated fuselage undersurface pressures, when compared with the total model loads and measured thrust, defined the effect of the fountain and its related flow field on model forces and moments; and (3) there was no indication of hot gas ingestion during simulated takeoff in calm winds from wheels on deck ground height.

Eshleman, J. E.↗
NASA NTRS1986

Unsteady aerodynamic load estimates on turning vanes in the national full-scale aerodynamic complex

Unsteady aerodynamic design loads have been estimated for each of the vane sets in the National Full-Scale Aerodynamic Complex (NFAC). These loads include estimates of local loads over one vane section and global loads over an entire vane set. The analytical methods and computer programs used to estimate these loads are discussed. In addition, the important computer input parameters are defined and the rationale used to estimate them is discussed. Finally, numerical values are presented for both the computer input parameters and the calculated design loads for each vane set.

Norman, Thomas R.↗
NASA NTRS1988

Aerodynamic flow quality and acoustic characteristics of the 40- by 80-foot test section circuit of the National Full-Scale Aerodynamic Complex

The 40- by 80-foot wind tunnel circuit of the National Full-Scale Aerodynamic Complex (NFAC) has recently undergone major modifications and subsequently completed final acceptance testing. The initial testing and calibration of the wind tunnel are described and in many cases these results are compared with predictions derived from model tests and theoretical analyses. The wind tunnel meets or exceeds essentially all performance objectives. The facility runs smoothly and routinely at its maximum test-section velocity of 300 knots (Mach number = 0.45). An effective cooling air exchange system enables the wind tunnel to operate indefinitely at this maximum power condition. Throughout the operating envelope of the wind tunnel the test-section dynamic pressure is uniform to within + or - 0.5 deg, and the axial component of turbulence is generally less than 0.5 percent. Acoustic measurements indicate that, due to the low noise fans and acoustic treatment in the wind-tunnel circuit and test section, the background noise level in the test section is comparable to other large-scale acoustic wind tunnels in the United States and abroad.

Olson, Lawrence E.↗
NASA NTRS1989

Performance and loads data from an outdoor hover test of a Lynx tail rotor

A Lynx tail rotor was tested in hover at the Outdoor Aerodynamic Research Facility at NASA Ames Research Center. The test objectives were to measure the isolated rotor performance to provide a baseline for subsequent testing, and to operate the rotor throughout the speed and collective envelope before testing in the NFAC 40- by 80-Foot Wind Tunnel. Rotor forces and blade bending moments were measured at ambient wind conditions from zero to 6.23 m/sec. The test envelope was limited to rotor speeds of 1550 to 1850 rpm and minus 13 deg to plus 20 deg of blade collective pitch. The isolated rotor performance and blade loads data are presented.

Signor, David B.↗
NASA NTRS1988

National full-scale aerodynamic complex integrated systems test data system

The data acquisition system of the 80 by 120 foot wind tunnel of the National Full-Scale Aerodynamic Facility (NFAC) is described. How the various satellite data stations are connected to the data acquisition system is shown. As an illustrative example, a strain gage signal is traced from one of the satellite data locations to its final destination in the data system where the signal is processed, observed in real time on various parallel graphic displays, and stored on magnetic disks for postrun data reduction.

Jung, Oscar↗
NASA NTRS1988

Utilization of wind tunnel instrumentation with software verifications

Software tools developed for the National Full-Scale Aerodynamic Complex (NFAC) for verifying data integrity and troublehooting problems are discussed. The Hardware Check verifies that the incoming signals are properly connected and are being acquired into the real time data system. The Zero/Cal Check program verifies the reliability of the wind tunnel instrumentation by checking the zero and calibration points. The Power Spectral Density Plots help to identify the frequency components of a signal. Drift Program and Thermal Plots tools are also described.

Silva, Betty W.↗
NASA NTRS1991

Analysis of open loop higher harmonic control at high airspeeds on a modern four-bladed articulated rotor

The effects of open loop higher harmonic control (HHC) on rotor hub loads, performance, and push rod loads of a Sikorsky S-76 helicopter rotor at high airspeeds (up to 200 knots) and moderate lift (10,000 lbs) were studied analytically. The analysis was performed as part of a wind tunnel pre-test prediction and preparation procedure, as well as to provide analytical results for post-test correlation efforts. The test associated with this study is to be concluded in the 40- by 80-Foot Wind Tunnel of the National Full-Scale Aerodynamics Complex (NFAC) at the NASA Ames Research Center. The results from this analytical study show that benefits from HHC can be achieved at high airspeeds. These results clear the way for conducting (with the requirement of safe pushrod loads) an open loop HHC test a high airspeeds in the 40- by 80-Foot Wind Tunnel using an S-76 rotor as the test article.

Kottapalli, Sesi↗
NASA NTRS1992

Analysis of open loop higher harmonic control at high airspeeds on a modern four-bladed articulated rotor

The effects of open loop higher harmonic control (HHC) on rotor hub loads, performance, and push rod loads of a Sikorsky S-76 helicopter rotor at high airspeeds (up to 200 knots) and moderate lift (10,000 lbs) were studied analytically. The present analysis was performed as a part of a wind tunnel pre-test prediction and preparation procedure, as well as to provide analytical results for post-test correlation efforts. The test associated with this study is to be concluded in the 40- by 80-Foot Wind Tunnel of the National Full-Scale Aerodynamics Complex (NFAC) at the NASA Ames Research Center. The results from this analytical study show that benefits from HHC can be achieved at high airspeeds. These results clear the way for conducting (with the requirement of safe pushrod loads) an open loop HHC test at high airspeeds in the 40- by 80-Foot Wind Tunnel using an S-76 rotor as the test article.

Kottapalli, Sesi↗
NASA NTRS1993

Application of the shadowgraph flow visualization technique to a full-scale helicopter rotor in hover and forward flight

The wide-field shadowgraph flow visualization technique was used for the first time with a full-scale helicopter rotor. This was accomplished during testing of a Sikorsky S-76 main rotor in the NASA Ames National Full-Scale Aerodynamics Complex (NFAC) 80- by 120-Foot Wind Tunnel. Hover, low-speed forward flight, and descent operating conditions were studied. Preliminary results are very promising with rotor wake tip vortices visible up to an advance ratio of 0.25. In addition, many details of the rotor wake were visible, including tip vortex roll-up, inboard wake vorticity, and flow unsteadiness due to test section recirculation effects in hover. Shadowgraphs of blade/vortex interactions were also acquired. Simultaneous top and side view shadowgraphs of the rotor wake were acquired by a newly developed synchronized digital imaging system. The imaging system proved to be a highly successful tool which made real-time examination of selected regions of the rotor wake possible.

Swanson, Alexandra A.↗
NASA NTRS1993

Rotor fatigue monitoring data acquisition system

The 40 by 80 Foot Wind Tunnel of the National Full Scale Aerodynamics Complex (NFAC) had a requirement to monitor rotor fatigue during a test. This test subjected various rotor components to stress levels higher than their structural fatigue limits. A data acquisition system was developed to monitor the cumulative fatigue damage of rotor components using National Instruments hardware and LabVIEW software. A full description of the data acquisition system including its configuration and salient features, is presented in this paper.

Smith, Scott M.↗
NASA NTRS1994

Computation of wind tunnel wall effects for complex models using a low-order panel method

A technique for determining wind tunnel wall effects for complex models using the low-order, three dimensional panel method PMARC (Panel Method Ames Research Center) has been developed. Initial validation of the technique was performed using lift-coefficient data in the linear lift range from tests of a large-scale STOVL fighter model in the National Full-Scale Aerodynamics Complex (NFAC) facility. The data from these tests served as an ideal database for validating the technique because the same model was tested in two wind tunnel test sections with widely different dimensions. The lift-coefficient data obtained for the same model configuration in the two test sections were different, indicating a significant influence of the presence of the tunnel walls and mounting hardware on the lift coefficient in at least one of the two test sections. The wind tunnel wall effects were computed using PMARC and then subtracted from the measured data to yield corrected lift-coefficient versus angle-of-attack curves. The corrected lift-coefficient curves from the two wind tunnel test sections matched very well. Detailed pressure distributions computed by PMARC on the wing lower surface helped identify the source of large strut interference effects in one of the wind tunnel test sections. Extension of the technique to analysis of wind tunnel wall effects on the lift coefficient in the nonlinear lift range and on drag coefficient will require the addition of boundary-layer and separated-flow models to PMARC.

Ashby, Dale L.↗