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Advanced Capabilities for Wind Tunnel Testing in the 21st Century

Wind tunnel testing methods and test technologies for the 21st century using advanced capabilities are presented. These capabilities are necessary to capture more accurate and high quality test results by eliminating the uncertainties in testing and to facilitate verification of computational tools for design. This paper discusses near term developments underway in ground testing capabilities, which will enhance the quality of information of both the test article and airstream flow details. Also discussed is a selection of new capability investments that have been made to accommodate such developments. Examples include advanced experimental methods for measuring the test gas itself; using efficient experiment methodologies, including quality assurance strategies within the test; and increasing test result information density by using extensive optical visualization together with computed flow field results. These points could be made for both major investments in existing tunnel capabilities or for entirely new capabilities.

Kegelman, Jerome T.↗

An experimental investigation of a free-tip rotor configuration in a forward flight wind-tunnel test

Results from an experimental evaluation of a free-tip rotor are presented. The evaluation included whirl tests and wind tunnel tests up to advance ratios of 0.4. The free tip extended over the outer 5% of the rotor blade and included a passive mechanical controller whose output characteristics were varied. The controller configuration combined with the free tip aerodynamics resulted in higher power requirements, because the tip's pitch angle was 5 to 10 degrees greater than that of the inboard portion of the blade, and its pitching motion capability was considered to be inhibited by frictional forces. Recommendations are included for design features for a follow-on test.

Stroub, R. H.↗

Model Design and Pre-Test CFD Analysis for a Supersonic Retropropulsion Wind Tunnel Test

Future Mars human lander missions will require using powered descent beginning at supersonic conditions, something which has never been done before at Mars. Significant aerosciences challenges exist due to interactions between the retrorocket exhaust plumes and the freestream flow that alter the aerodynamic behavior of the powered descent vehicle. Historically, wind tunnel tests have been used to study supersonic retropropulsion with inert gas exhaust simulants. Also, SpaceX has successfully decelerated the Falcon 9 first stage numerous times by using powered flight at supersonic conditions. On the computational side, Reynolds-Averaged Navier-Stokes flowfield simulations are regularly completed at full-scale conditions. However, the available ground and flight data do not provide a basis for calibrating the computational uncertainties for aerodynamic interference forces and moments on proposed Mars descent vehicles, either because of insufficient data or dissimilar vehicles geometries and/or conditions. Thus, additional ground testing is needed to continue addressing the aerosciences risks for large-scale human Mars landers. To that end, a retropropulsion wind tunnel test will be conducted in the NASA Langley Unitary Plan Wind Tunnel in 2020. The test is designed to improve upon similar past tests, both in terms of model design and measured data. The test campaign will use subscale model geometries derived from the two current NASA powered descent reference vehicles: a blunt low lift-to-drag vehicle and a more slender geometry. This paper covers the reference vehicles, test objectives, model design, scaling parameters, test matrix, and computational analysis to date.

Karl T Edquist↗

Evaluation of CFD as a Surrogate for Mach 2.4 to 4.6 Wind-Tunnel Testing – Project Overview

The debate over when wind-tunnel testing will be replaced by Computational Fluid Dynamics (CFD) comes and goes. More recently the debate has subsided with a more collaborative spirit between practitioners of these two disciplines resulting in significant improvements in the outcomes of both. There may come a time, however, when CFD has sufficient accuracy to supplant WTT as the dominant or perhaps only tool for aerodynamic simulation. If and/or when that happens, financial pressures favor efforts to close or severely limit the operations of wind tunnels. Presumably additional resources will go toward CFD to generate aerodynamic databases, load environments, and new aero/fluid-dynamic knowledge. It is therefore important to develop appropriate processes by which wind-tunnel closure decisions are made to ensure that facilities critical to industry and government research and development aren’t closed prematurely without proof that the available CFD tools have sufficient accuracy and low-enough cost (and enough experts and computational facilities) to take on the traditional role of wind tunnels. This paper will describe a project intended to answer the specific question of whether CFD can replace wind-tunnel testing for the limited Mach-number range 2.4 to 4.6. The project involves wind-tunnel testing and coordinated CFD for a variety of vehicle and flow-physics types in the high-speed leg of the Unitary Plan Wind Tunnel at NASA’s Langley Research Center.

James C Ross↗

Integration of CFD and Wind-Tunnel Testing at NASA

The debate over when wind-tunnel testing will be replaced by Computational Fluid Dynamics (CFD) comes and goes. More recently, however, the debate has subsided with a more collaborative spirit between practitioners of these two disciplines. Combining these complementary disciplines has led to significant improvements in both as well as better understanding of aero- and fluid dynamics. Also, as CFD codes become more accurate, the need for comparisons with experimental data has increased. New measurement techniques, pressure-sensitive paint and off-body velocity measurements for example, have provided detailed, high-quality data for the comparisons. In-tunnel CFD simulations are also providing more direct comparisons between predicted and measured flows. Given this newenvironment, a concerted effort is now underway to facilitate in-tunnel CFD for the 12 major wind tunnels operated by NASA.The Aerosciences Evaluation and Test Capabilities Portfolio (AETC) manages the major aerodynamic ground-testing facilities within NASA. This group is responsible for the operation, maintenance, and improvement of the wind-tunnel facilities and their capabilities. AETC has recently added a project to integrate CFD and wind-tunnel testing to better support customers of the NASA wind tunnels and to better understand the flow in the wind tunnels themselves. Being able to perform CFD simulations of wind-tunnel models in the wind tunnel environment providesthe cleanest way to assess the accuracy of the simulations relative to test data. AETC plans to provide accurate geometry and guidance to wind-tunnel customers who request it, to facilitate in-tunnel simulations. How this effort got started will be presented along with the status and plans for the project.

CFD↗

Documentation and archiving of the Space Shuttle wind tunnel test data base. Volume 1: Background and description

Development of the space shuttle necessitated an extensive wind tunnel test program, with the cooperation of all the major wind tunnels in the United States. The result was approximately 100,000 hours of space shuttle wind tunnel testing conducted for aerodynamics, heat transfer, and structural dynamics. The test results were converted into Chrysler DATAMAN computer program format to facilitate use by analysts, a very cost effective method of collecting the wind tunnel test results from many test facilities into one centralized location. This report provides final documentation of the space shuttle wind tunnel program. The two-volume set covers evolution of space shuttle aerodynamic configurations and gives wind tunnel test data, titles of wind tunnel data reports, sample data sets, and instructions for accessing the digital data base.

Romere, Paul O.↗

Validation of US3D for Capsule Aerodynamics using 05-CA Wind Tunnel Test Data

Several comparisons of computational fluid dynamics to wind tunnel test data are shown for the purpose of code validation. The wind tunnel test, 05-CA, uses a 7.66% model of NASA's Multi-Purpose Crew Vehicle in the 11-foot test section of the Ames Unitary Plan Wind tunnel. A variety of freestream conditions over four Mach numbers and three angles of attack are considered. Test data comparisons include time-averaged integrated forces and moments, time-averaged static pressure ports on the surface, and Strouhal Number. The applicability of the US3D code to subsonic and transonic flow over a bluff body is assessed on a comprehensive data set. With close comparison, this work validates US3D for highly separated flows similar to those examined here.

Schwing, Alan↗

SMART Rotor Wind Tunnel Test Report

The Boeing Company, Mesa Arizona, has been developing smart material actuated rotor technology (SMART) under in-house, DARPA (Defense Advanced Research Projects Agency), NASA and Army funding. A whirl tower test of the SMART active flap rotor system was successfully conducted at the remote test facility (RTF) in Mesa, Arizona, in 2003. Under DARPA and NASA funding, the SMART rotor system was tested in the NASA Ames National Full Scale Aerodynamic Complex (NFAC) 40- by 80-Foot Wind Tunnel in 2008. The DARPA program objectives were to demonstrate the active flap impact on rotor acoustics in forward flight and establish a validation database for noise prediction tools. Under NASA funding, additional wind tunnel tests were conducted, with the objective to demonstrate and quantify vibration, noise, and performance improvements.Wind tunnel testing was successfully and safely concluded, meeting all high priority objectives. The authority, effectiveness, and reliability of the flap actuation system were demonstrated in 65 hours of testing at up to 155 knots and 7,700 pound thrust. Validation data was successfully acquired for four test conditions; blade loads were too high for the high speed condition. The effectiveness of the flap for noise and vibration control was demonstrated conclusively, with results showing significant reductions in BVI (Blade-Vortex Interaction) and in-plane noise as well as vibratory hub loads. The impact of the flap on control power and rotor smoothing was also demonstrated. Data evaluating any benefits in aerodynamic performance and impact on flight controls were acquired, but will need more detailed evaluation. Both open loop control and closed loop feedback control, using continuous time and higher harmonic controllers, were applied.The purpose of the Test Report is to provide a comprehensive document that describes the preparation for and conduct of the wind tunnel test and summarizes the processing and evaluation of wind tunnel test data for the DARPA and the NASA portion of the test. An overview of the wind tunnel test and results can be found in Reference 1. Details on the testing and results for BVI noise, in-plane noise, and vibrations can be found in References 2-4, respectively. These references are four papers, presented at the American Helicopter Society Annual Forum in 2009. A brief description of the delivered electronic data is provided in Reference 5.

Rotor↗

Overview of the Integrated Adaptive Wing Technology Maturation Wind-Tunnel Test Objectives

The Integrated Adaptive Wing Technology Maturation wind-tunnel test is the culmination of a cooperative effort between NASA and Boeing to develop control techniques that can improve the performance and safety of higher aspect ratio flexible transport aircraft. The wind-tunnel test article, to be tested at the NASA Langley Research Center Transonic Dynamics Tunnel, is a semispan model of a modern transport configuration with an aspect ratio 13.5 wing based on the NASA Common Research Model. Multiobjective control laws have been developed targeting drag optimization, maneuver load alleviation, gust load alleviation, and modal suppression. In this paper, the integrated model design, active control system, and sensor suite will be presented, and pretest modeling and characterization activities will be described. A summary of the planned wind-tunnel test entries will provide an overview of the experimental approach and expected outcomes.

wind-tunnel↗

Overview of the Integrated Adaptive Wing Technology Maturation Wind-Tunnel Test Objectives

The Integrated Adaptive Wing Technology Maturation wind-tunnel test is the culmination of a cooperative effort between NASA and Boeing to develop control techniques that can improve the performance and safety of higher aspect ratio flexible transport aircraft. The wind-tunnel test article, to be tested at the NASA Langley Research Center Transonic Dynamics Tunnel, is a semispan model of a modern transport configuration based on the NASA Common Research Model with an aspect ratio 13.5 wing. Multiobjective control laws have been developed targeting drag optimization, maneuver load alleviation, gust load alleviation, and active flutter suppression. In this paper, the integrated model design, active control system, and sensor suite will be presented, and pretest modeling and characterization activities will be described. A summary of the planned wind-tunnel test entries will provide an overview of the experimental approach and expected outcomes.

wind-tunnel↗

Documentation and archiving of the Space Shuttle wind tunnel test data base. Volume 2: User's Guide to the Archived Data Base

Development of the Space Shuttle necessitated an extensive wind tunnel test program, with the cooperation of all the major wind tunnels in the United States. The result was approximately 100,000 hours of Space Shuttle wind tunnel testing conducted for aerodynamics, heat transfer, and structural dynamics. The test results were converted into Chrysler DATAMAN computer program format to facilitate use by analysts, a very cost effective method of collecting the wind tunnel test results from many test facilities into one centralized location. This report provides final documentation of the Space Shuttle wind tunnel program. The two-volume set covers the evolution of Space Shuttle aerodynamic configurations and gives wind tunnel test data, titles of wind tunnel data reports, sample data sets, and instructions for accessing the digital data base.

Romere, Paul O.↗

Analysis of the free-tip rotor wind-tunnel test results

The results from a wind tunnel test of a small scale free-tip rotor are analyzed. The free-tip rotor has blade tips that are free to weathervane into the tip's relative wind, thus producing a more uniform lift around the azimuth. The free-tip assembly, which includes the controller, functioned flawlessly throughout the test. In a test of the free-tip's response after passing through a vertical air jet, the tip pitched freely and in a controlled manner. Analysis of the tip's response characteristics showed the free-tip system's damped natural frequency to be 5.2 per rev. Tip pitch angle responses to the local airstream are presented for an advance-ratio range of 0.1 to 0.397 and for a solidity weighted rotor lift coefficient range of 0.038 to 0.092. Harmonic analysis of the responses showed a dominance by the first harmonic. As a result of the tip being free, forward flight power requirements were reduced by 8% or more. More power reduction was recorded for high thrust conditions. In addition to the power reduction, flatwise blade bending moments were reduced by as much as 30% at the inboard blade stations.

Stroub, Robert H.↗

Application of two design methods for active flutter suppression and wind-tunnel test results

The synthesis, implementation, and wind tunnel test of two flutter suppression control laws for an aeroelastic model equipped with a trailing edge control surface are presented. One control law is based on the aerodynamic energy method, and the other is based on results of optimal control theory. Analytical methods used to design the control laws and evaluate their performance are described. At Mach 0.6, 0.8, and 0.9, increases in flutter dynamic pressure were obtained but the full 44 percent increase was not achieved. However at Mach 0.95, the 44 percent increase was achieved with both control laws. Experimental results indicate that the performance of the systems is not so effective as that predicted by analysis, and that wind tunnel turbulence plays an important role in both control law synthesis and demonstration of system performance.

Newsom, J. R.↗

Supersonic Retropropulsion Test 1853 in NASA LaRC Unitary Plan Wind Tunnel Test Section 2

A supersonic retropropulsion experiment was conducted in the Langley Research Center Unitary Plan Wind Tunnel Test Section 2 at Mach numbers of 2.4, 3.5, and 4.6. Intended as a code validation effort, this study used pretest computations to size and refine the model such that tunnel blockage and internal flow separations were minimized. A 5-in diameter 70 degree sphere-cone forebody, which can accommodate up to four 4:1 area ratio nozzles, followed by a 9.55 inches long cylindrical aft body was selected for this test after computational maturation. The primary measurements for this experiment were high spatial-density surface pressures. In addition, high speed schlieren video and internal pressures and temperatures were acquired. The test included parametric variations in the number of nozzles utilized, thrust coefficients (roughly 0 to 4), and angles of attack (-8 to 20 degrees). The run matrix was developed to also allow quantification of various sources of experimental uncertainty, such as random errors due to run-to-run variations and systematic errors due to flowfield or model misalignments. To accommodate the uncertainty assessment, many runs and replicates were conducted with the model at various locations within the tunnel and with model roll angles of 0, 60, 120, and 180 degrees. This test report provides operational details of the experiment, contains a review of trends, and provides all schlieren and pressure results within appendices.

Berry, Scott A.↗

Solid rocket booster sting interference wind tunnel test analysis, appendix D

Additional analyses of wind tunnel test results from SRB sting interference test TWT 660 and HRWT 042 were conducted to evaluate the sting interference that may be present in the Space Shuttle SRB reentry aerodynamic math model. Additional wind tunnel data was obtained at higher angles of attack from test program TWT 660 and test program HRWT 042. The additional data were analyzed to evaluate the procedures used to fair the data in the development of the SRB reentry aerodynamic data Tape no. 5.

Conine, B.↗

Wind tunnel test of a variable-diameter tiltrotor (VDTR) model

This report documents the results from a wind tunnel test of a 1/6th scale Variable Diameter Tiltrotor (VDTR). This test was a joint effort of NASA Ames and Sikorsky Aircraft. The objective was to evaluate the aeroelastic and performance characteristics of the VDTR in conversion, hover, and cruise. The rotor diameter and nacelle angle of the model were remotely changed to represent tiltrotor operating conditions. Data is presented showing the propulsive force required in conversion, blade loads, angle of attack stability and simulated gust response, and hover and cruise performance. This test represents the first wind tunnel test of a variable diameter rotor applied to a tiltrotor concept. The results confirm some of the potential advantages of the VDTR and establish the variable diameter rotor a viable candidate for an advanced tiltrotor. This wind tunnel test successfully demonstrated the feasibility of the Variable Diameter rotor for tilt rotor aircraft. A wide range of test points were taken in hover, conversion, and cruise modes. The concept was shown to have a number of advantages over conventional tiltrotors such as reduced hover downwash with lower disk loading and significantly reduced longitudinal gust response in cruise. In the conversion regime, a high propulsive force was demonstrated for sustained flight with acceptable blade loads. The VDTR demonstrated excellent gust response capabilities. The horizontal gust response correlated well with predictions revealing only half the response to turbulence of the conventional civil tiltrotor.

Matuska, David↗