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NASA NTRS1992

Inverse design of a proper number, shapes, sizes, and locations of coolant flow passages

During the past several years we have developed an inverse method that allows a thermal cooling system designer to determine proper sizes, shapes, and locations of coolant passages (holes) in, say, an internally cooled turbine blade, a scram jet strut, a rocket chamber wall, etc. Using this method the designer can enforce a desired heat flux distribution on the hot outer surface of the object, while simultaneously enforcing desired temperature distributions on the same hot outer surface as well as on the cooled interior surfaces of each of the coolant passages. This constitutes an over-specified problem which is solved by allowing the number, sizes, locations and shapes of the holes to adjust iteratively until the final internally cooled configuration satisfies the over-specified surface thermal conditions and the governing equation for the steady temperature field. The problem is solved by minimizing an error function expressing the difference between the specified and the computed hot surface heat fluxes. The temperature field analysis was performed using our highly accurate boundary integral element code with linearly varying temperature along straight surface panels. Examples of the inverse design applied to internally cooled turbine blades and scram jet struts (coated and non-coated) having circular and non-circular coolant flow passages will be shown.

George S. Dulikravich↗

NASA NTRS2023

BOLT II Forebody Surface Measurement Analysis

Surface impression molds of the nosetip/forebody interface, discrete tripping elements, and other surface imperfections were formed on the BOLT II flight vehicle prior to its launch in March 2022. The silicon-rubber molds cast on the interface between the nickel nosetip and the stainless steel forebody were measured using a 3D optical measurement system and a stylus profilometer and were evaluated for step direction and height. The step around the nosetip/forebody interface was found to vary in both magnitude and direction, but values were generally modest with most samples below 60 μm across the span and only two samples, both cast in the gutter, with step values larger than 100 μm. Impressions of the secondary-side tripping elements were strictly scanned with the optical device and similar methods were used to calculate trip height as step height. The measured centerline trip height was 2623 ±12 μm, while the leading-edge, quadrant 2 and 3, trip heights were 897 ±5 μm and 891 ±18 μm, respectively. Surface imperfections on the nose and forebody were also evaluated. Surface roughness values and spectra were estimated, and profiles were extracted across the imperfections to quantify the magnitude of those features.

Trip height↗

NASA NTRS1989

Multigrid solution of the Navier-Stokes equations on triangular meshes

A Navier-Stokes algorithm for use on unstructured triangular meshes is presented. Spatial discretization of the governing equations is achieved using a finite element Galerkin approximation, which can be shown to be equivalent to a finite volume approximation for regular equilateral triangular meshes. Integration steady-state is performed using a multistage time-stepping scheme, and convergence is accelerated by means of implicit residual smoothing and an unstructured multigrid algorithm. Directional scaling of the artificial dissipation and the implicit residual smoothing operator is achieved for unstructured meshes by considering local mesh stretching vectors at each point. The accuracy of the scheme for highly stretched triangular meshes is validated by comparing computed flat-plate laminar boundary layer results with the well known similarity solution, and by comparing laminar airfoil results with those obtained from various well-established structured quadrilateral-mesh codes. The convergence efficiency of the present method is also shown to be competitive with those demonstrated by structured quadrilateral-mesh algorithms.

Mavriplis, Dimitri J.↗

NASA NTRS1990

Multigrid solution of the Navier-Stokes equations on triangular meshes

Mavriplis, D. J.↗

NASA NTRS2018

Tetrahedral-Mesh Simulations of Shock-Turbulence Interaction

Despite decades of development of unstructured mesh methods, direct numerical simulations (DNS) of turbulent flows are still predominantly performed on structured or unstructured hexahedral meshes with high-order finite-difference methods, weighted essentially nonoscillatory (WENO) schemes, or hybrid schemes formed by their combinations. Tetrahedral meshes offer easy mesh generation and adaptation around complex geometries and the potential of an orientation-free grid that would benefit the isotropic nature of small-scale dissipation, as well as the solution accuracy of intermediate scales. To advance the state of the art of unstructured-mesh simulation capabilities for shock/turbulence interaction, DNS using pure tetrahedral meshes are carried out with the space-time conservation element, solution element (CESE) method in this research. By its design, the CESE method is constructed based on a non-dissipative scheme and is a genuinely multidimensional numerical framework that is free from the use of an approximate Riemann-solver. The numerical framework also provides the ability to add numerical dissipation (the nondissipative scheme acts as the reference state like that of the reversible state in thermodynamics) when needed (with justification from mathematics/physics). The above-mentioned features along with the CESE method's consistent shock-capturing approach and strong enforcement of flux conservation in spacetime offers a novel method to accurately simulate turbulent flows and their interaction with shocks using tetrahedral meshes. Two canonical problems, namely, isotropic turbulence interaction with a normal shock and a Mach 2.9 turbulent boundary layer flow over a 24deg compression corner are investigated in this study. Computational results show reasonably good agreement with experimental data and results from structured-mesh, high-order simulations available in the literature. Successful validation of these canonical problems demonstrated here paves the way for future high-fidelity supersonic flow simulations involving complex-geometries.

Venkatachari, Balaji Shankar↗

NASA NTRS2002

Aerodynamic Design Study of Advanced Multistage Axial Compressor

As a direct response to the need for further performance gains from current multistage axial compressors, an investigation of advanced aerodynamic design concepts that will lead to compact, high-efficiency, and wide-operability configurations is being pursued. Part I of this report describes the projected level of technical advancement relative to the state of the art and quantifies it in terms of basic aerodynamic technology elements of current design systems. A rational enhancement of these elements is shown to lead to a substantial expansion of the design and operability space. Aerodynamic design considerations for a four-stage core compressor intended to serve as a vehicle to develop, integrate, and demonstrate aerotechnology advancements are discussed. This design is biased toward high efficiency at high loading. Three-dimensional blading and spanwise tailoring of vector diagrams guided by computational fluid dynamics (CFD) are used to manage the aerodynamics of the high-loaded endwall regions. Certain deleterious flow features, such as leakage-vortex-dominated endwall flow and strong shock-boundary-layer interactions, were identified and targeted for improvement. However, the preliminary results were encouraging and the front two stages were extracted for further aerodynamic trimming using a three-dimensional inverse design method described in part II of this report. The benefits of the inverse design method are illustrated by developing an appropriate pressure-loading strategy for transonic blading and applying it to reblade the rotors in the front two stages of the four-stage configuration. Multistage CFD simulations based on the average passage formulation indicated an overall efficiency potential far exceeding current practice for the front two stages. Results of the CFD simulation at the aerodynamic design point are interrogated to identify areas requiring additional development. In spite of the significantly higher aerodynamic loadings, advanced CFD-based tools were able to effectively guide the design of a very efficient axial compressor under state-of-the-art aeromechanical constraints.

Larosiliere, Louis M.↗

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 NTRS2018

Comparing Free-Free and Shaker Table Model Correlation Methods Using Jim Beam

Finite element model correlation as part of a spacecraft program has always been a challenge. For any NASA mission, the coupled system response of the spacecraft and launch vehicle can be determined analytically through a Coupled Loads Analysis (CLA), as it is not possible to test the spacecraft and launch vehicle coupled system before launch. The value of the CLA is highly dependent on the accuracy of the frequencies and mode shapes extracted from the spacecraft model. NASA standards require the spacecraft model used in the final Verification Loads Cycle to be correlated by either a modal test or by comparison of the model with Frequency Response Functions (FRFs) obtained during the environmental qualification test. Due to budgetary and time constraints, most programs opt to correlate the spacecraft dynamic model during the environmental qualification test, conducted on a large shaker table. For any model correlation effort, the key has always been finding a proper definition of the boundary conditions. This paper is a correlation case study to investigate the difference in responses of a simple structure using a free-free boundary, a fixed boundary on the shaker table, and a base-drive vibration test, all using identical instrumentation. The NAVCON Jim Beam test structure, featured in the IMAC round robin modal test of 2009, was selected as a simple, well recognized and well characterized structure to conduct this investigation. First, a free-free impact modal test of the Jim Beam was done as an experimental control. Second, the Jim Beam was mounted to a large 20,000 lbf shaker, and an impact modal test in this fixed configuration was conducted. Lastly, a vibration test of the Jim Beam was conducted on the shaker table. The free-free impact test, the fixed impact test, and the base-drive test were used to assess the effect of the shaker modes, evaluate the validity of fixed-base modeling assumptions, and compare final model correlation results between these boundary conditions.

Modal Test↗

NASA NTRS1990

Resolution of the 1D regularized Burgers equation using a spatial wavelet approximation

The Burgers equation with a small viscosity term, initial and periodic boundary conditions is resolved using a spatial approximation constructed from an orthonormal basis of wavelets. The algorithm is directly derived from the notions of multiresolution analysis and tree algorithms. Before the numerical algorithm is described these notions are first recalled. The method uses extensively the localization properties of the wavelets in the physical and Fourier spaces. Moreover, the authors take advantage of the fact that the involved linear operators have constant coefficients. Finally, the algorithm can be considered as a time marching version of the tree algorithm. The most important point is that an adaptive version of the algorithm exists: it allows one to reduce in a significant way the number of degrees of freedom required for a good computation of the solution. Numerical results and description of the different elements of the algorithm are provided in combination with different mathematical comments on the method and some comparison with more classical numerical algorithms.

Liandrat, J.↗

NASA NTRS1985

Analysis of a finite composite plate with smooth rigid pin

An elastic continuum method of analysis developed for a smooth rigid pin in a finite composite plate by using complex potentials that satisfy the governing orthotropic differential equation is presented. The plate is subjected to uniaxial loading and the nonlinear problems of partial contact in the pin-plate are studied. Three types of pin fits are examined: interference, push, and clearance. The problems of stresses due to pure interference, load contact behavior, and stresses variations are addressed. The effects of the rectangular geometry and the orthotropic property of the plate are demonstrated through numerical results. It is found that the use of large hole diameter/plate width ratios have deleterious effects and the use of interference has beneficial effects. The solutions obtained will help in the development of special finite elements for fastener joints. Finally, the boundary conditions on the finite outer boundaries are found to be satisfied by a successive integration technique.

Naidu, A. C. B.↗

NASA NTRS2004

Design and Evaluation of Modifications to the NASA Langley Flow Impedance Tube

The need to minimize fan noise radiation from commercial aircraft engine nacelles continues to provide an impetus for developing new acoustic liner concepts. If the full value of such concepts is to be attained, an understanding of grazing flow effects is crucial. Because of this need for improved understanding of grazing flow effects, the NASA Langley Research Center Liner Physics Group has invested a large effort over the past decade into the development of a 2-D finite element method that characterizes wave propagation through a lined duct. The original test section in the Langley Grazing IncidenceTube was used to acquire data needed for implementation of this finite element method. This test section employed a stepper motor-driven axial-traversing bar, embedded in the wall opposite the test liner, to position a flush-mounted microphone at pre-selected locations. Complex acoustic pressure data acquired with this traversing microphone were used to educe the acoustic impedance of test liners using this 2-D finite element method and a local optimization technique. Results acquired in this facility have been extensively reported, and were compared with corresponding results from various U.S. aeroacoustics laboratories in the late 1990 s. Impedance data comparisons acquired from this multi-laboratory study suggested that it would be valuable to incorporate more realistic 3-D aeroacoustic effects into the impedance eduction methodology. This paper provides a description of modifications that have been implemented to facilitate studies of 3-D effects. The two key features of the modified test section are (1) the replacement of the traversing bar and its flush-mounted microphone with an array of 95 fixed-location microphones that are flush-mounted in all four walls of the duct, and (2) the inclusion of a suction device to modify the boundary layer upstream of the lined portion of the duct. The initial results achieved with the modified test section are provided in this report, and a comparison of these results with those achieved using the original test section is used to demonstrate that the data acquisition and analysis with the new test section can be confidently used for impedance eduction.

Jones, Michael G.↗

NASA NTRS1982

Finite element analysis of the effect of a non-planar solid-liquid interface on the lateral solute segregation during unidirectional solidification

The effect of solid-liquid interface shape on lateral solute segregation during steady-state unidirectional solidification of a binary mixture is calculated under the assumption of no convection in the liquid. A finite element technique is employed to compute the concentration field in the liquid and the lateral segregation in the solid with a curved boundary between the liquid and solid phases. The computational model is constructed assuming knowledge of the solid-liquid interface shape; no attempt is made to relate this shape to the thermal field. The influence of interface curvature on the lateral compositional variation is investigated over a range of system parameters including diffusivity, growth speed, distribution coefficient, and geometric factors of the system. In the limiting case of a slightly nonplanar interface, numerical results from the finite element technique are in good agreement with the analytical solutions of Coriell and Sekerka obtained by using linear theory. For the general case of highly non-planar interface shapes, the linear theory fails and the concentration field in the liquid as well as the lateral solute segregation in the solid can be calculated by using the finite element method.

Carlson, F. M.↗

NASA NTRS1994

Neotectonics of Asia: Thin-shell finite-element models with faults

As India pushed into and beneath the south margin of Asia in Cenozoic time, it added a great volume of crust, which may have been (1) emplaced locally beneath Tibet, (2) distributed as regional crustal thickening of Asia, (3) converted to mantle eclogite by high-pressure metamorphism, or (4) extruded eastward to increase the area of Asia. The amount of eastward extrusion is especially controversial: plane-stress computer models of finite strain in a continuum lithosphere show minimal escape, while laboratory and theoretical plane-strain models of finite strain in a faulted lithosphere show escape as the dominant mode. We suggest computing the present (or neo)tectonics by use of the known fault network and available data on fault activity, geodesy, and stress to select the best model. We apply a new thin-shell method which can represent a faulted lithosphere of realistic rheology on a sphere, and provided predictions of present velocities, fault slip rates, and stresses for various trial rheologies and boundary conditions. To minimize artificial boundaries, the models include all of Asia east of 40 deg E and span 100 deg on the globe. The primary unknowns are the friction coefficient of faults within Asia and the amounts of shear traction applied to Asia in the Himalayan and oceanic subduction zones at its margins. Data on Quaternary fault activity prove to be most useful in rating the models. Best results are obtained with a very low fault friction of 0.085. This major heterogeneity shows that unfaulted continum models cannot be expected to give accurate simulations of the orogeny. But, even with such weak faults, only a fraction of the internal deformation is expressed as fault slip; this means that rigid microplate models cannot represent the kinematics either. A universal feature of the better models is that eastern China and southeast Asia flow rapidly eastward with respect to Siberia. The rate of escape is very sensitive to the level of shear traction in the Pacific subduction zones, which is below 6 MPa. Because this flow occurs across a wide range of latitudes, the net eastward escape is greater than the rate of crustal addition in the Himalaya. The crustal budget is balanced by extension and thinning, primarily within the Tibetan plateau and the Baikal rift. The low level of deviation stresses in the best models suggests that topographic stress plays a major role in the orogeny; thus, we have to expect that different topography in the past may have been linked with fundamentally different modes of continental collision.

Kong, Xianghong↗

NASA NTRS1998

The Space-Time Conservation Element and Solution Element Method: A New High-Resolution and Genuinely Multidimensional Paradigm for Solving Conservation Laws: The Two Dimensional Time Marching Schemes - 1

A new high resolution and genuinely multidimensional numerical method for solving conservation laws is being, developed. It was designed to avoid the limitations of the traditional methods. and was built from round zero with extensive physics considerations. Nevertheless, its foundation is mathmatically simple enough that one can build from it a coherent, robust. efficient and accurate numerical framework. Two basic beliefs that set the new method apart from the established methods are at the core of its development. The first belief is that, in order to capture physics more efficiently and realistically, the modeling, focus should be placed on the original integral form of the physical conservation laws, rather than the differential form. The latter form follows from the integral form under the additional assumption that the physical solution is smooth, an assumption that is difficult to realize numerically in a region of rapid chance. such as a boundary layer or a shock. The second belief is that, with proper modeling of the integral and differential forms themselves, the resulting, numerical solution should automatically be consistent with the properties derived front the integral and differential forms, e.g., the jump conditions across a shock and the properties of characteristics. Therefore a much simpler and more robust method can be developed by not using the above derived properties explicitly.

Chang, Sin-Chung↗

NASA NTRS1994

A simulation of the intracluster medium with feedback from cluster galaxies

We detail method and report first results from a three-dimensional hydrodynamical and N-body simulation of the formation and evolution of a Coma-sized cluster of galaxies, with the intent of studying the history of the hot, X-ray emitting intracluster medium. Cluster gas, galaxies, and dark matter are included in the model. The galaxies and dark matter fell gravitational forces; the cluster gas also undergoes hydrodynamical effects such as shock heating and PdV work. For the first time in three dimensions, we include modeling of ejection of processed gas from the simulated galaxies by winds, including heating and heavy element enrichment. For comparison, we employ a `pure infall' simulation using the same initial conditions but with no galaxies or winds. We employ an extreme ejection history for galactic feedback in order to define the boundary of likely models. As expected, feedback raises the entropy of the intracluster gas, preventing it from collapsing to densities as high as those attained in the infall model. The effect is more pronounced in subclusters formed at high redshift. The cluster with feedback is always less X-ray luminous, but experiences more rapid luminosity evolution, than the pure infall cluster. Even employing an extreme ejection model, the final gas temperature is only approximately 15% larger than in the infall model. The radial temperature profile is very nearly isothermal within 1.5 Mpc. The cluster galaxies in the feedback model have a velocity dispersion approximately 15% lower than the dark matter. This results in the true ratio of specific energies in galaxies to gas being less than one, beta(sub spec) approximately 0.7. The infall model predicts beta(sub spec) approximately 1.2. Large excursions in these values occur over time, following the complex dynamical history of the cluster. The morphology of the X-ray emission is little affected by feedback. The emission profiles of both clusters are well described by the standard beta-model with beta(sub fit) approximately equal to 0.7 - 0.9. X-ray mass estimates based on the assumptions of hydrostatic equilibrium and the applicability of the beta-model are quite accurate in both cases. A strong, radial iron abundance gradient is present, which develops as a consequence of the steepening of the galaxy density profile over time. Spectroscopic observations using nonimaging detectors with wide (approximately 45 min) fields of view dramatically smear the gradient. Observations with arcminute resolution, made available with the ASCA satellite, would readily resolve the gradient.

Metzler, Christopher A.↗

NASA NTRS1993

A new flux conserving Newton's method scheme for the two-dimensional, steady Navier-Stokes equations

A new numerical method is developed for the solution of the two-dimensional, steady Navier-Stokes equations. The method that is presented differs in significant ways from the established numerical methods for solving the Navier-Stokes equations. The major differences are described. First, the focus of the present method is on satisfying flux conservation in an integral formulation, rather than on simulating conservation laws in their differential form. Second, the present approach provides a unified treatment of the dependent variables and their unknown derivatives. All are treated as unknowns together to be solved for through simulating local and global flux conservation. Third, fluxes are balanced at cell interfaces without the use of interpolation or flux limiters. Fourth, flux conservation is achieved through the use of discrete regions known as conservation elements and solution elements. These elements are not the same as the standard control volumes used in the finite volume method. Fifth, the discrete approximation obtained on each solution element is a functional solution of both the integral and differential form of the Navier-Stokes equations. Finally, the method that is presented is a highly localized approach in which the coupling to nearby cells is only in one direction for each spatial coordinate, and involves only the immediately adjacent cells. A general third-order formulation for the steady, compressible Navier-Stokes equations is presented, and then a Newton's method scheme is developed for the solution of incompressible, low Reynolds number channel flow. It is shown that the Jacobian matrix is nearly block diagonal if the nonlinear system of discrete equations is arranged approximately and a proper pivoting strategy is used. Numerical results are presented for Reynolds numbers of 100, 1000, and 2000. Finally, it is shown that the present scheme can resolve the developing channel flow boundary layer using as few as six to ten cells per channel width, depending on the Reynolds number.

Scott, James R.↗

NASA NTRS1992

Optimal design of geodesically stiffened composite cylindrical shells

An optimization system based on the finite element code Computations Structural Mechanics (CSM) Testbed and the optimization program, Automated Design Synthesis (ADS), is described. The optimization system can be used to obtain minimum-weight designs of composite stiffened structures. Ply thickness, ply orientations, and stiffener heights can be used as design variables. Buckling, displacement, and material failure constraints can be imposed on the design. The system is used to conduct a design study of geodesically stiffened shells. For comparison purposes, optimal designs of unstiffened shells and shells stiffened by rings and stingers are also obtained. Trends in the design of geodesically stiffened shells are identified. An approach to include local stress concentrations during the design optimization process is then presented. The method is based on a global/local analysis technique. It employs spline interpolation functions to determine displacements and rotations from a global model which are used as 'boundary conditions' for the local model. The organization of the strategy in the context of an optimization process is described. The method is validated with an example.

Gendron, G.↗

NASA NTRS1994

A Method for Thermal Analysis of Spiral Bevel Gears

A modeling method for analyzing the three-dimensional thermal behavior of spiral bevel gears has been developed. The model surfaces are generated through application of differential geometry to the manufacturing process for face-milled spiral bevel gears. Contact on the gear surface is found by combining tooth contact analysis with three-dimensional Hertzian theory. The tooth contact analysis provides the principle curvatures and orientations of the two surfaces. This information is then used directly in the Hertzian analysis to find the contact size and maximum pressure. Heat generation during meshing is determined as a function of the applied load, sliding velocity, and coefficient of friction. Each of these factors change as the point of contact changes during meshing. A nonlinear finite element program was used to conduct the heat transfer analysis. This program permitted the time- and position-varying boundary conditions, found in operation, to be applied to a one-tooth model. An example model and analytical results are presented.

Handschuh, Robert F.↗