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NASA NTRS1997

Solution adaptive Cartesian grid methods for aerodynamic flows with complex geometries

Cartesian methods for computational fluid dynamics are considered to offer an accurate and robust approach for the simulation of aerodynamic flows around geometrically complex bodies. A part of the ongoing research in this domain is reviewed with the aim of providing insight into the fundamental challenges faced by the practitioners of this approach, and a guide to further research. The integration schemes used in Cartesian solvers are similar to those used in other approaches. The emphasis is on the geometric algorithms, surface modeling and boundary conditions required to design a successful Cartesian mesh scheme.

Aftosmis, Michael J.↗

NASA NTRS2002

Face Gear Drive with Spur Involute Pinion: Geometry, Generation by a Worm, Stress Analysis

A face gear drive with a spur involute pinion is considered. The generation of the face gear is based on application of a grinding or cutting worm whereas the conventional method of generation is based on application of an involute shaper. An analytical approach is proposed for the determination of: (1) the worm thread surface; (2) avoidance of singularities of the worm thread surface, (air) dressing of the worm; and (3) determination of stresses of the face-gear drive. A computer program for simulation of meshing and contact of the pinion and face-gear has been developed. Correction of machine-tool settings is proposed for reduction of the shift of the bearing contact caused by misalignment. An automatic development of the model of five contacting teeth has been proposed for stress analysis. Numerical examples for illustration of the developed theory are provided.

Litvin, Faydor L.↗

DOE OSTI2022

Initial ASME code rule analysis on Simple and Full assessment

ASME & ASTM codes present simple and full assessment methodologies to qualify nuclear grade graphite components. This report explains the theory behind the statistical portion of the codes and describes the issues discussed in a 2020 workshop in the simple assessment, as well as the full assessment. The methodology for the full assessment was developed by Hindley []. He used a validation methodology to match the experimental average failure load of test specimens from several geometries to the calculated 50% POF load to tune the grouping criteria parameters based on an RMSE penalty function. The grouping criteria consists of a minimum volume to satisfy the weakest link theory of the Weibull distribution and a minimum stress range parameter. Hindley’s work found a minimum link volume of 10 times the grain size and a stress range parameter of 7% [satisfy the validation requirements. Several studies found that the link volume of 10 times the grain size was not satisfactory for the volume grouping criteria for graphite grades with fine grains. ASME 2021 code adopted a new volume grouping criteria based on fracture toughness for calculation of the process zone volume. However, errors were found in the ASME 2021 code process zone volume equation and the question is now open as to what volume grouping criteria is satisfactory. This report presents results from sensitivity studies that were done to evaluate the volume grouping criteria effect on the full assessment POF. This report also presents results from sensitivity studies on other aspects of the code that affect the POF, the mesh size and the choice of the Weibull threshold parameter. All three sensitivity studies: the volume grouping criteria, the mesh size, and the threshold parameter choice are found to affect the component qualification decision for components of structural reliability class 1 (SRC-1). The sensitivity analysis results are presented in the body of the report for NBG-18, which is the same grade of graphite as Hindley used in his thesis. Results from NBG-17, IG-110, 2114, and PCEA are presented in the Appendix. For NBG-18, it was found that increasing the threshold increases the POF, finer meshes result in higher POFs, and that smaller link volume requirements lead to higher POFs (which is inconsistent with Hindley’s findings). This report proposes a new validation study similar to Hindley’s []. The purpose of the new validation study is to tune the threshold, mesh size and grouping criteria based on results from multiple grades of graphite, including finer grain graphites T220 (1-3 microns) and NG-CT-50 (5 microns). The test specimens will be broken at 3 labs, such that we can measure between lab measurement variability, with at least 5 test specimens per lab such that the within lab uncertainty can also be measured. Hindley’s validation method tried matching the average experimental load with the median. The future study will attempt to match failures at lower percentiles, which would be closer to the SRC POF limit. We are currently looking into what geometries make sense and the best method to measure multi-axial stress states. These design decisions are still being set.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Multi-region approach to free-boundary three-dimensional tokamak equilibria and resistive wall instabilities

Free-boundary 3D tokamak equilibria and resistive wall instabilities are calculated using a new resistive wall model in the two-fluid M3D-C1 code. In this model, the resistive wall and surrounding vacuum region are included within the computational domain. This implementation contrasts with the method typically used in fluid codes in which the resistive wall is treated as a boundary condition on the computational domain boundary and has the advantage of maintaining purely local coupling of mesh elements. This new capability is used to simulate perturbed, free-boundary non-axisymmetric equilibria; the linear evolution of resistive wall modes; and the linear and nonlinear evolution of axisymmetric vertical displacement events (VDEs). Calculated growth rates for a resistive wall mode with arbitrary wall thickness are shown to agree well with the analytic theory. Equilibrium and VDE calculations are performed in diverted tokamak geometry, at physically realistic values of dissipation, and with resistive walls of finite width. Simulations of a VDE disruption extend into the current-quench phase, in which the plasma becomes limited by the first wall, and strong currents are observed to flow in the wall, in the SOL, and from the plasma to the wall.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1978

Flow of liquid jets through closely woven screens

Previously developed analytical models relate pressure drop across a fine-mesh screen to throughflow velocity for duct systems. These models are shown to be unreliable for an unconfined flow, such as a free jet, impinging on a screen. A new model is developed for these kinds of systems, incorporating the important influence of liquid deflection by the screen. A new parameter, the boundary layer blockage coefficient, is introduced. This coefficient, which depends on the screen weave geometry and the jet impingement angle, accounts for the increase in fluid path length through the screen resulting from the flow deflection. Comparisons are made with previous experimental studies to determine empirical values of the blockage coefficient. It is concluded that the new model reliably predicts the bulk flow and penetration characteristics of an impinging liquid jet interacting with a screen.

Dodge, F. T.↗

NASA NTRS2018

Meander-Like Shape Optimization of the Stator-Rotor Platform Cavity

Recent progress in additive manufacturing has enabled opportunities to explore novel stator rim geometries which can be implemented to improve cooling strategies in turbomachinery. This paper presents a simplified stationary geometry optimization strategy to produce enhanced stator-rotor cavity sealing and highlights main driving mechanisms.The stator and rotor rims were designed using a design strategy based on inspiration from the meandering of rivers. A minimum thickness of 2 millimeters was maintained throughout the cavity to ensure a practical implementation. The computational domain comprised of the stator outlet, hub disk leakage cavity, and rotor platform was meshed using NUMECA Int. package, Hexpress. The numerical analysis required 3D Unsteady Reynolds Average Navier-Stokes to replicate vorticial structures using Ansys Fluent. The operating conditions were representative of engine-like conditions, exploring a wide range of mass flow ratios from 1 to 3 percent. The optimization yielded designs that provide 30 percent reduction in rear platform temperature while minimizing coolant mass flow. The applicability of the design was compared against 3D sector in both stationary and in rotation.

Shape Optimization↗

DOE OSTI2024

Investigation of Ring-heterogeneous Geometry Approximation for Efficient and Practical SFR Analysis

A novel geometry approximation scheme named ring-heterogeneous approximation for intermediate resolution multiphysics analysis of SFRs is presented. This approach particularly targets neutronics coupled with thermo-mechanics feedback, which dominate the passive safety of SFR designs. The ring-heterogeneous approximation casts an array of pins into volume-preserving bands of materials that constitute the pins. It allows to efficiently simulate SFRs with an unstructured mesh and also to explicitly consider the deformation of each material by retaining their heterogeneity. Verification results with single assembly and core problems of the ABTR benchmark demonstrated that the ring-heterogeneous approximation is a reasonable approximation for SFRs. For a 2D full core problem, the ring-heterogeneous approximation significantly reduced the number of elements by at least a factor of 70 from a fully-heterogeneous mesh while almost exactly preserving the reference fully-heterogeneous solutions with the RMS error of only 0.02% in the ring-wise fission reaction rate.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1978

Flow of liquid jets through closely woven screens

Previously developed analytical models relate pressure drop across a fine-mesh screen to throughflow velocity for duct systems. These models are shown to be unreliable for an unconfined flow, such as a free jet, impinging on a screen. A new model is developed for these kinds of systems, incorporating the important influence of liquid deflection by the screen. A new parameter, the boundary-layer blockage coefficient, is introduced. This coefficient, which depends on the screen weave geometry and the jet impingement angle, accounts for the increase in fluid path length through the screen resulting from the flow deflection. Comparisons are made with previous experimental studies to determine empirical values of the blockage coefficient. It is concluded that the new model reliably predicts the bulk flow and penetration characteristics of an impinging liquid jet interacting with a screen.

Dodge, F. T.↗

DOE OSTI2020

Simulation of coupled multiphase flow and geomechanics in porous media with embedded discrete fractures

In fractured natural formations, the equations governing fluid flow and geomechanics are strongly coupled. Hydrodynamical properties depend on the mechanical configuration, and they are therefore difficult to accurately resolve using uncoupled methods. In recent years, significant research has focused on discretization strategies for these coupled systems, particularly in the presence of complicated fracture network geometries. In this work, we explore a finite-volume discretization for the multiphase flow equations coupled with a finite-element scheme for the mechanical equations. Fractures are treated as lower dimensional surfaces embedded in a background grid. Interactions are captured using the embedded discrete fracture model (EDFM) and the embedded finite element method (EFEM) for the flow and the mechanics, respectively. This nonconforming approach significantly alleviates meshing challenges. EDFM considers fractures as lower dimension finite volumes that exchange fluxes with the rock matrix cells. The EFEM method provides, instead, a local enrichment of the finite-element space inside each matrix cell cut by a fracture element. Both the use of piecewise constant and piecewise linear enrichments are investigated. They are also compared to an extended finite element approach. One key advantage of EFEM is the element-based nature of the enrichment, which reduces the geometric complexity of the implementation and leads to linear systems with advantageous properties. Synthetic numerical tests are presented to study the convergence and accuracy of the proposed method. It is also applied to a realistic scenario, involving a heterogeneous reservoir with a complex fracture distribution, to demonstrate its relevance for field applications.

58 GEOSCIENCES↗

DOE OSTI2023

Soft, malleable double diamond twin

A twin boundary (TB) is a common low energy planar defect in crystals including those with the atomic diamond structure (C, Si, Ge, etc.). We study twins in a self-assembled soft matter block copolymer (BCP) supramolecular crystal having the double diamond (DD) structure, consisting of two translationally shifted, interpenetrating diamond networks of the minority polydimethyl siloxane block embedded in a polystyrene block matrix. The coherent, low energy, mirror-symmetric double tubular network twin has one minority block network with its nodes offset from the (222) TB plane, while nodes of the second network lie in the plane of the boundary. The offset network, although at a scale about a factor of 10 3 larger, has precisely the same geometry and symmetry as a (111) twin in atomic single diamond where the tetrahedral units spanning the TB retain nearly the same strut (bond) lengths and strut (bond) angles as in the normal unit cell. In DD, the second network undergoes a dramatic restructuring—the tetrahedral nodes transform into two new types of mirror-symmetric nodes (pentahedral and trihedral) which alternate and link to form a hexagonal mesh in the plane of the TB. The collective reorganization of the supramolecular packing highlights the hierarchical structure of ordered BCP phases and emphasizes the remarkable malleability of soft matter.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Uncertainty Quantification and Sensitivity Analysis for Simulation of Hostile Blast Events [Slides]

A mesh convergence study shows that shock arrival times converge for basic flow shots. Sensitivity study reveals a surprisingly high sensitivity to the placement of the HE package. Bayesian inference tools used on the experimental datasets suggest this is a real effect. Sensitivity analysis of ambient conditions such as temperature and pressure reveal minimal effect. Porting of pressure data from QUINOA simulations to perform structural analysis on the aeroshell geometry was successful, and shows a strong dependence of payload response to the angle of attack.

42 ENGINEERING↗

NASA NTRS1993

Advanced Multi-Phase Flow CFD Model Development for Solid Rocket Motor Flowfield Analysis

It is known that the simulations of solid rocket motor internal flow field with AL-based propellants require complex multi-phase turbulent flow model. The objective of this study is to develop an advanced particulate multi-phase flow model which includes the effects of particle dynamics, chemical reaction and hot gas flow turbulence. The inclusion of particle agglomeration, particle/gas reaction and mass transfer, particle collision, coalescence and breakup mechanisms in modeling the particle dynamics will allow the proposed model to realistically simulate the flowfield inside a solid rocket motor. The Finite Difference Navier-Stokes numerical code FDNS is used to simulate the steady-state multi-phase particulate flow field for a 3-zone 2-D axisymmetric ASRM model and a 6-zone 3-D ASRM model at launch conditions. The 2-D model includes aft-end cavity and submerged nozzle. The 3-D model represents the whole ASRM geometry, including additional grain port area in the gas cavity and two inhibitors. FDNS is a pressure based finite difference Navier-Stokes flow solver with time-accurate adaptive second-order upwind schemes, standard and extended k-epsilon models with compressibility corrections, multi zone body-fitted formulations, and turbulence particle interaction model. Eulerian/Lagrangian multi-phase solution method is applied for multi-zone mesh. To simulate the chemical reaction, penalty function corrected efficient finite-rate chemistry integration method is used in FDNS. For the AL particle combustion rate, the Hermsen correlation is employed. To simulate the turbulent dispersion of particles, the Gaussian probability distribution with standard deviation equal to (2k/3)(exp 1/2) is used for the random turbulent velocity components. The computational results reveal that the flow field near the juncture of aft-end cavity and the submerged nozzle is very complex. The effects of the turbulent particles affect the flow field significantly and provide better prediction of the ASRM performance. The multi-phase flow analysis using the FDNS code in the present research can be used as a design tool for solid rocket motor applications.

Liaw, Paul↗

DOE OSTI2022

Development of a high fidelity model of the CROCUS experimental reactor

Measurements of scalar flux distributions with fine spatial and energy resolutions are needed to remedy one of the validation shortcomings of the novel neutronics full core solvers, such as MPACT and nTRACER. While a very detailed resolution of the flux can be calculated with such codes, only a limited experimental data set is available to check their accuracy. Such type of measurements are on-going at the zero power reactor CROCUS, operated at the Laboratory for Reactor Physics and System Behaviours of the EPFL, thanks to the development of advanced miniature neutron detection systems. This kind of experimental data would provide the community with a suitable benchmark for the validation of high fidelity neutronics solvers. In parallel, a multi-physics solver for steady-state and transient analysis of nuclear reactors, named GeN-Foam, has been developed. Based on the finite-volume OpenFOAM library, GeN-Foam provides us with enough flexibility to analyze non-conventional reactor geometries such as that of CROCUS. While CROCUS heterogeneities cannot be modeled by MPACT and nTRACER for the moment, GeN-Foam offers a unique opportunity to build a high fidelity model which mimics these codes' method to reach sub-pin simulation resolution. This document aims at describing the work achieved to get from the existing GeN-Foam model of the CROCUS reactor based on a structured mesh and using the neutron diffusion, the first high-fidelity model using discrete ordinates method as an approximation to neutron transport and an unstructured mesh for inter lattice water gap description and sub-pin heterogeneous modeling. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Tunable phononic bandgap materials designed via topology optimization

Topology optimization is used to design phononic bandgap materials that are tunable by mechanical deformation. A periodic media is considered, which due to the assumption of length scale separation, allows the dispersion relations to be obtained by analyzing a single unit cell subjected to Floquet–Bloch boundary conditions. A finite macroscopic deformation is applied to the unit cell to affect its geometry and hence dispersion. We tune the dispersion–deformation relation to our liking by solving a topology optimization problem using nonlinear programming. The adjoint method is employed to compute the sensitivities, and the non-differentiability of degenerate eigenvalues is avoided using symmetric polynomials. Several tunable phononic crystal designs are presented. Also, a verification analysis is performed, wherein the optimized design is interpreted and analyzed using a conforming finite element mesh.

42 ENGINEERING↗

NASA NTRS1995

Bending strength model for internal spur gear teeth

Internal spur gear teeth are normally stronger than pinion teeth of the same pitch and face width since external teeth are smaller at the base. However, ring gears which are narrower have an unequal addendum or are made of a material with a lower strength than that of the meshing pinion may be loaded more critically in bending. In this study, a model for the bending strength of an internal gear tooth as a function of the applied load pressure angle is presented which is based on the inscribed Lewis constant strength parabolic beam. The bending model includes a stress concentration factor and an axial compression term which are extensions of the model for an external gear tooth. The geometry of the Lewis factor determination is presented, the iteration to determine the factor is described, and the bending strength J factor is compared to that of an external gear tooth. This strength model will assist optimal design efforts for unequal addendum gears and gears of mixed materials.

Savage, Michael↗

NASA NTRS2000

Stress Recovery and Error Estimation for Shell Structures

The Penalized Discrete Least-Squares (PDLS) stress recovery (smoothing) technique developed for two dimensional linear elliptic problems is adapted here to three-dimensional shell structures. The surfaces are restricted to those which have a 2-D parametric representation, or which can be built-up of such surfaces. The proposed strategy involves mapping the finite element results to the 2-D parametric space which describes the geometry, and smoothing is carried out in the parametric space using the PDLS-based Smoothing Element Analysis (SEA). Numerical results for two well-known shell problems are presented to illustrate the performance of SEA/PDLS for these problems. The recovered stresses are used in the Zienkiewicz-Zhu a posteriori error estimator. The estimated errors are used to demonstrate the performance of SEA-recovered stresses in automated adaptive mesh refinement of shell structures. The numerical results are encouraging. Further testing involving more complex, practical structures is necessary.

Yazdani, A. A.↗

DOE OSTI2015

SU-F-BRB-05: Collision Avoidance Mapping Using Consumer 3D Camera

Purpose: To develop a fast and economical method of scanning a patient’s full body contour for use in collision avoidance mapping without the use of ionizing radiation. Methods: Two consumer level 3D cameras used in electronic gaming were placed in a CT simulator room to scan a phantom patient set up in a high collision probability position. A registration pattern and computer vision algorithms were used to transform the scan into the appropriate coordinate systems. The cameras were then used to scan the surface of a gantry in the treatment vault. Each scan was converted into a polygon mesh for collision testing in a general purpose polygon interference algorithm. All clinically relevant transforms were applied to the gantry and patient support to create a map of all possible collisions. The map was then tested for accuracy by physically testing the collisions with the phantom in the vault. Results: The scanning fidelity of both the gantry and patient was sufficient to produce a collision prediction accuracy of 97.1% with 64620 geometry states tested in 11.5 s. The total scanning time including computation, transformation, and generation was 22.3 seconds. Conclusion: Our results demonstrate an economical system to generate collision avoidance maps. Future work includes testing the speed of the framework in real-time collision avoidance scenarios. Research partially supported by a grant from Varian Medical Systems.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2014

Methodological Aspects of Shielding and Activation Analyses for ITER Diagnostics Systems - Paper 125

It is expected that the diagnostics systems of the ITER tokamak will provide valuable measurement data about the first in its kind D-T fusion plasma with emission of 14 MeV neutrons. These systems must withstand the neutron and secondary photon radiation along the ITER operation. Under the neutron irradiation the ITER materials are getting radioactive and therefore an adequate shielding must be provided along all the time of ITER operation and shut-down for the reliable machine operation and for the safe personnel access to its components, such as the diagnostics ports. These are the prerequisites for the shielding and activation analysis of the ITER diagnostics systems discussed in this paper. This paper provides insight into the current tasks of neutronics support for the development of ITER diagnostics systems. The tasks themselves range from relatively straightforward ones such as Monte Carlo radiation transport calculations for shielding analyses of the diagnostics systems, to more advanced tasks of Shut-Down Dose Rate (SDDR) analyses for which the dedicated Rigorous 2-Step mesh-based (R2Smesh) and Direct 1-Step (D1S) methodologies were applied. The accuracy and precision of the ITER neutronics analysis is dependent on the methodological approaches and the implying modeling assumptions. In addition to the SDDR challenges, another distinguishing feature of fusion neutronics is a wide use of CAD-based neutronics modeling to design components of fusion devices such as ITER and DEMO. Basically, there are two possibilities of CAD geometry settings in Monte Carlo (MC) radiation transport models, either by the geometry format conversion of CAD models into the format of MC models by means of the interface programs such as McCad and MCAM or by the direct use of CAD geometry engine in MC calculations such as it was realized in the DAGMC code approach. Several conversion interfaces and the DAGMC software library have been tested on the 3D ITER model developed for the CAD-MCNP benchmark. It was concluded that the considered approaches have reached the maturity level to allow their application to real ITER design analyses.

61 RADIATION PROTECTION AND DOSIMETRY↗