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DOE OSTI2019

Thermal Analysis for SRS Saltstone Disposal Unit Facility

Saltstone Disposal Units (SDU) are long term disposal units for low activity grout produced from the solidification of decontaminated non-hazardous salt waste at SRS. The unit is a cylindrical disposal vault of 150 ft. in diameter and 23 ft. in height. The total volume the SDU can hold is 3 million gallons of grout. The hydration process of the grout material produces heat from an exothermic chemical reaction. If the grout reaches temperatures higher than the maximum safety temperature of 95 deg. C, cracks can start forming leading to contamination of the environment. The purpose of this study is to develop the optimal baseline domain boundary conditions and to perform a sensitivity analysis with respect to the baseline modeling conditions. The following assumptions were made for the modeling calculations: - The system geometry is axisymmetric; - The system was at steady state; - Ambient temperature was set to 100 deg. F; - Air was assumed to be an incompressible ideal gas; - Radiation was neglected for a conservative estimation; - Natural convection for the SDU vapor space is assumed to be turbulent because Rayleigh number based on typical operating conditions is higher than 10{sup 8}; - Water tables were not taken into consideration. The following sensitivity analyses were performed to find the optimal domain boundary: - Mesh size sensitivity; - Soil depth sensitivity - Soil depth varied from 30 ft to 250 ft with a soil thickness of 90 ft; - Soil thickness sensitivity - Soil thickness varied from 30 ft to 270 ft with a soil depth of 180 ft; - Soil conductivity sensitivity - Soil thermal conductivity varied from 0.25 W/m-K to 1 W/m-K; - Ambient Temperature Sensitivity - Ambient temperature varied from 70 deg. F to 110 deg. F. For the thermal calculations, the temperature of the bottom of the soil was set to 17.4 deg. C. The heat flux on the roof of the building and surface of the earth is 163.2 W/m{sup 2}. The soil sides are set to be adiabatic. The sensitivity analysis shows that the mesh size has no effect on the numerical results. This is mainly due to a small convection zone and large conduction zones in the modeling domain. The optimal domain boundary was found to be a soil thickness of 90 ft and a soil depth of 150 ft. The different sensitivity analysis performed here shows the optimal boundary domain to be used for thermal calculations is a soil depth of 150 ft beneath the SDU and a soil thickness of 90 ft. Anything larger would produce similar solutions but at a longer computational time to solve. The maximum temperature was more sensitive to soil properties as shown here. While the ambient temperature affected the max temperature linearly. Most of the heat transfer takes place downward vertically between the SDU and the soil beneath it. Using the optimal domain boundary determined by the sensitivity analyses, the maximum thermal loading to keep the maximum grout temperature below 95 deg. C is 1.646 W/m{sup 3}.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS2018

NASA Additive Manufacturing Initiatives for Deep Space Human Exploration

Additive Manufacturing (AM) is being infused into aerospace industries at an accelerated pace. Reasons for this rapid adoption include: (1) Innovation Capability e.g. design features such as topology optimization, integrated fluid passages, and mesh structures; (2) Rapid Development and Optimization - ability to quickly iterate the design, development, and test cycle; (3) Affordability - reductions in part counts, cost, and schedule. NASA's Marshall Space Flight Center (MSFC) has taken a leadership role in application of AM technologies for deep space human exploration, leading the Agency's In Space Manufacturing (ISM) initiative and the application of AM for a broad variety of space propulsion systems. MSFC has championed the development of ISM capabilities since our first reduced-gravity aircraft experiment flew in 1999. Partnering with Made In Space, MSFC placed the first 3D Printer on ISS in 2014 and the second generation printer, the Additive Manufacturing Facility, in 2016. The next ISS technology demonstration will be the Refabricator, a recycler/basic printer scheduled to launch in late Fall 2018. Ground-based development is progressing in common use materials, metals 3D printing, printed electronics, and the new cornerstone of ISM, the FabLab. The latest developments in each area will be described. An overview of NASA's In Space Robotic Manufacturing and Assembly (IRMA) ground-based risk reduction projects will also be presented. MSFC has aggressively incorporated AM capabilities for design and development of space propulsion components. The capabilities have been rapidly matured and extensively exercised to produce and hot-fire test the Additive Manufacturing Demonstrator Engine, an in-space class prototype engine. This experience base has been extended to support Aerojet Rocketdyne in the application of AM to the RS-25, the Space Launch System Core Stage engine, and to small propulsion systems and thrusters for small satellites and cubesats. The latest developments will be described. In responding to a request from NASA's Commercial Crew Program for a consistent methodology for evaluation of AM processes and parts, MSFC began development of a draft standard for AM space flight hardware in late 2014. The draft was broadly disseminated for comments in mid-2015, and subsequently revised into two documents, a standard and a specification for AM space flight hardware, which were formally released by MSFC in October 2017. An overview of the key elements of these documents will be presented.

Clinton, Raymond↗

NASA NTRSDate not supplied

Optimization of Plug Nozzles Using CFD Informed Design Space Querying

This paper presents an axisymmetric CFD approach based on Reynolds-averaged Navier-Stokes (RANS) calculations for the shape optimization of plug nozzle contours for both supersonic cruise and landing/takeoff (LTO) conditions. Three key external plug design parameters were defined as independent variables in the optimization scheme, while nozzle performance was evaluated using thrust coefficient (Cfg) and discharge coefficient (Cd) as the primary dependent variables. By varying these parameters, a wide range of axisymmetric conic section plug profiles can be achieved, simplifying the problem. The paper also discusses the supersonic plug nozzle optimization approach, design space seeding, meshing, and CFD simulations for the optimization process. The results demonstrate that the approach is effective in exploring the parameter space and reducing computational expenses, making it a viable option for optimizing nozzle plug contours. Using this optimization toolchain, the study yielded preliminary designs for LTO, cruise, and LTO-cruise balanced plug nozzles.

nozzles↗

NASA NTRSDate not supplied

Optimization of Plug Nozzles Using CFD Informed Design Space Querying

CFD↗

NASA NTRS1996

Quantification of Gear Tooth Damage by Optimal Tracking of Vibration Signatures

This paper presents a technique for quantifying the wear or damage of gear teeth in a transmission system. The procedure developed in this study can be applied as a part of either an onboard machine health-monitoring system or a health diagnostic system used during regular maintenance. As the developed methodology is based on analysis of gearbox vibration under normal operating conditions, no shutdown or special modification of operating parameters is required during the diagnostic process. The process of quantifying the wear or damage of gear teeth requires a set of measured vibration data and a model of the gear mesh dynamics. An optimization problem is formulated to determine the profile of a time-varying mesh stiffness parameter for which the model output approximates the measured data. The resulting stiffness profile is then related to the level of gear tooth wear or damage. The procedure was applied to a data set generated artificially and to another obtained experimentally from a spiral bevel gear test rig. The results demonstrate the utility of the procedure as part of an overall health-monitoring system.

Choy, F. K.↗

DOE OSTI2023

CrossLink: General Overview [Slides]

Problem: Traditional mesh generation approaches are labor intensive and have limited robustness when applied to parametric design exploration and optimization of complex geometries. While automatic mesh generation approaches exist, they tend to generate tetrahedral or mixed-hybrid meshes which are generally unsuitable for physics applications with strong shock waves, thin boundary layers, and strong gradients. In addition, simulations sizes in the billions of cells are becoming more common with traditional mesh generation methods quickly reaching scalability limits. Solution: CrossLink offers a topology-based mesh generation approach with unstructured block-filling methods and a scalable mesh generation engine. In addition, CrossLink incorporates a python-based API for seamless workflow integration and robust repeatability of the geometry handling and mesh generation process. This makes it ideal for parametric design study and optimization of complex geometries. Finally, future versions of CrossLink will offer a parametric mesh capability that optimizes a high-order mesh and enables reconstruction of the final mesh in memory by the physics solver.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Advancing the STS Neutron Moderator Optimization with an Automated Workflow and Unstructured Mesh Modeling

Explore the source record for details and available documents.

Ghoos, Kristel [ORNL] (ORCID:0000000177128289)↗

NASA NTRS2018

Design of a Modular Monolithic Implicit Solver for Multi-Physics Applications

The design of a modular multi-physics high-order space-time finite-element framework is presented together with its extension to allow monolithic coupling of different physics. One of the main objectives of the framework is to perform efficient high- fidelity simulations of capsule/parachute systems. This problem requires simulating multiple physics including, but not limited to, the compressible Navier-Stokes equations, the dynamics of a moving body with mesh deformations and adaptation, the linear shell equations, non-re effective boundary conditions and wall modeling. The solver is based on high-order space-time - finite element methods. Continuous, discontinuous and C1-discontinuous Galerkin methods are implemented, allowing one to discretize various physical models. Tangent and adjoint sensitivity analysis are also targeted in order to conduct gradient-based optimization, error estimation, mesh adaptation, and flow control, adding another layer of complexity to the framework. The decisions made to tackle these challenges are presented. The discussion focuses first on the "single-physics" solver and later on its extension to the monolithic coupling of different physics. The implementation of different physics modules, relevant to the capsule/parachute system, are also presented. Finally, examples of coupled computations are presented, paving the way to the simulation of the full capsule/parachute system.

Carton De Wiart, Corentin↗

DOE OSTI2015

Wireless Sensor Networks - Node Localization for Various Industry Problems

Fast, effective monitoring following airborne releases of toxic substances is critical to mitigate risks to threatened population areas. Wireless sensor nodes at fixed predetermined locations may monitor such airborne releases and provide early warnings to the public. A challenging algorithmic problem is determining the locations to place these sensor nodes while meeting several criteria: 1) provide complete coverage of the domain, and 2) create a topology with problem dependent node densities, while 3) minimizing the number of sensor nodes. This manuscript presents a novel approach to determining optimal sensor placement, Advancing Front mEsh generation with Constrained dElaunay Triangulation and Smoothing (AFECETS) that addresses these criteria. A unique aspect of AFECETS is the ability to determine wireless sensor node locations for areas of high interest (hospitals, schools, high population density areas) that require higher density of nodes for monitoring environmental conditions, a feature that is difficult to find in other research work. The AFECETS algorithm was tested on several arbitrary shaped domains. AFECETS simulation results show that the algorithm 1) provides significant reduction in the number of nodes, in some cases over 40%, compared to an advancing front mesh generation algorithm, 2) maintains and improves optimal spacing between nodes, and 3) produces simulation run times suitable for real-time applications.

42 ENGINEERING↗

NASA NTRS1991

Local Synthesis and Tooth Contact Analysis of Face-Milled Spiral Bevel Gears

Computerized simulation of meshing and bearing contact for spiral bevel gears and hypoid gears is a significant achievement that could substantially improve the technology and the quality of the gears. An approach to the synthesis of face-milled spiral bevel gears and their tooth contact analysis is presented. The proposed approach is based on the following ideas: application of the principle of local synthesis that provides optimal conditions of meshing and contact at the mean contact point, M, and in the neighborhood of M; and application of relations between principle directions and curvatures for surfaces being in line contact or in point contact. The developed local synthesis of gears provides the following: (1) the required gear ratio at M; (2) a localized bearing contact with the desired direction of the tangent to the contact path on gear tooth surface and the desired length of the major axis of contact ellipse at M; (3) a predesigned parabolic function of a controlled level for transmission errors which enables absorption of linear functions of transmission errors caused by misalignment and reduces the level of vibrations. The proposed approach does not require either the tilt of the head-cutter for the process of generation or modified roll for the pinion generation. Improved conditions of meshing and contact of the gears can be achieved without the above mentioned parameters. A computer program for determination of basic machine-tool settings and tooth contact analysis for the designed gears is presented. The approach is illustrated with a numerical example.

Litvin, Faydor L.↗

DOE OSTI2017

Combined shape and topology optimization for minimization of maximal von Mises stress

Here, this work shows that a combined shape and topology optimization method can produce optimal 2D designs with minimal stress subject to a volume constraint. The method represents the surface explicitly and discretizes the domain into a simplicial complex which adapts both structural shape and topology. By performing repeated topology and shape optimizations and adaptive mesh updates, we can minimize the maximum von Mises stress using the p-norm stress measure with p-values as high as 30, provided that the stress is calculated with sufficient accuracy.

42 ENGINEERING↗

DOE OSTI2017

Coupling LaGrit unstructured mesh generation and model setup with TOUGH2 flow and transport: A case study

Furthermore, there are many applications in science and engineering modeling where an accurate representation of a complex model geometry in the form of a mesh is important. In applications of flow and transport in subsurface porous media, this is manifest in models that must capture complex geologic stratigraphy, structure (faults, folds, erosion, deposition) and infrastructure (tunnels, boreholes, excavations). Model setup, defined as the activities of geometry definition, mesh generation (creation, optimization, modification, refine, de-refine, smooth), assigning material properties, initial conditions and boundary conditions requires specialized software tools to automate and streamline the process. In addition, some model setup tools will provide more utility if they are designed to interface with and meet the needs of a particular flow and transport software suite. A control volume discretization that uses a two point flux approximation is for example most accurate when the underlying control volumes are 2D or 3D Voronoi tessellations. In this paper we will present the coupling of LaGriT, a mesh generation and model setup software suite and TOUGH2 to model subsurface flow problems and we show an example of how LaGriT can be used as a model setup tool for the generation of a Voronoi mesh for the simulation program TOUGH2. To generate the MESH file for TOUGH2 from the LaGriT output a standalone module Lagrit2Tough2 was developed, which is presented here and will be included in a future release of LaGriT. Here in this paper an alternative method to generate a Voronoi mesh for TOUGH2 with LaGriT is presented and thanks to the modular and command based structure of LaGriT this method is well suited to generating a mesh for complex models.

58 GEOSCIENCES↗

DOE OSTI2020

The distribution-based remapping of the nodal mass and momentum between arbitrary meshes for staggered arbitrary Lagrangian-Eulerian hydrodynamics

We present a new distribution-based remapping of the nodal mass and momentum between arbitrary source (Lagrangian) and arbitrary target (rezoned) meshes for indirect staggered arbitrary Lagrangian-Eulerian hydrodynamics. Here, the method is based on the following ideas: define cell-centered momentum and mass on the source mesh; conservatively remap those cell-centered quantities from source to target meshes; and use local constrained optimization for each cell of the target mesh to conservatively distribute cell mass and momentum to the nodes of the cell. This new method is efficient, conservative, accurate and bounds preserving.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRS1990

Shape design sensitivities using fully automatic 3-D mesh generation

Previous work in three dimensional shape optimization involved specifying design variables by associating parameters directly with mesh points. More recent work has shown the use of fully-automatic mesh generation based upon a parameterized geometric representation. Design variables have been associated with a mathematical model of the part rather than the discretized representation. The mesh generation procedure uses a nonuniform grid intersection technique to place nodal points directly on the surface geometry. Although there exists an associativity between the mesh and the geometrical/topological entities, there is no mathematical functional relationship. This poses a problem during certain steps in the optimization process in which geometry modification is required. For the large geometrical changes which occur at the beginning of each optimization step, a completely new mesh is created. However, for gradient calculations many small changes must be made and it would be too costly to regenerate the mesh for each design variable perturbation. For that reason, a local remeshing procedure has been implemented which operates only on the specific edges and faces associated with the design variable being perturbed. Two realistic design problems are presented which show the efficiency of this process and test the accuracy of the gradient computations.

Botkin, M. E.↗

NASA NTRS2021

A Study into Validating a Coupled Method of Characteristics and Direct Simulation Monte Carlo Method Against Empirical Data

The following will outline the methodology and results of validating a coupled Method of Characteristics (MOC) and Direct Simulation Monte Carlo (DSMC) method. This research focused specifically on modeling plume impingement, induced by Reaction Control System (RCS) thrusters that flew on the National Aeronautics and Space Administration’s (NASA’s) space shuttle Discovery. For each simulation, the continuum portion of the RCS thruster was simulated using MOC for solving hyperbolic Partial Differential Equations (PDEs) and computed with the NASA code, Reacting and Multi-phase Program (RAMP). The solution was then implemented as a starting condition into the NASA DSMC code, Direct Simulation and Monte Carlo Analysis Code (DAC). Typically, DSMC models rely on code-to-code validation for fidelity. The significance of this research is in its ability to validate its models against empirical data. Prior to computing solutions for these simulations, the mesh size and structure were optimized and many variants of DSMC input parameters were iterated on in order to acquire a reliable, mesh-independent, fully optimized numerical solution. This research will discuss the mathematical formulation of MOC for nozzle flow and DSMC for rarefied gases. Additionally, it will provide an explanation of how to implement these mathematical concepts into the two solvers: RAMP and DAC. Ultimately, this research will demonstrate that the overall process illustrated produces results in good agreement with empirical data. As a consequence, the methodology presented is granted an increased level of confidence and will greatly contribute to the aerospace industry and its effort in understanding and predicting rarefied flow fields.

Direct Simulation Monte Carlo Analysis Code↗

NASA NTRS2021

A Study into Validating A Coupled Method of Characteristics And Direct Simulation Monte Carlo Method Against Empirical Data

DAC↗

DOE OSTI2017

A Weak Galerkin Method for the Reissner–Mindlin Plate in Primary Form

We developed a new finite element method for the Reissner–Mindlin equations in its primary form by using the weak Galerkin approach. Like other weak Galerkin finite element methods, this one is highly flexible and robust by allowing the use of discontinuous approximating functions on arbitrary shape of polygons and, at the same time, is parameter independent on its stability and convergence. Furthermore, error estimates of optimal order in mesh size h are established for the corresponding weak Galerkin approximations. Numerical experiments are conducted for verifying the convergence theory, as well as suggesting some superconvergence and a uniform convergence of the method with respect to the plate thickness.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

A cell-centered AMR-ALE framework for 3D multi-material hydrodynamics. Part I: Lagrangian and indirect Euler AMR algorithms

Many applications of physics and engineering involve wide ranges of time and spatial scales. The numerical simulation of localized small scales such as shock waves and material interfaces requires a large number of computational cells in these regions. For these applications, Lagrangian and Arbitrary-Lagrangian-Eulerian (ALE) related methods are engaging since the moving mesh feature naturally brings mesh cells on shock discontinuities and material interfaces are carefully captured. In addition, Adaptive-Mesh-Refinement (AMR) strategies aim to optimize computational resources by concentrating finer mesh cells only in areas of interest while using coarser cells elsewhere. A key but challenging AMR requirement consists in efficiently distributing the computational effort to achieve high accuracy without the prohibitive computational costs associated with uniformly fine grids. Here, in this document, the coupling of the p4est AMR library with a cell-centered Lagrangian scheme is presented with the goal to perform reliable 3D Lagrangian-AMR and indirect Euler-AMR multi-material simulations. In particular, it is shown that starting from a 3D indirect ALE code, the memory management and load balancing requirements can be delegated to an external library (here the p4est library) to unlock ALE-AMR capabilities. First, we present a strategy to transcribe the octant-based connectivity of the 3D AMR framework with that of an unstructured mesh of polygonal cells used in Lagrangian hydrodynamics. Then, we show how refinement and coarsening operations must be adapted to the particular Lagrangian framework to ensure the conservation of volume during those steps. Finally, several numerical test cases are presented that demonstrate the capabilities of the Lagrangian-AMR and indirect Euler-AMR algorithms.

3D cell-centered Lagrangian numerical scheme↗