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NASA NTRS2007

CFD to Flight: Some Recent Success Stories of X-plane Design to Flight Test at the NASA Dryden Flight Research Center

Several examples from the past decade of success stories involving the design and ight test of three true X-planes will be described: in particular, X-plane design techniques that relied heavily upon computational fluid dynamics (CFD). Three specific examples chosen from the authors personal experience are presented: the X-36 Tailless Fighter Agility Research Aircraft, the X-45A Unmanned Combat Air Vehicle, and, most recently, the X-48B Blended Wing Body Demonstrator Aircraft. An overview will be presented of the uses of CFD analysis, comparisons and contrasts with wind tunnel testing, and information derived from the CFD analysis that directly related to successful flight test. Some lessons learned on the proper application, and misapplication, of CFD are illustrated. Finally, some highlights of the flight-test results of the three example X-planes will be presented. This overview paper will discuss some of the authors experience with taking an aircraft shape from early concept and three-dimensional modeling through CFD analysis, wind tunnel testing, further re ned CFD analysis, and, finally, flight. An overview of the key roles in which CFD plays well during this process, and some other roles in which it does not, are discussed. How wind tunnel testing complements, calibrates, and verifies CFD analysis is also covered. Lessons learned on where CFD results can be misleading are also given. Strengths and weaknesses of the various types of ow solvers, including panel methods, Euler, and Navier-Stokes techniques, are discussed. The paper concludes with the three specific examples, including some flight test video footage of the X-36, the X-45A, and the X-48B.

Cosentino, Gary B.↗

NASA NTRS2007

CFD to Flight: Some Recent Success Stories of X-Plane Design to Flight Test at the NASA Dryden Flight Research Center

Several examples from the past decade of success stories involving the design and flight test of three true X-planes will be described: in particular, X-plane design techniques that relied heavily upon computational fluid dynamics (CFD). Three specific examples chosen from the author s personal experience are presented: the X-36 Tailless Fighter Agility Research Aircraft, the X-45A Unmanned Combat Air Vehicle, and, most recently, the X-48B Blended Wing Body Demonstrator Aircraft. An overview will be presented of the uses of CFD analysis, comparisons and contrasts with wind tunnel testing, and information derived from the CFD analysis that directly related to successful flight test. Some lessons learned on the proper application, and misapplication, of CFD are illustrated. Finally, some highlights of the flight-test results of the three example X-planes will be presented. This overview paper will discuss some of the author s experience with taking an aircraft shape from early concept and three-dimensional modeling through CFD analysis, wind tunnel testing, further refined CFD analysis, and, finally, flight. An overview of the key roles in which CFD plays well during this process, and some other roles in which it does not, are discussed. How wind tunnel testing complements, calibrates, and verifies CFD analysis is also covered. Lessons learned on where CFD results can be misleading are also given. Strengths and weaknesses of the various types of flow solvers, including panel methods, Euler, and Navier-Stokes techniques, are discussed. The paper concludes with the three specific examples, including some flight test video footage of the X-36, the X-45A, and the X-48B.

Cosentino, Gary B.↗

NASA NTRS2010

Combustion and Performance Analyses of Coaxial Element Injectors with Liquid Oxygen/Liquid Methane Propellants

Liquid rocket engines using oxygen and methane propellants are being considered by the National Aeronautics and Space Administration (NASA) for in-space vehicles. This propellant combination has not been previously used in a flight-qualified engine system, so limited test data and analysis results are available at this stage of early development. NASA has funded several hardware-oriented activities with oxygen and methane propellants over the past several years with the Propulsion and Cryogenic Advanced Development (PCAD) project, under the Exploration Technology Development Program. As part of this effort, the NASA Marshall Space Flight Center has conducted combustion, performance, and combustion stability analyses of several of the configurations. This paper summarizes the analyses of combustion and performance as a follow-up to a paper published in the 2008 JANNAF/LPS meeting. Combustion stability analyses are presented in a separate paper. The current paper includes test and analysis results of coaxial element injectors using liquid oxygen and liquid methane or gaseous methane propellants. Several thrust chamber configurations have been modeled, including thrust chambers with multi-element swirl coax element injectors tested at the NASA MSFC, and a uni-element chamber with shear and swirl coax injectors tested at The Pennsylvania State University. Configurations were modeled with two one-dimensional liquid rocket combustion analysis codes, the Rocket Combustor Interaction Design and Analysis (ROCCID), and the Coaxial Injector Combustion Model (CICM). Significant effort was applied to show how these codes can be used to model combustion and performance with oxygen/methane propellants a priori, and what anchoring or calibrating features need to be applied or developed in the future. This paper describes the test hardware configurations, presents the results of all the analyses, and compares the results from the two analytical methods

Hulka, J. R.↗

NASA NTRS1988

Ply-level failure analysis of a graphite/epoxy laminate under bearing-bypass loading

A combined experimental and analytical study was conducted to investigate and predict the failure modes of a graphite/epoxy laminate subjected to combined bearing and bypass loading. Tests were conducted in a test machine that allowed the bearing-bypass load ratio to be controlled while a single-fastener coupon was loaded to failure in either tension or compression. Onset and ultimate failure modes and strengths were determined for each test case. The damage-onset modes were studied in detail by sectioning and micrographing the damaged specimens. A two-dimensional, finite-element analysis was conducted to determine lamina strains around the bolt hole. Damage onset consisted of matrix cracks, delamination, and fiber failures. Stiffness loss appeared to be caused by fiber failures rather than by matrix cracking and delamination. An unusual offset-compression mode was observed for compressive bearing-bypass laoding in which the specimen failed across its width along a line offset from the hole. The computed lamina strains in the fiber direction were used in a combined analytical and experimental approach to predict bearing-bypass diagrams for damage onset from a few simple tests.

Naik, R. A.↗

NASA NTRS1990

Ply-level failure analysis of a graphite/epoxy laminate under bearing-bypass loading

A combined experimental and analytical study was conducted to investigate and predict the failure modes of a graphite/epoxy laminate subjected to combined bearing and bypass loading. Tests were conducted in a test machine that allowed the bearing-bypass load ratio to be controlled while a single-fastener coupon was loaded to failure in either tension or compression. Onset and ultimate failure modes and strengths were determined for each test case. The damage-onset modes were studied in detail by sectioning and micrographing the damaged specimens. A two-dimensional, finite-element analysis was conducted to determine lamina strains around the bolt hole. Damage onset consisted of matrix cracks, delamination, and fiber failures. Stiffness loss appeared to be caused by fiber failures rather than by matrix cracking and delamination. An unusual offset-compression mode was observed for compressive bearing-bypass loading in which the specimen failed across its width along a line offset from the hole. The computed lamina strains in the fiber direction were used in a combined analytical and experimental approach to predict bearing-bypass diagrams for damage onset from a few simple tests.

Naik, R. A.↗

NASA NTRS1997

Three-dimensional culture of a mixed mullerian tumor of the ovary: expression of in vivo characteristics

The Rotating-Wall Vessel (RWV) is a novel in vitro cell culture system used to successfully culture a cell line derived from a heterologous mixed mullerian tumor cell of the ovary. Although the original tumor was comprised of both epithelial and mesodermal components, long-term culture in conventional flasks established a cell line from this tumor with homogeneous epitheliallike growth characteristics (1). Cells from Passage 36 were seeded into a Rotating-Wall Vessel containing Cytodex-3 microcarrier beads. Scanning electron micrographs of tumor cells cultured for 32 d in the RWV showed the presence of heterogeneous cell populations organized into three-dimensional tissuelike architecture. Immunocytochemical analysis confirmed the cellular heterogeneity, as demonstrated by expression of both epithelial and mesenchymal antigens. Reverse transcription polymerase chain reaction amplification demonstrated the presence of mRNA for cellular oncogenes HER-2/neu, H-ras, K-ras, and tumor suppressor p53. Thus, there are two advantages to propagation of tissue in the RWV culture system:(a) tissue diversification representing populations present in the original tumor, and (b) the three-dimensional freedom to organize tissues morphologically akin to those observed in vivo. These data indicate that the RWV culture system is suitable for generating large quantities of ovarian tumor cells in vitro that are amenable to immunocytochemical, oncogenic, morphologic characteristics demonstrated in vivo.

Mixed Tumor, Mullerian/ultrastructure↗

NASA NTRS1987

A direct algorithm for solution of incompressible three-dimensional unsteady Navier-Stokes equations

A direct, implicit, numerical solution algorithm, with second-order accuracy in space and time, is constructed for the three-dimensional unsteady incompressible Navier-Stokes equations formulated in terms of velocity and vorticity, using generalized orthogonal coordinates to achieve the accurate solution of complex viscous flow configurations. A numerically stable, efficient, direct inversion procedure is developed for the computationally intensive divergence-curl elliptic velocity problem. This overdetermined partial differential operator is first formulated as a uniquely determined, nonsingular matrix-vector problem; this aspect of the procedure is a unique feature of the present analysis. The three-dimensional vorticity-transport equation is solved by a modified factorization technique which completely eliminates the need for any block-matrix inversions and only scalar tridiagonal matrices need to be inverted. The method is applied to the test problem of the three-dimensional flow within a shear-driven cubical box. Coherent streamwise vortex structures are observed within the steady-state flow at Re = 100.

Osswald, G. A.↗

NASA NTRS2010

Performance and Stability Analyses of Rocket Combustion Devices Using Liquid Oxygen/Liquid Methane Propellants

Liquid rocket engines using oxygen and methane propellants are being considered by the National Aeronautics and Space Administration (NASA) for in-space vehicles. This propellant combination has not been previously used in flight-qualified engine systems, so limited test data and analysis results are available at this stage of early development. NASA has funded several hardware-oriented programs with oxygen and methane propellants over the past several years with the Propulsion and Cryogenic Advanced Development (PCAD) project, under the Exploration Technology Development Program. As part of this effort, NASA Marshall Space Flight Center has conducted combustion, performance, and combustion stability analyses of several of the configurations on these programs. This paper summarizes these analyses. Test and analysis results of impinging and coaxial element injectors using liquid oxygen and liquid methane propellants are included. Several cases with gaseous methane are included for reference. Several different thrust chamber configurations have been modeled, including thrust chambers with multi-element like-on-like and swirl coax element injectors tested at NASA MSFC, and a unielement chamber with shear and swirl coax injectors tested at The Pennsylvania State University. Configurations were modeled with two one-dimensional liquid rocket combustion analysis codes, the Rocket Combustor Interaction Design and Analysis (ROCCID), and the Coaxial Injector Combustion Model (CICM). Significant effort was applied to show how these codes can be used to model combustion and performance with oxygen/methane propellants a priori, and what anchoring or calibrating features need to be applied or developed in the future. This paper describes the test hardware configurations, presents the results of all the analyses, and compares the results from the two analytical methods.

Hulka, James R.↗

NASA NTRS1981

Numerical simulation of a sudden stratospheric warming with a three-dimensional, spectral, quasi-geostrophic model

An analysis of a sudden stratospheric warming which developed spontaneously during a winter simulation with a three-dimensional quasi-geostrophic model is described. Changes in the circulation and thermal structure of the winter polar stratosphere that occurred during the warming are shown to be in close agreement with observed behavior: enhanced vertical flux of eddy energy into the stratosphere, rapid temperature increase in high latitudes with a reversal of the zonal mean temperature gradient between midlatitude and pole, destruction of the circumpolar cyclonic vortex, and a marked deceleration of the westerly jet and the appearance of zonal mean easterlies. Energies of the warming are also consistent with observed characteristics. Many aspects of the dynamical development of the present model simulation are shown to agree with a previous model simulation, but there are also areas of disagreement.

Grose, W. L.↗

NASA NTRS1989

Thermal analysis of a hypersonic wing test structure

The three-dimensional finite element modeling techniques developed for the thermal analysis of a hypersonic wing test structure (HWTS) are described. The computed results are compared to measured test data. In addition, the results of a NASA two-dimensional parameter finite difference local thermal model and the results of a contractor two-dimensional lumped parameter finite difference local thermal model will be presented.

Sandlin, Doral R.↗

NASA NTRS1976

A theoretical evaluation of rigid baffles in suppression of combustion instability

An analytical technique for the prediction of the effects of rigid baffles on the stability of liquid propellant combustors is presented. This analysis employs a three dimensional combustor model characterized by a concentrated combustion source at the chamber injector and a constant Mach number nozzle. An eigenfunction-matching method is used to solve the linearized partial differential equations describing the unsteady flow field. Boundary layer corrections to this unsteady flow are used in a mechanical energy dissipation model to evaluate viscous and turbulence effects within the flow. An integral stability relationship is then employed to predict the decay rate of the oscillations. Results of this analysis agree qualitatively with experimental observations and show that sufficient dissipation exists to indicate that the proper mechanism of baffle damping is a fluid dynamic loss. The response of the dissipation model to varying baffle blade length, mean flow Mach number and oscillation amplitude is examined.

Combustion instability↗

NASA NTRS2003

Design and Analysis of Turbines for Space Applications

In order to mitigate the risk of rocket propulsion development, efficient, accurate, detailed fluid dynamics analysis of the turbomachinery is necessary. This analysis is used for component development, design parametrics, performance prediction, and environment definition. To support this requirement, a task was developed at NASAh4arshall Space Flight Center (MSFC) to improve turbine aerodynamic performance through the application of advanced design and analysis tools. There are four major objectives of this task: 1) to develop, enhance, and integrate advanced turbine aerodynamic design and analysis tools; 2) to develop the methodology for application of the analytical techniques; 3) to demonstrate the benefits of the advanced turbine design procedure through its application to a relevant turbine design point; and 4) to verify the optimized design and analysis with testing. The turbine chosen on which to demonstrate the procedure was a supersonic design suitable for a reusable launch vehicle (RLV). The hot gas path and blading were redesigned to obtain an increased efficiency. The redesign of the turbine was conducted with a consideration of system requirements, realizing that a highly efficient turbine that, for example, significantly increases engine weight, is of limited benefit. Both preliminary and detailed designs were considered. To generate an improved design, one-dimensional (1D) design and analysis tools, computational fluid dynamics (CFD), response surface methodology (RSM), and neural nets (NN) were used.

Griffin, Lisa W.↗

NASA NTRS1979

Analysis of graphite/polyimide rail shear specimens subjected to mechanical and thermal loading

A two-dimensional, linear-elastic, finite element analysis of selected graphite/polyimide rail shear test specimens was made to determine the mechanical loading and the effect of heating the specimen to a uniform temperature. The presence of specimen free edges and their influence on the accuracy of the rail shear test is discussed. Parameters include the length-to-width ratio of the specimen and the ply layup for symmetric, balanced laminates. Results presented include shear and normal stress distributions and the deflection behavior of various specimens caused by the mechanical loading and elevated temperature.

Weisshaar, T. A.↗

NASA NTRS1989

Euler flutter analysis of airfoils using unstructured dynamic meshes

Modifications to a two-dimensional unsteady Euler code for the aeroelastic analysis of airfoils are described. The modifications involve including the structural equations of motion and their simultaneous time-integration with the governing flow equations. A novel aspect of the capability is that the solutions are obtained using unstructured grids made up of triangles. Comparisons are made with parallel calculations performed using linear theory and a structured grid Euler code to assess the accuracy of the unstructured grid Euler results. Results are presented for a flat plate airfoil and the NACA 0012 airfoil to demonstrate applications of the Euler code for generalized force computations and aeroelastic analysis. In these comparisons, two different finite-volume discretizations of the Euler equations on unstructured meshes were employed. Sensitivity of the Euler results to changes in numerical parameters were also investigated.

Rausch, Russ D.↗

NASA NTRS1991

Unified aeroacoustics analysis for high speed turboprop aerodynamics and noise. Volume 5: Propagation of propeller tone noise through a fuselage boundary layer

An analysis of tone noise propagation through a boundary layer and fuselage scattering effects was derived. This analysis is a three dimensional and the complete wave field is solved by matching analytical expressions for the incident and scattered waves in the outer flow to a numerical solution in the boundary layer flow. The outer wave field is constructed analytically from an incident wave appropriate to the source and a scattered wave in the standard Hankel function form. For the incident wave, an existing function - domain propeller noise radiation theory is used. In the boundary layer region, the wave equation is solved by numerical methods. The theoretical analysis is embodied in a computer program which allows the calculation of correction factors for the fuselage scattering and boundary layer refraction effects. The effects are dependent on boundary layer profile, flight speed, and frequency. Corrections can be derived for any point on the fuselage, including those on the opposite side from the source. The theory was verified using limited cases and by comparing calculations with available measurements from JetStar tests of model prop-fans. For the JetStar model scale, the boundary layer refraction effects produce moderate fuselage pressure reinforcements aft of and near the plane of rotation and significant attenuation forward of the plane of rotation at high flight speeds. At lower flight speeds, the calculated boundary layer effects result in moderate amplification over the fuselage area of interest. Apparent amplification forward of the plane of rotation is a result of effective changes in the source directivity due to boundary layer refraction effects. Full scale effects are calculated to be moderate, providing fuselage pressure amplification of about 5 dB at the peak noise location. Evaluation using available noise measurements was made under high-speed, high-altitude flight conditions. Comparisons of calculations made of free field noise, using a current frequency-domain propeller noise prediction method, and fuselage effects using this new procedure show good agreement with fuselage measurements over a wide range of flight speeds and frequencies. Correction factors for the JetStar measurements made on the fuselage are provided in an Appendix.

Magliozzi, B.↗

NASA NTRS1978

Stress-Intensity Factors for Corner Cracks at the Edge of a Hole

Stress-intensity factors, calculated by a three-dimensional finite-element analysis, for shallow or deep quarter-elliptical corner cracks at the edge of a hole in a finite-thickness plate are presented. The plate was subjected to remote uniform tension, remote bending, or simulated pin loading in the hole. The crack depth-to-plate thickness ranged from 0.2 to 0.8, while the ratio of crack depth-to-plate crack length ranged from 0.2 to 2. The ratio of hole radius-to-plate thickness was held at 0.5. To verify the accuracy of the three-dimensional finite-element models empolyed, convergence studies were conducted (number of degrees of freedom ranged from 4400 to 9300). The stress-intensity factor variations along the crack front are presented and compared with other solutions from the literature.

Raju, I. S.↗

NASA NTRS1993

Unsteady three-dimensional thermal field prediction in turbine blades using nonlinear BEM

A time-and-space accurate and computationally efficient fully three dimensional unsteady temperature field analysis computer code has been developed for truly arbitrary configurations. It uses boundary element method (BEM) formulation based on an unsteady Green's function approach, multi-point Gaussian quadrature spatial integration on each panel, and a highly clustered time-step integration. The code accepts either temperatures or heat fluxes as boundary conditions that can vary in time on a point-by-point basis. Comparisons of the BEM numerical results and known analytical unsteady results for simple shapes demonstrate very high accuracy and reliability of the algorithm. An example of computed three dimensional temperature and heat flux fields in a realistically shaped internally cooled turbine blade is also discussed.

Martin, Thomas J.↗

NASA NTRS1984

Transonic analysis of canted winglets

A computational method developed to provide a transonic analysis for upper/lower surface wing-tip mounted winglets is described. Winglets with arbitrary planform, cant and toe angle, and airfoil section can be modeled. The embedded grid approach provides high flow field resolution and the required geometric flexibility. In particular, coupled Cartesian/cylindrical grid systems are used to model the complex geometry presented by canted upper/lower surface winglets. A new rotated difference scheme is introduced in order to maintain the stability of the small-disturbance formulation in the presence of large spanwise velocities. Wing and winglet viscous effects are modeled using a two-dimensional 'strip' boundary layer analysis. Correlations with wind tunnel and flight test data for three transport configurations are included.

Rosen, B. S.↗