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At least 19 records

USM3D-ME Analyses Performed in Support of a Wind Tunnel Test of a Boundary-Layer Ingestion Configuration

Boundary Layer Ingestion (BLI) has been proposed as a technology with the potential to decrease fuel burn. However, one major concern for BLI configurations is the potential degradation of the flow quality, both on the airframe and at the fan face, resulting from the tightly integrated propulsor. A wind tunnel test was performed in the National Transonic Facility (NTF) at the NASA Langley Research Center to investigate the flow quality ingested by a tail cone thruster configuration, similar to the Single Aisle Turboelectric Aircraft Concept with Aft Boundary Layer Ingestion (STARC-ABL). The wind tunnel model was a modified version of the Common Research Model (CRM) to include an aft-mounted, flow-through propulsor. The experimental data obtained from the wind tunnel test provide insight into the flow and enables an assessment of the accuracy of the USM3D-ME flow solver for predicting the flow at the fan face, which will be crucial for fan design purposes. Both grid refinement and turbulence model studies were performed for the Clean and Cruise MFP configurations at the condition corresponding to ReMAC = 5 million, Mach = 0.8, and alpha = 2 deg. The selected grid refinement level and turbulence model were then used to perform simulations over the range of conditions considered in the NTF wind tunnel test. The condition sweep comparisons illustrate favorable agreement with the experimental data over the entire range of conditions and for all Mass Flow Plug (MFP) configurations. The largest differences were observed for the Idle MFP configuration, with approximately 3% difference observed between USM3D-ME and the experimental data. Future work should investigate the impact of higher fidelity turbulence models and grid adaptation on the USM3D-ME predictions.

CRM

USM3D-ME Analyses Performed in Support of a Wind Tunnel Test of a Boundary-Layer Ingestion Configuration

Boundary Layer Ingestion (BLI) has been proposed as a technology with the potential to decrease fuel burn. However, one major concern for BLI configurations is the potential degradation of the flow quality, both on the airframe and at the fan face, resulting from the tightly integrated propulsor. A wind tunnel test was performed in the National Transonic Facility (NTF) at the NASA Langley Research Center to investigate the flow quality ingested by a tail cone thruster configuration, similar to the Single Aisle Turboelectric Aircraft Concept with Aft Boundary Layer Ingestion (STARC-ABL). The wind tunnel model was a modified version of the Common Research Model (CRM) to include an aft-mounted, flow-through propulsor. The experimental data obtained from the wind tunnel test provide insight into the flow and enables an assessment of the accuracy of the USM3D-ME flow solver for predicting the flow at the fan face, which will be crucial for fan design purposes. Both grid refinement and turbulence model studies were performed for the Clean and Cruise MFP configurations at the condition corresponding to ReMAC = 5 million, Mach = 0.8, and alpha = 2 deg. The selected grid refinement level and turbulence model were then used to perform simulations over the range of conditions considered in the NTF wind tunnel test. The condition sweep comparisons illustrate favorable agreement with the experimental data over the entire range of conditions and for all Mass Flow Plug (MFP) configurations. The largest differences were observed for the Idle MFP configuration, with approximately 3% difference observed between USM3D-ME and the experimental data. Future work should investigate the impact of higher fidelity turbulence models and grid adaptation on the USM3D-ME predictions.

CRM

Aeromechanics Analysis of a Boundary Layer Ingesting Fan

Boundary layer ingesting propulsion systems have the potential to significantly reduce fuel burn but these systems must overcome the challe nges related to aeromechanics-fan flutter stability and forced response dynamic stresses. High-fidelity computational analysis of the fan a eromechanics is integral to the ongoing effort to design a boundary layer ingesting inlet and fan for fabrication and wind-tunnel test. A t hree-dimensional, time-accurate, Reynolds-averaged Navier Stokes computational fluid dynamics code is used to study aerothermodynamic and a eromechanical behavior of the fan in response to both clean and distorted inflows. The computational aeromechanics analyses performed in th is study show an intermediate design iteration of the fan to be flutter-free at the design conditions analyzed with both clean and distorte d in-flows. Dynamic stresses from forced response have been calculated for the design rotational speed. Additional work is ongoing to expan d the analyses to off-design conditions, and for on-resonance conditions.

Bakhle, Milind A.

Artificial Thickening of a Transonic Boundary Layer in the Presence of a Pressure Gradient Associated with a Boundary Layer Ingestion Concept

Boundary layer ingestion is an aeropropulsive concept associated with a propulsion airframe integration technique that integrates viscous aerodynamics into a propulsion system to achieve more efficient flight. The effectiveness of this concept is heavily dependent on how much of the boundary layer is being ingested into the propulsor. Scaling this concept for transonic wind tunnel testing is often plagued with blockage issues and requires a modification to the model dimensions such as fuselage length and diameter and wingspan. To simulate the boundary layer for these modified models requires a manipulation of the boundary layer height to achieve the appropriate ratio of boundary layer to propulsor inlet diameter or height. This paper will focus on 15 different transonic boundary layer manipulators to achieve varying turbulent boundary layer heights for a representative single-aisle transport utilizing Boundary Layer Ingestion.

Gregory S Jones

Active Flow Control on a Boundary-Layer-Ingesting Inlet

Boundary layer ingestion (BLI) is explored as means to improve overall system performance for Blended Wing Body configuration. The benefits of BLI for vehicle system performance benefit are assessed with a process derived from first principles suitable for highly-integrated propulsion systems. This performance evaluation process provides framework within which to assess the benefits of an integrated BLI inlet and lays the groundwork for higher-fidelity systems studies. The results of the system study show that BLI provides a significant improvement in vehicle performance if the inlet distortion can be controlled, thus encouraging the pursuit of active flow control (AFC) as a BLI enabling technology. The effectiveness of active flow control in reducing engine inlet distortion was assessed using a 6% scale model of a 30% BLI offset, diffusing inlet. The experiment was conducted in the NASA Langley Basic Aerodynamics Research Tunnel with a model inlet designed specifically for this type of testing. High mass flow pulsing actuators provided the active flow control. Measurements were made of the onset boundary layer, the duct surface static pressures, and the mass flow through the duct and the actuators. The distortion was determined by 120 total pressure measurements located at the aerodynamic interface plane. The test matrix was limited to a maximum freestream Mach number of 0.15 with scaled mass flows through the inlet for that condition. The data show that the pulsed actuation can reduce distortion from 29% to 4.6% as measured by the circumferential distortion descriptor DC60 using less than 1% of inlet mass flow. Closed loop control of the actuation was also demonstrated using a sidewall surface static pressure as the response sensor.

Gorton, Susan Althoff

Conceptual Design of a Counter-Rotating Fan System for Distributed Boundary Layer Ingesting Propulsion

The present paper details the design of the counter rotating fans for a Turboelectric Distributed Propulsion (TeDP) system. Sixteen propulsors installed in mail-slot-shape nacelles are embedded on an aerodynamically optimized hybrid wing-body configuration. The hybrid-wing/body (HWB) configuration which was previously designed to satisfy the conditions of trim, longitudinally static stability and specific cargo space is employed as the baseline configuration in pursuing an optimal distributed propulsion system. A set of distributed propulsors is conceptually designed and the collective performance is evaluated against the target thrust mandated by the mission requirements. The concept of the distributed propulsion allows the fan pressure ratio to be around 1.27~1.32 for the target thrust. In addition, further splitting of the fan pressure ratio by using the counter-rotating fans for each slot realizes the target pressure ratio with low tip speed. In the distributed propulsion system, the nature of the flow conditions and/or the thickness of the ingested boundary layer may differ and result in different propulsive reaction of each individual propulsor. The optimization is, thus, approached from both the propulsion system and individual propulsor perspectives. An optimal distribution of the thrust and power output is determined by how the system utilizes each passage's propulsive characteristics and its interaction with the airframe. These system level analysis and optimization are conducted using an actuator disk model to account for the propulsion-airframe integration numerically. With respect to the propulsor level, aerodynamic shape optimizations of the fan blades are performed in a sequential multi-objective optimization process for various design objectives, such as mass flow rate condition, fan pressure ratio, efficiency and the exit flow angle of the fan stage by using a genetic algorithm, NSGA-II. The radial chord distribution, and meanline distribution of the rotors are designed on the circumferentially averaged axi-symmetric inlet profiles and tested on the six inlet profiles from six divided sectors to reckon flow distortion. The performances of the counter rotating fans are, thus, evaluated accordingly for obtaining distortion tolerant fan. The performance of the distributed propulsion system is evaluated by two CFD tools, i.e., a multi-stage turbo-machinery CFD code and one propulsion-airframe integration flow solver coupled with a body-force model. The optimized boundary layer ingestion propulsion system of 16 distributed slots not only reaches the system target thrust, but also delivers a close to 20% fuel saving benefit against its counterpart 12 distributed clean inlet propulsion system.

Boundary-Layer-Ingestion Propulsion

Aeropropulsive Design Optimization of a Turboelectric Boundary Layer Ingestion Propulsion System

Boundary Layer Ingestion (BLI) for aircraft applications was first proposed by Apollo Smith and Howard Roberts in a 1947 paper that studied the use of jet intakes embedded in the boundary layer as a means to maintain laminar flow and reduce aircraft drag. While the use of BLI in aviation didn't catch on it was heavily studied and utilized for marine applications. In 1993 interest in BLI applications to aircraft design was renewed when Leyroy Smith published novel work using a boundary layer analysis combined with basic propulsion modeling to show the potential for significant fuel burn reduction. Smith identified the tightly coupled aero-propulsive nature of BLI as a key challenge in the analysis and design of the concept.

Gray, Justin S.

Evaluation of Flush-Mounted, S-Duct Inlets with Large Amounts of Boundary Layer Ingestion

A new high Reynolds number test capability for boundary layer ingesting inlets has been developed for the NASA Langley Research Center 0.3-Meter Transonic Cryogenic Tunnel. Using this new capability, an experimental investigation of four S-duct inlet configurations with large amounts of boundary layer ingestion (nominal boundary layer thickness of about 40% of inlet height) was conducted at realistic operating conditions (high subsonic Mach numbers and full-scale Reynolds numbers). The objectives of this investigation were to 1) provide a database for CFD tool validation on boundary layer ingesting inlets operating at realistic conditions and 2) provide a baseline inlet for future inlet flow-control studies. Tests were conducted at Mach numbers from 0.25 to 0.83, Reynolds numbers (based on duct exit diameter) from 5.1 million to a full-scale value of 13.9 million, and inlet mass-flow ratios from 0.39 to 1.58 depending on Mach number. Results of this investigation indicate that inlet pressure recovery generally decreased and inlet distortion generally increased with increasing Mach number. Except at low Mach numbers, increasing inlet mass-flow increased pressure recovery and increased distortion. Increasing the amount of boundary layer ingestion (by decreasing inlet throat height) or ingesting a boundary layer with a distorted (adverse) profile decreased pressure recovery and increased distortion. Finally, increasing Reynolds number had almost no effect on inlet distortion but increased inlet recovery by about one-half percent at a Mach number near cruise.

Berrier, Bobby L.

Benefit and Critical Factors for the Performance of the Boundary Layer Ingesting Propulsion

The benefit of the boundary layer ingestion (BLI) is described in the perspective of the propulsion and engine development. A power saving map of the BLI engines is derived based on the correlation of the shape factor of the ingested boundary layer and the propulsive efficiency. The ratio of the mass flow rate between BLI and non-BLI propulsors is introduced to quantify the power saving of the BLI engine relative to a corresponding clean inlet flow engine that generates the same amount of net thrust. The wake recovery factor from the jet flow is applied to find the optimum sizing of the engine for the given design requirement. The effects of the fan pressure ratio of the propulsor toward the power saving are also investigated to seek out the feasible range of the BLI propulsor design. The derived correlation is validated with CFD analyses. Simulation models using variously sized engines relative to an influencing body are developed so that a numerical experiment is carried out with the various shape factors. The effect of the propulsion airframe integration toward the aerodynamic forces on the fuselage and nacelle is investigated via parametric study of the engine sizing and fan pressure ratio for the wake ingestion models. The propulsor efficiency is quantified toward the saving in the actual shaft power and correlated with the efficiency penalty of the BLI propulsor. The correlation is also validated via comparison of the turbo-machinery CFD results for BLI2DTF and conventional transonic fan stages.

Boundary Layer Ingestion

Evaluation of Flush-Mounted, S-Duct Inlets With Large Amounts of Boundary Layer Ingestion

A new high Reynolds number test capability for boundary layer ingesting inlets has been developed for the NASA Langley Research Center 0.3-Meter Transonic Cryogenic Tunnel. Using this new capability, an experimental investigation of four S-duct inlet configurations with large amounts of boundary layer ingestion (nominal boundary layer thickness of about 40% of inlet height) was conducted at realistic operating conditions (high subsonic Mach numbers and full-scale Reynolds numbers). The objectives of this investigation were to 1) develop a new high Reynolds number, boundary-layer ingesting inlet test capability, 2) evaluate the performance of several boundary layer ingesting S-duct inlets, 3) provide a database for CFD tool validation, and 4) provide a baseline inlet for future inlet flow-control studies. Tests were conducted at Mach numbers from 0.25 to 0.83, Reynolds numbers (based on duct exit diameter) from 5.1 million to a fullscale value of 13.9 million, and inlet mass-flow ratios from 0.39 to 1.58 depending on Mach number. Results of this investigation indicate that inlet pressure recovery generally decreased and inlet distortion generally increased with increasing Mach number. Except at low Mach numbers, increasing inlet mass-flow increased pressure recovery and increased distortion. Increasing the amount of boundary layer ingestion (by decreasing inlet throat height and increasing inlet throat width) or ingesting a boundary layer with a distorted profile decreased pressure recovery and increased distortion. Finally, increasing Reynolds number had almost no effect on inlet distortion but increased inlet recovery by about one-half percent at a Mach number near cruise.

Berrier, Bobby L.

BENEFIT AND CRITICAL FACTORS FOR THE PERFORMANCE OF THE BOUNDARY LAYER INGESTING PROPULSION

The benefit of the boundary layer ingestion(BLI)is described in the perspective of the propulsion and engine development. A power saving map of the BLI engines is derived based on the correlation of the wake velocity ratio of the ingested boundary layer profile and the propulsive efficiency. The ratio of the mass flow rate between BLI and non-BLI propulsors is introduced to quantify the power saving of the BLI engine relative to a clean inlet flow engine which generates same amount of thrust. The wake recovery factor from the jet flow out of the BLI engine is employed to find an adequate sizing of the BLI engine for the given design requirement. The effects of the fan pressure ratio on the power saving are also investigated to explore the feasible range of the BLI engine design. The derived correlation is validated with CFD analyses. A numerical experiment is carried out by varying the wake velocity ratio through different BLI engines sized with respect to an influencing body. Consequently, the propulsor efficiency is quantified and presented by the saving in the actual shaft power. The efficiency penalty, pressure ratio of the BLI fan stage are correlated with the power saving and the correlation is validated through BLI2DTF and R4 fan stage CFD analyses based on rig test data.

B J Lee

Aeromechanics Analysis of a Distortion-Tolerant Fan with Boundary Layer Ingestion

A propulsion system with Boundary Layer Ingestion (BLI) has the potential to significantly reduce aircraft engine fuel burn. But a critical challenge is to design a fan that can operate continuously with a persistent BLI distortion without aeromechanical failure -- flutter or high cycle fatigue due to forced response. High-fidelity computational aeromechanics analysis can be very valuable to support the design of a fan that has satisfactory aeromechanic characteristics and good aerodynamic performance and operability. Detailed aeromechanics analyses together with careful monitoring of the test article is necessary to avoid unexpected problems or failures during testing. In the present work, an aeromechanics analysis based on a three-dimensional, time-accurate, Reynolds-averaged Navier-Stokes computational fluid dynamics code is used to study the performance and aeromechanical characteristics of the fan in both circumferentially-uniform and circumferentially-varying distorted flows. Pre-test aeromechanics analyses are used to prepare for the wind tunnel test and comparisons are made with measured blade vibration data after the test. The analysis shows that the fan has low levels of aerodynamic damping at various operating conditions examined. In the test, the fan remained free of flutter except at one near-stall operating condition. Analysis could not be performed at this low mass flow rate operating condition since it fell beyond the limit of numerical stability of the analysis code. The measured resonant forced response at a specific low-response crossing indicated that the analysis under-predicted this response and work is in progress to understand possible sources of differences and to analyze other larger resonant responses. Follow-on work is also planned with a coupled inlet-fan aeromechanics analysis that will more accurately represent the interactions between the fan and BLI distortion.

Propulsion Aeroelasticity

Approach to Modeling Boundary Layer Ingestion Using a Fully Coupled Propulsion-RANS Model

Airframe-propulsion integration concepts that use boundary layer ingestion have the potential to reduce aircraft fuel burn. One concept that has been recently explored is NASA's Starc-ABL aircraft configuration, which offers the potential for 12% mission fuel burn reduction by using a turbo-electric propulsion system with an aft-mounted electrically driven boundary layer ingestion propulsor. This large potential for improved performance motivates a more detailed study of the boundary layer ingestion propulsor design, but to date, analyses of boundary layer ingestion have used uncoupled methods. These methods account for only aerodynamic effects on the propulsion system or propulsion system effects on the aerodynamics, but not both simultaneously. This work presents a new approach for building fully coupled propulsive-aerodynamic models of boundary layer ingestion propulsion systems. A 1D thermodynamic cycle analysis is coupled to a RANS simulation to model the Starc-ABL aft propulsor at a cruise condition and the effects variation in propulsor design on performance are examined. The results indicates that both propulsion and aerodynamic effects contribute equally toward the overall performance and that the fully coupled model yields substantially different results compared to uncoupled. The most significant finding is that boundary layer ingestion, while offering substantial fuel burn savings, introduces throttle dependent aerodynamics effects that need to be accounted for. This work represents a first step toward the multidisciplinary design optimization of boundary layer ingestion propulsion systems.

Boundary Layer Ingestion

Development of a Rotating Rake Array for Boundary-Layer-Ingesting Fan-Stage Measurements

The recent Boundary-Layer-Ingesting Inlet/Distortion Tolerant Fan wind tunnel experiment at NASA Glenn Research Center's 8-foot by 6-foot supersonic wind tunnel examined the performance of a novel inlet and fan stage that was designed to ingest the vehicle boundary layer in order to take advantage of a predicted overall propulsive efficiency benefit. A key piece of the experiment's instrumentation was a pair of rotating rake arrays located upstream and downstream of the fan stage. This paper examines the development of these rake arrays. Pre-test numerical solutions were sampled to determine placement and spacing for rake pressure and temperature probes. The effects of probe spacing and survey density on the repeatability of survey measurements was examined. These data were then used to estimate measurement uncertainty for the adiabatic efficiency.

Wolter, John D.

Development of a Rotating Rake Array for Boundary-Layer-Ingesting Fan-Stage Measurements

The recent Boundary-Layer-Ingesting Inlet/Distortion Tolerant Fan wind tunnel experiment at NASA Glenn Research Center's 8- by 6-foot Supersonic Wind Tunnel (SWT) examined the performance of a novel inlet and fan stage that was designed to ingest the vehicle boundary layer in order to take advantage of a predicted overall propulsive efficiency benefit. A key piece of the experiment's instrumentation was a pair of rotating rake arrays located upstream and downstream of the fan stage. This paper examines the development of these rake arrays. Pre-test numerical solutions were sampled to determine placement and spacing for rake pressure and temperature probes. The effects of probe spacing and survey density on the repeatability of survey measurements was examined. These data were then used to estimate measurement uncertainty for the adiabatic efficiency.

turbomachinery

Computational Analysis of a Boundary Layer Ingesting Tailcone Thruster Configuration Using the LAVA Curvilinear Solver

Boundary layer ingesting (BLI) propulsion systems are one of the many technologies currently under investigation within the aerospace community to meet NASA's Advanced Air Transport Technology project goal of a sustainable future in aviation. To that end, an experimental campaign was conducted in the National Transonic Facility (NTF) wind tunnel to study the propulsion-airframe integration effects of the Boundary Layer Ingesting Tailcone System installed in the aft portion of a 2.7% scale design of the NASA Common Research Model (CRM). This test was accompanied by a numerical simulation effort using the Launch, Ascent, and Vehicle Aerodynamics (LAVA) curvilinear solver to validate the applicability of current best-practice Reynolds-Averaged Navier-Stokes (RANS) models in accurately predicting the relevant flow physics in free-air. A total of 205 steady RANS simulations were performed using LAVA, covering the range of conditions present in the NTF test matrix. Flow conditions ranged from 5- to 15-million Reynolds number, Mach numbers of 0.75, 0.80 and 0.85, and angles of attack between -3 and 4 degrees. Four different mass-flow plugs were also tested to assess propulsor operating condition effects. Sensitivity to these flow conditions is analyzed in detail, especially in terms of the nacelle flow distortion which was the main subject of the study. Aerodynamic load coefficients, aft body boundary layer measurements and fuselage pressure tap results are also discussed, providing a wide range of validation results from this experimental campaign. This validation effort shows that current best-practices using RANS models within the LAVA curvilinear solver flow solver are well suited for predicting the inlet flow distortion characteristics of novel aircraft configurations employing BLI at the aft end of the fuselage. This talk will cover the combined experimental and numerical efforts that resulted from this BLI-focused investigation.

ARMD

Numerical Simulation of Boundary Layer Ingesting (BLI) Inlet-Fan Interaction

Future civil transport designs may incorporate engine inlets integrated into the body of the aircraft to take advantage of efficiency increases due to weight and drag reduction. Additional increases in engine efficiency are predicted if the inlet ingests the lower momentum boundary layer flow. Previous studies have shown, however, that efficiency benefits of Boundary Layer Ingesting (BLI) ingestion are very sensitive to the magnitude of fan and duct losses, and blade structural response to the non-uniform flow field that results from a BLI inlet has not been studied in-depth. This paper presents an effort to extend the modeling capabilities of an existing rotating turbomachinery unsteady analysis code to include the ability to solve the external and internal flow fields of a BLI inlet. The TURBO code has been a successful tool in evaluating fan response to flow distortions for traditional engine/inlet integrations, such as the development of rotating stall and inlet distortion through compressor stages. This paper describes the first phase of an effort to extend the TURBO model to calculate the external and inlet flowfield upstream of fan so that accurate pressure distortions that result from BLI configurations can be computed and used to analyze fan aerodynamics and structural response. To validate the TURBO program modifications for the BLI flowfield, experimental test data obtained by NASA for a flushmounted S-duct with large amounts of boundary layer ingestion was modeled. Results for the flow upstream and in the inlet are presented and compared to experimental data for several high Reynolds number flows to validate the modifications to the solver. Quantitative data is presented that indicates good predictive capability of the model in the upstream flow. A representative fan is attached to the inlet and results are presented for the coupled inlet/fan model. The impact on the total pressure distortion at the AIP after the fan is attached is examined.

Inlet Fan Interactions

An Examination of the Effect of Boundary Layer Ingestion on Turboelectric Distributed Propulsion Systems

A Turboelectric Distributed Propulsion (TeDP) system differs from other propulsion systems by the use of electrical power to transmit power from the turbine to the fan. Electrical power can be efficiently transmitted over longer distances and with complex topologies. Also the use of power inverters allows the generator and motors speeds to be independent of one another. This decoupling allows the aircraft designer to place the core engines and the fans in locations most advantageous for each. The result can be very different installation environments for the different devices. Thus the installation effects on this system can be quite different than conventional turbofans where the fan and core both see the same installed environments. This paper examines a propulsion system consisting of two superconducting generators, each driven by a turboshaft engine located so that their inlets ingest freestream air, superconducting electrical transmission lines, and an array of superconducting motor driven fan positioned across the upper/rear fuselage area of a hybrid wing body aircraft in a continuous nacelle that ingests all of the upper fuselage boundary layer. The effect of ingesting the boundary layer on the design of the system with a range of design pressure ratios is examined. Also the impact of ingesting the boundary layer on off-design performance is examined. The results show that when examining different design fan pressure ratios it is important to recalculate of the boundary layer mass-average Pt and MN up the height for each inlet height during convergence of the design point for each fan design pressure ratio examined. Correct estimation of off-design performance is dependent on the height of the column of air measured from the aircraft surface immediately prior to any external diffusion that will flow through the fan propulsors. The mass-averaged Pt and MN calculated for this column of air determine the Pt and MN seen by the propulsor inlet. Since the height of this column will change as the amount of air passing through the fans change as the propulsion system is throttled, and since the mass-average Pt and MN varies by height, this capture height must be recalculated as the airflow through the propulsor is varied as the off-design performance point is converged.

Felder, James L.