Engineering topics

Lin, Jeff

Publications and source records attributed to Lin, Jeff.

11 records

NASA NTRS2012

Transient Side Load Analysis of Out-of-Round Film-Cooled Nozzle Extensions

There was interest in understanding the impact of out-of-round nozzle extension on the nozzle side load during transient startup operations. The out-of-round nozzle extension could be the result of asymmetric internal stresses, deformation induced by previous tests, and asymmetric loads induced by hardware attached to the nozzle. The objective of this study was therefore to computationally investigate the effect of out-of-round nozzle extension on the nozzle side loads during an engine startup transient. The rocket engine studied encompasses a regeneratively cooled chamber and nozzle, along with a film cooled nozzle extension. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and transient inlet boundary flow properties derived from an engine system simulation. Six three-dimensional cases were performed with the out-of-roundness achieved by three different degrees of ovalization, elongated on lateral y and z axes: one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The results show that the separation line jump was the primary source of the peak side loads. Comparing to the peak side load of the perfectly round nozzle, the peak side loads increased for the slightly and more ovalized nozzle extensions, and either increased or decreased for the two significantly ovalized nozzle extensions. A theory based on the counteraction of the flow destabilizing effect of an exacerbated asymmetrical flow caused by a lower degree of ovalization, and the flow stabilizing effect of a more symmetrical flow, created also by ovalization, is presented to explain the observations obtained in this effort.

Wang, Ten-See↗

NASA NTRS2010

Transient Three-Dimensional Side Load Analysis of Out-of-Round Film Cooled Nozzles

The objective of this study is to investigate the effect of nozzle out-of-roundness on the transient startup side loads. The out-of-roundness could be the result of asymmetric loads induced by hardware attached to the nozzle, asymmetric internal stresses induced by previous tests and/or deformation, such as creep, from previous tests. The rocket engine studied encompasses a regeneratively cooled thrust chamber and a film cooled nozzle extension with film coolant distributed from a turbine exhaust manifold. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Transient startup computations were performed with the out-of-roundness achieved by four degrees of ovalization of the nozzle: one perfectly round, one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The computed side load physics caused by the nozzle out-of-roundness and its effect on nozzle side load are reported and discussed.

Wang, Ten-See↗

NASA NTRS2010

Transient Three-Dimensional Side Load Analysis of Out-of-Round Film Cooled Nozzles

The objective of this study is to investigate the effect of nozzle out-of-roundness on the transient startup side loads at a high altitude, with an anchored computational methodology. The out-of-roundness could be the result of asymmetric loads induced by hardware attached to the nozzle, asymmetric internal stresses induced by previous tests, and deformation, such as creep, from previous tests. The rocket engine studied encompasses a regeneratively cooled thrust chamber and a film cooled nozzle extension with film coolant distributed from a turbine exhaust manifold. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Transient startup computations were performed with the out-of-roundness achieved by four different degrees of ovalization: one perfectly round, one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The results show that the separation-line-jump is the peak side load physics for the round, slightly our-of-round, and more out-of-round cases, and the peak side load increases as the degree of out-of-roundness increases. For the significantly out-of-round nozzle, however, the peak side load reduces to comparable to that of the round nozzle and the separation line jump is not the peak side load physics. The counter-intuitive result of the significantly out-of-round case is found to be related to a side force reduction mechanism that splits the effect of the separation-line-jump into two parts, not only in the circumferential direction and most importantly in time.

Wang, Ten-See↗

NASA NTRS2006

Accuracy Quantification of the Loci-CHEM Code for Chamber Wall Heat Transfer in a GO2/GH2 Single Element Injector Model Problem

A robust rocket engine combustor design and development process must include tools which can accurately predict the multi-dimensional thermal environments imposed on solid surfaces by the hot combustion products. Currently, empirical methods used in the design process are typically one dimensional and do not adequately account for the heat flux rise rate in the near-injector region of the chamber. Computational Fluid Dynamics holds promise to meet the design tool requirement, but requires accuracy quantification, or validation, before it can be confidently applied in the design process. This effort presents the beginning of such a validation process for the Loci-CHEM CFD code. The model problem examined here is a gaseous oxygen (GO2)/gaseous hydrogen (GH2) shear coaxial single element injector operating at a chamber pressure of 5.42 MPa. The GO2/GH2 propellant combination in this geometry represents one the simplest rocket model problems and is thus foundational to subsequent validation efforts for more complex injectors. Multiple steady state solutions have been produced with Loci-CHEM employing different hybrid grids and two-equation turbulence models. Iterative convergence for each solution is demonstrated via mass conservation, flow variable monitoring at discrete flow field locations as a function of solution iteration and overall residual performance. A baseline hybrid was used and then locally refined to demonstrate grid convergence. Solutions were obtained with three variations of the k-omega turbulence model.

West, Jeff↗

NASA NTRS2006

Accuracy Quantification of the Loci-CHEM Code for Chamber Wall Heat Transfer in a GO2/GH2 Single Element Model Problem

All solutions with Loci-CHEM achieved demonstrated steady state and mesh convergence. Preconditioning had no effect on solution accuracy and typically yields a 3-5times solution speed-up. The SST turbulence model has superior performance, relative to the data in the head end region, for the rise rate and peak heat flux. It was slightly worse than the others in the downstream region where all over-predicted the data by 30-100%.There was systematic mesh refinement in the unstructured volume and structured boundary layer areas produced only minor solution differences. Mesh convergence was achieved. Overall, Loci-CHEM satisfactorily predicts heat flux rise rate and peak heat flux and significantly over predicts the downstream heat flux.

West, Jeff↗

NASA NTRS2006

Use, Assessment, and Improvement of the Loci-CHEM CFD Code for Simulation of Combustion in a Single Element GO2/GH2 Injector and Chamber

This document is a viewgraph presentation of a paper that documents a continuing effort at Marshall Space Flight Center (MSFC) to use, assess, and continually improve CFD codes to the point of material utility in the design of rocket engine combustion devices. This paper describes how the code is presently being used to simulate combustion in a single element combustion chamber with shear coaxial injectors using gaseous oxygen and gaseous hydrogen propellants. The ultimate purpose of the efforts documented is to assess and further improve the Loci-CHEM code and the implementation of it. Single element shear coaxial injectors were tested as part of the Staged Combustion Injector Technology (SCIT) program, where detailed chamber wall heat fluxes were measured. Data was taken over a range of chamber pressures for propellants injected at both ambient and elevated temperatures. Several test cases are simulated as part of the effort to demonstrate use of the Loci-CHEM CFD code and to enable us to make improvements in the code as needed. The simulations presented also include a grid independence study on hybrid grids. Several two-equation eddy viscosity low Reynolds number turbulence models are also evaluated as part of the study. All calculations are presented with a comparison to the experimental data. Weaknesses of the code relative to test data are discussed and continuing efforts to improve the code are presented.

Westra, Douglas G.↗

NASA NTRS2006

Accuracy Quantification of the Loci-CHEM Code for Chamber Wall Heat Fluxes in a G02/GH2 Single Element Injector Model Problem

A robust rocket engine combustor design and development process must include tools which can accurately predict the multi-dimensional thermal environments imposed on solid surfaces by the hot combustion products. Currently, empirical methods used in the design process are typically one dimensional and do not adequately account for the heat flux rise rate in the near-injector region of the chamber. Computational Fluid Dynamics holds promise to meet the design tool requirement, but requires accuracy quantification, or validation, before it can be confidently applied in the design process. This effort presents the beginning of such a validation process for the Loci- CHEM CPD code. The model problem examined here is a gaseous oxygen (GO2)/gaseous hydrogen (GH2) shear coaxial single element injector operating at a chamber pressure of 5.42 MPa. The GO2/GH2 propellant combination in this geometry represents one the simplest rocket model problems and is thus foundational to subsequent validation efforts for more complex injectors. Multiple steady state solutions have been produced with Loci-CHEM employing different hybrid grids and two-equation turbulence models. Iterative convergence for each solution is demonstrated via mass conservation, flow variable monitoring at discrete flow field locations as a function of solution iteration and overall residual performance. A baseline hybrid grid was used and then locally refined to demonstrate grid convergence. Solutions were also obtained with three variations of the k-omega turbulence model.

West, Jeff↗

NASA NTRS2005

CFD Code Validation of Wall Heat Fluxes for a G02/GH2 Single Element Combustor

This paper puts forth the case for the need for improved injector design tools to meet NASA s Vision for Space Exploration goals. Requirements for this improved tool are outlined and discussed. The potential for Computational Fluid Dynamics (CFD) to meet these requirements is noted along with its current shortcomings, especially relative to demonstrated solution accuracy. The concept of verification and validation is introduced as the primary process for building and quantifying the confidence necessary for CFD to be useful as an injector design tool. The verification and validation process is considered in the context of the Marshall Space Flight Center (MSFC) Combustion Devices CFD Simulation Capability Roadmap via the Simulation Readiness Level (SRL) concept. The portion of the validation process which demonstrates the ability of a CFD code to simulate heat fluxes to a rocket engine combustor wall is the focus of the current effort. The FDNS and Loci-CHEM codes are used to simulate a shear coaxial single element G02/GH2 injector experiment. The experiment was conducted a t a chamber pressure of 750 psia using hot propellants from preburners. A measured wall temperature profile is used as a boundary condition to facilitate the calculations. Converged solutions, obtained from both codes by using wall functions with the K-E turbulence model and integrating to the wall using Mentor s baseline turbulence model, are compared to the experimental data. The initial solutions from both codes revealed significant issues with the wall function implementation associated with the recirculation zone between the shear coaxial jet and the chamber wall. The FDNS solution with a corrected implementation shows marked improvement in overall character and level of comparison to the data. With the FDNS code, integrating to the wall with Mentor s baseline turbulence model actually produce a degraded solution when compared to the wall function solution with the K--E model. The Loci-CHEM solution, produced by integrating to the wall with Mentor s baseline turbulence model, matches both the heat flux rise rate in the near injector region and the peak heat flux level very well. However, it moderately over predicts the heat fluxes downstream of the reattachment point. The Loci-CHEM solution achieved by integrating to the wall with Mentor s baseline turbulence model was clearly superior to the other solutions produced in this effort.

Lin, Jeff↗

NASA NTRS2005

Using CFD as a Rocket Injector Design Tool: Recent Progress at Marshall Space Flight Center

New programs are forcing American propulsion system designers into unfamiliar territory. For instance, industry s answer to the cost and reliability goals set out by the Next Generation Launch Technology Program are engine concepts based on the Oxygen- Rich Staged Combustion Cycle. Historical injector design tools are not well suited for this new task. The empirical correlations do not apply directly to the injector concepts associated with the ORSC cycle. These legacy tools focus primarily on performance with environment evaluation a secondary objective. Additionally, the environmental capability of these tools is usually one-dimensional while the actual environments are at least two- and often three-dimensional. CFD has the potential to calculate performance and multi-dimensional environments but its use in the injector design process has been retarded by long solution turnaround times and insufficient demonstrated accuracy. This paper has documented the parallel paths of program support and technology development currently employed at Marshall Space Flight Center in an effort to move CFD to the forefront of injector design. MSFC has established a long-term goal for use of CFD for combustion devices design. The work on injector design is the heart of that vision and the Combustion Devices CFD Simulation Capability Roadmap that focuses the vision. The SRL concept, combining solution fidelity, robustness and accuracy, has been established as a quantitative gauge of current and desired capability. Three examples of current injector analysis for program support have been presented and discussed. These examples are used to establish the current capability at MSFC for these problems. Shortcomings identified from this experience are being used as inputs to the Roadmap process. The SRL evaluation identified lack of demonstrated solution accuracy as a major issue. Accordingly, the MSFC view of code validation and current MSFC-funded validation efforts were discussed in some detail. The objectives of each effort were noted. Issues relative to code validation for injector design were discussed in some detail. The requirement for CFD support during the design of the experiment was noted and discussed in terms of instrumentation placement and experimental rig uncertainty. In conclusion, MSFC has made significant progress in the last two years in advancing CFD toward the goal of application to injector design. A parallel effort focused on program support and technology development via the SCIT Task have enabled the progress.

Tucker, Kevin↗

NASA NTRS2004

CFD Code Validation of Wall HeatFluxes for a GO2/GH2 Single Combustor

Computational Fluid Dynamics (CFD) is becoming an important component of injector design in the rocket industry. Injector designers who use CFD in the design process need to understand the accuracy level of the particular code being used for certain aspects of the design. This paper represents a recent effort to demonstrate the accuracy of two CFD codes to calculate the wall heat flux for a single element injector. The FDNS and Loci- CHEM codes currently in use at NASA Marshall Space Flight Center were evaluated. The test case was a single shear coaxial element with gaseous oxygen and hydrogen in a chamber instrumented with coaxial heat flux gauges on the chamber wall down the axis. The data were taken at Penn State University. Measured wall temperatures were used as boundary conditions for the CFD calculations. Calculations were compared to experimental data at chamber pressures of 300,450 600, and 750 psia. The accuracy level of both codes was assessed.

Lin, Jeff↗

NASA NTRS2003

Using CFD as Rocket Injector Design Tool: Recent Progress at Marshall Space Flight Center

The choice of tools used for injector design is in a transitional phase between exclusive reliance on the empirically based correlations and extensive use of computational fluid dynamics (CFD). The Next Generation Launch Technology (NGLT) Program goals emphasizing lower costs and increased reliability have produced a need to enable CFD as an injector design tool in a shorter time frame. This is the primary objective of the Staged Combustor Injector Technology Task currently under way at Marshall Space Flight Center (MSFC). The documentation of this effort begins with a very brief status of current injector design tools. MSFC's vision for use of CFD as a tool for combustion devices design is stated and discussed with emphasis on the injector. The concept of the Simulation Readiness Level (SRL), comprised of solution fidelity, robustness and accuracy, is introduced and discussed. This quantitative measurement is used to establish the gap between the current state of demonstrated capability and that necessary for regular use in the design process. MSFC's view of the validation process is presented and issues associated with obtaining the necessary data are noted and discussed. Three current experimental efforts aimed at generating validation data are presented. The importance of uncertainty analysis to understand the data quality is also demonstrated. First, a brief status of current injector design tools is provided as context for the current effort. Next, the MSFC vision for using CFD as an injector design tool is stated. A generic CFD-based injector design methodology is also outlined and briefly discussed. Three areas where MSFC is using injector CFD analyses for program support will be discussed. These include the Integrated Powerhead Development (IPD) engine which uses hydrogen and oxygen propellants in a full flow staged combustion (FFSC) cycle and the TR-107 and the RS84 engine both of which use RP-1 and oxygen in an ORSC cycle. Finally, an attempt is made to objectively summarize what progress has been made at MSFC in enabling CFD as an injector design tool.

Tucker, Kevin↗