Numerical modeling for primary atomization of liquid jets
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Chuech, S. G.↗
Engineering topics
Singhal, A. K.
Publications and source records attributed to Singhal, A. K..
Conjugate (solid/fluid) computational fluid dynamics analysis of the space shuttle solid rocket motor nozzle/case and case field joints
Three-dimensional, conjugate (solid/fluid) heat transfer analyses of new designs of the Solid Rocket Motor (SRM) nozzle/case and case field joints are described. The main focus was to predict the consequences of multiple rips (or debonds) in the ambient cure adhesive packed between the nozzle/case joint surfaces and the bond line between the mating field joint surfaces. The models calculate the transient temperature responses of the various materials neighboring postulated flow/leakpaths into, past, and out from the nozzle/case primary O-ring cavity and case field capture O-ring cavity. These results were used to assess if the design was failsafe (i.e., no potential O-ring erosion) and reusable (i.e., no excessive steel temperatures). The models are adaptions and extensions of the general purpose PHOENICS fluid dynamics code. A non-orthogonal coordinate system was employed and 11,592 control cells for the nozzle/case and 20,088 for the case field joints are used with non-uniform distribution. Physical properties of both fluid and solids are temperature dependent. A number of parametric studies were run for both joints with results showing temperature limits for reuse for the steel case on the nozzle joint being exceeded while the steel case temperatures for the field joint were not. O-ring temperatures for the nozzle joint predicted erosion while for the field joint they did not.
Doran, D.↗
Numerical modeling for primary atomization of liquid jets
In the proposed numerical model for primary atomization, surface-wave dispersion equations are solved in conjunction with the jet-embedding technique of solving mean flow equations of a liquid jet. Linear and approximate nonlinear models have been considered. In each case, the dispersion equation is solved over the whole wavelength spectrum to predict drop sizes, frequency, and liquid-mass breakup rates without using any empirical constants. The present model has been applied to several low-speed and high-speed jets. For the high-speed case (the LOX/H2 coaxial injector of the Space Shuttle Main Engine Preburner), predicted drop sizes and liquid breakup rates are in good agreement with the results of the CICM code, which have been calibrated against measured data.
Przekwas, A. J.↗
A fixed grid numerical methodology for phase change problems involving a moving heat source
A numerical method for solving phase change problems involving a moving heat source is presented and illustrated by a two-dimensional example. The method uses a fixed grid and does not require the implementation of the Stefan condition at the solid-liquid interface; the procedure can thus be easily implemented using existing fixed grid codes. The problem considered as an example involves natural convection flow in the molten metal during tungsten inert gas welding.
Prakash, C.↗
Liquid oxygen sloshing in Space Shuttle External Tank
This paper describes a numerical simulation of the hydrodynamics within the liquid oxygen tank of the Space Shuttle External Tank during liftoff. Before liftoff, the tank is filled with liquid oxygen (LOX) to approximately 97 percent with the other 3 percent containing gaseous oxygen (GOX) and helium. During liftoff, LOX is drained from the bottom of the tank, and GOX is pumped into the tank's ullage volume. There is a delay of several seconds before the GOX reaches the tank which causes the ullage pressure to decrease for several seconds after liftoff; this pressure 'slump' is a common phenomenon in rocket propulsion. When four slosh baffles were removed from the tank, the ullage gas pressure dropped more rapidly than in all previous flights. The purpose of this analysis was to determine whether the removal of the baffles could have caused the increased pressure 'slump' by changing the LOX surface dynamics. The results show that the LOX surface undergoes very high vertical accelerations (up to 5 g) and, therefore, splashing almost certainly occurs. The number of baffles does not affect the surface if the structural motion is assumed; but, the number of baffles may affect the structural motion of the tank.
Kannapel, M. D.↗
Discrete element weld model, phase 2
A numerical method was developed for analyzing the tungsten inert gas (TIG) welding process. The phenomena being modeled include melting under the arc and the flow in the melt under the action of buoyancy, surface tension, and electromagnetic forces. The latter entails the calculation of the electric potential and the computation of electric current and magnetic field therefrom. Melting may occur at a single temperature or over a temperature range, and the electrical and thermal conductivities can be a function of temperature. Results of sample calculations are presented and discussed at length. A major research contribution has been the development of numerical methodology for the calculation of phase change problems in a fixed grid framework. The model has been implemented on CHAM's general purpose computer code PHOENICS. The inputs to the computer model include: geometric parameters, material properties, and weld process parameters.
Prakash, C.↗
Three-dimensional analysis of liquid oxygen sloshing in Space Shuttle external tank
A three-dimensional numerical simulation has been performed in order to investigate the hydrodynamics within the liquid oxygen tank of the Space Shuttle external tank after liftoff. The results indicate that the LOX surface undergoes very high vertical accelerations (up to 5 g) and that splashing almost certainly occurs. Although the number of slosh baffles is not found to affect the surface, it is noted that the number of baffles may affect the structural motion of the tank. Surface accelerations are similar to those observed in previous two-dimensional simulations.
Kannapel, M. D.↗
Thermal environment around the Space Shuttle with hot-gas jets for ice suppression
To prevent prelaunch ice formation on the external tank of the Space Shuttle, the final selected approach is to heat the surrounding air with vertical hot-gas jets located at the launch pad. This approach was considerably more cost-effective than other ice suppression methods considered, although its feasibility was not easily discernible due to the complex flowfield interactions. This paper describes how the use of vertical jets was first evaluated with the aid of a computational fluid dynamics (CFD) technique. An existing general-purpose CFD program (PHOENICS) was used to predict the thermal environment around the Shuttle under various jet configurations and wind conditions. The program accounts for effects of buoyancy, turbulence, and structural obstructions in the flowfield. The computed results showed physically plausible and consistent trends. The wind wake effects were found to be significant, and normally resulted in higher temperatures on the leeward side of the tank. High wind conditions were found to be more severe than calm wind conditions. The use of four jets with two different temperatures was identified as a promising option in which the air temperatures were raised sufficiently to prevent ice formation on the external tank, without excessive increase in Orbiter surface temperature. The use of the numerical model also facilitated the selection of test configurations and a test matrix for verifying the approach. Selected results of an experimental verification (by using a 2 percent scale model in a wind tunnel) are also presented.
Singhal, A. K.↗
Computational simulation of liquid rocket injector anomalies
A computer model has been developed to analyze the three-dimensional two-phase reactive flows in liquid fueled rocket combustors. The model is designed to study the influence of liquid propellant injection nonuniformities on the flow pattern, combustion and heat transfer within the combustor. The Eulerian-Lagrangian approach for simulating polidisperse spray flow, evaporation and combustion has been used. Full coupling between the phases is accounted for. A nonorthogonal, body fitted coordinate system along with a conservative control volume formulation is employed. The physical models built into the model include a kappa-epsilon turbulence model, a two-step chemical reaction, and the six-flux radiation model. Semiempirical models are used to describe all interphase coupling terms as well as chemical reaction rates. The purpose of this study was to demonstrate an analytical capability to predict the effects of reactant injection nonuniformities (injection anomalies) on combustion and heat transfer within the rocket combustion chamber. The results show promising application of the model to comprehensive modeling of liquid propellant rocket engines.
Przekwas, A. J.↗
Thermofluid analysis of the SSME preburner using a gas-gas diffusion model for oxygen and hydrogen combustion at supercritical pressures
The paper discusses the thermofluid analysis of the Space Shuttle Main Engine (SSME) fuelside preburner. The governing equations have been solved numerically to predict flow, heat transfer, mixing, and combustion. A two-fluid approach is adopted in which oxygen is regarded as one fluid and hydrogen is regarded as the other fluid. The chemical kinetics is assumed to be very fast so that combustion is primarily controlled by the rate of mixing between oxygen and hydrogen. The preburner pressure is much greater than the critical pressures of oxygen and hydrogen; hence, a gas-gas diffusion model (rather than an evaporation model) has been developed to compute the rate of interphase mixing. Empirical correlations have been incorporated to account for the effect of slip on the interphase exchange. A sensitivity study has been performed with various model parameters. It is observed that the model can predict possibility of incomplete combustion and local regions of high temperatures under steady operating conditions. Some of these anomalies have been observed in actual tests, and the numerical model is useful for understanding possible causes and remedies. At least some measurements are needed for quantitative verification of the model.
Prakash, C.↗
Numerical analysis of flow in the hot gas manifold of the Space Shuttle main engine
This paper presents a numerical model and results of analyses carried out to characterize the flow through the two duct configuration of the Hot Gas Manifold of the Space Shuttle Main Engine. Three dimensional computations have been performed for a half-scale air test model using a nonorthogonal body-fitted coordinate system. The calculation domain is extended from the inlet of the turnaround duct to the exit of the transfer duct. Three test cases, one for laminar flow and two for turbulent flow, have been considered. For turbulent flows, constant eddy viscosity and the k-epsilon model of turbulence were employed. As expected, laminar flow calculation predicts much larger pressure drop than turbulent flow cases. The turbulent flow results are in good agreement with the available flow-visualization data. This study and experimental data indicate that the two-transfer duct design will significantly improve the flow distribution in the Hot Gas Manifold and thereby enhance the overall performance of the SSME.
Owens, S. F.↗
Analysis of physical-chemical processes governing SSME internal fluid flows
The basic issues concerning the physical chemical processes of the Space Shuttle Main Engine are discussed. The objectives being to supply the general purpose CFD code PHOENICS and the associated interactive graphics package - GRAFFIC; to demonstrate code usage on SSME related problems; to perform computations and analyses of problems relevant to current and future SSME's; and to participate in the development of new physical models of various processes present in SSME components. These objectives are discussed in detail.
Singhal, A. K.↗
Analysis of physical-chemical processes governing SSME internal fluid flows
The efforts to adapt CHAM's computational fluid dynamics code, PHOENICS, to the analysis of flow within the high pressure fuel turbopump (HPFTP) aft-platform seal cavity of the SSME are summarized. In particular, the special purpose PHOENICS satellite and ground station specifically formulated for this application are listed and described, and the preliminary results of the first part two-dimensional analyses are presented and discussed. Planned three-dimensional analyses are also briefly outlined. To further understand the mixing and combustion processes in the SSME fuelside preburners, a single oxygen-hydrogen jet element was investigated.
Singhal, A. K.↗
Numerical analysis of flow and heat transfer in the VAFB LOX storage Dewar tank
The present report describes numerical simulation of three-dimensional transient distributions of velocity and temperature of liquid oxygen (LOX) in the LOX Dewar tank of Vendenberg Air Force Base (VAFB). The present analyses cover the replenish time period only. Four test cases have been considered. For all four cases, the input boundary conditions are comprised of LOX facility heat loads, drain flow rates, recirculation flow rates and dewar heating. All the quantities are prescribed as functions of time. The first two test cases considered sensitivity of results to the computational grid. In Case 3, system heat load was changed, while in Case 4, a lower LOX level was specified. Cases 1 and 2 showed that the temperatures were not sensitive to the grid refinement. This provided a basic check on the numerical model. Cases 3 and 4 showed that the thermal boundary layer motion near the tank surface becomes more significant at the late time, e.g., 5 1/2 hours from replenish start. Comparison between results of Cases 3 and 4 showed, as expected, that the smaller initial LOX volume given in Case 4, results in higher temperature level. All calculated velocity and temperature distributions were found to be plausible.
Tam, L. T.↗
SSME thrust chamber simulation using Navier-Stokes equations
The capability of the PHOENICS fluid dynamics code in predicting two-dimensional, compressible, and reacting flow in the combustion chamber and nozzle of the space shuttle main engine (SSME) was evaluated. A non-orthogonal body fitted coordinate system was used to represent the nozzle geometry. The Navier-Stokes equations were solved for the entire nozzle with a turbulence model. The wall boundary conditions were calculated based on the wall functions which account for pressure gradients. Results of the demonstration test case reveal all expected features of the transonic nozzle flows. Of particular interest are the locations of normal and barrel shocks, and regions of highest temperature gradients. Calculated performance (global) parameters such as thrust chamber flow rate, thrust, and specific impulse are also in good agreement with available data.
Przekwas, A. J.↗
Rocket injector anomalies study. Volume 1: Description of the mathematical model and solution procedure
The capability of simulating three dimensional two phase reactive flows with combustion in the liquid fuelled rocket engines is demonstrated. This was accomplished by modifying an existing three dimensional computer program (REFLAN3D) with Eulerian Lagrangian approach to simulate two phase spray flow, evaporation and combustion. The modified code is referred as REFLAN3D-SPRAY. The mathematical formulation of the fluid flow, heat transfer, combustion and two phase flow interaction of the numerical solution procedure, boundary conditions and their treatment are described.
Przekwas, A. J.↗
Rocket injector anomalies study. Volume 2: Results of parametric studies
The employment of a existing computer program to simulate three dimensional two phase gas spray flows in liquid propellant rocket engines. This was accomplished by modification of an existing three dimensional computer program (REFLAN3D) with Euler/Lagrange approach for simulating two phase spray flow, evaporation and combustion. The modified code is referred to as REFLAN3D-SPRAY. Computational studies of the model rocket engine combustion chamber are presented. The parametric studies of the two phase flow and combustion shows qualitatively correct response for variations in geometrical and physical parameters. The injection nonuniformity test with blocked central fuel injector holes shows significant changes in the central flame core and minor influence on the wall heat transfer fluxes.
Przekwas, A. J.↗
Analysis of physical-chemical processes governing SSME internal fluid flows
In order to aid the development of current and future SSME type engines, it is necessary to improve the understanding of basic issues related with physical-chemical processes of SSME internal flows. Accomplishments under each of the following specific objectives are described herein: (1) supplying a state-of-the-art CFD code and graphics package; (2) demonstrating code usage on SSME-related problems to NASA MSFC personnel; and (3) performance computations and analysis of problems relevant to current and future SSME's.
Singhal, A. K.↗