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DOE OSTI2022

Physics-informed Bayesian machine learning case study: Integral blade rotors

This paper provides a physics-informed Bayesian machine learning (PIBML) description and case study. The PIBML approach applies three physics-based models to establish the initial beliefs before testing to determine the probability of milling stability (or prior). These include: receptance coupling substructure analysis (RCSA) prediction for the tool tip frequency response functions; finite element software prediction of the mechanistic force model coefficients; and a spindle speed-dependent power law model for process damping. Testing was then performed to identify optimal stable machining conditions using an expected improvement in material removal rate criterion. The prior probability of stability was updated using the test results to determine the posterior probability of stability. The test results were compared to the parameter recommendations provided by the endmill manufacturer. A demonstration integral blade rotor was machined at the optimal stable machining conditions for 304 stainless steel and 6061-T6 aluminum. Finally, the disagreement between manufacturer recommendations and milling performance in both materials tested emphasizes the need for broad implementation of PIBML approaches to increase machining productivity and efficiency.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

NASA NTRSDate not supplied

Acoustic and Performance Measurements Obtained in the NASA Langley Small Hover Anechoic Chamber

The emergence of small Unmanned Aircraft Systems (UAS) and Advanced Air Mobility (AAM) vehicles has motivated the need to acoustically characterize the rotors found on these vehicle platforms. Hover chamber tests of small rotors are beneficial in assessing the noise impact of UAS, and potentially larger AAM vehicles. Various experiments have been conducted in the NASA Langley Small Hover Anechoic Chamber (SHAC), formerly known as the Small Anechoic Jet Facility (SAJF), in order to investigate the noise and performance of small rotors. One of these tests was that of an “ideally twisted rotor”, which was designed in order to simplify the theoretical rotor inflow for a target thrust condition in hover. This rotor was fabricated using state-of-the-art rapid prototyping and tested in the SHAC. Aerodynamic load and acoustic data were acquired across a range of rotation rates and rotor collective settings. Both tonal and broadband components were identified in the acoustic data, with broadband noise being a prominent contributor to the overall rotor system noise.

Nicole Pettingill↗

NASA NTRS1982

AGT101 automotive gas turbine system development

The AGT101 automotive gas turbine system consisting of a 74.6 kw regenerated single-shaft gas turbine engine, is presented. The development and testing of the system is reviewed, and results for aerothermodynamic components indicate that compressor and turbine performance levels are within one percent of projected levels. Ceramic turbine rotor development is encouraging with successful cold spin testing of simulated rotors to speeds over 12,043 rad/sec. Spin test results demonstrate that ceramic materials having the required strength levels can be fabricated by net shape techniques to the thick hub cross section, which verifies the feasibility of the single-stage radial rotor in single-shaft engines.

Rackley, R. A.↗

NASA NTRS1991

A comparison of the analytical and experimental performance of the solid version of a cooled radial turbine

An evaluation of the aerodynamic performance of the solid version of an Allison-designed cooled radial turbine was conducted at NASA Lewis' Warm Turbine Test Facility. The resulting pressure and temperature measurements are used to calculate vane, rotor, and overall stage performance. These performance results are then compared to the analytical results obtained by using NASA's MTSB (MERIDL-TSONIC-BLAYER) code.

Tirres, Lizet↗

NASA NTRS1984

An overview of the NASA rotary engine research program

A brief overview and technical highlights of the research efforts and studies on rotary engines over the last several years at the NASA Lewis Research Center are presented. The test results obtained from turbocharged rotary engines and preliminary results from a high performance single rotor engine were discussed. Combustion modeling studies of the rotary engine and the use of a Laser Doppler Velocimeter to confirm the studies were examined. An in-house program in which a turbocharged rotary engine was installed in a Cessna Skymaster for ground test studies was reviewed. Details are presented on single rotor stratified charge rotary engine research efforts, both in-house and on contract.

Meng, P. R.↗

NASA NTRS2014

Investigation of Active Flow Control to Improve Aerodynamic Performance of Oscillating Wings

The objective of this effort is to design a promising active flow control concept on an oscillating airfoil for on-blade alleviation of dynamic stall. The concept must be designed for a range of representative Mach numbers (0.2 to 0.5) and representative reduced frequency characteristics of a full-scale rotorcraft. Specifications for a sweeping-jet actuator to mitigate the detrimental effects of retreating blade stall experienced by edgewise rotors in forward flight has been performed. Wind tunnel modifications have been designed to accommodate a 5x6 test section in the Oran W. Nicks Low Speed Wind Tunnel at Texas A&M University that will allow the tunnel to achieve Mach 0.5. The flow control design is for a two-dimensional oscillating VR-7 blade section with a 15- inch chord at rotor-relevant flow conditions covering the range of reduced frequencies from 0.0 to 0.15 and Mach numbers from 0.2 to 0.5. A Computational Fluid Dynamics (CFD) analysis has been performed to influence the placement of the flow control devices for optimal effectiveness.

Narducci, Robert P.↗

NASA NTRS2019

Acoustic Testing of the Tiltrotor Test Rig in the National Full-Scale Aerodynamics Complex 40- by 80-Foot Wind Tunnel

The Tiltrotor Test Rig (TTR) was tested in the National Full-Scale Aerodynamics Complex (NFAC) 40- by 80-Foot Wind Tunnel from 2017 to 2018. The primary goal of the test was to understand the operational capabilities of the TTR, while also acquiring research data, including acoustic data. Four microphones were placed around the TTR: two on the wind tunnel floor and two on struts. Acoustic measurements of the TTR rotor were acquired to 1) understand the acoustic testing capabilities of the TTR in the NFAC 40- by 80-FootWind Tunnel, 2) compare to previous XV-15 rotor acoustic data acquired in the NFAC 80- by 120-Foot Wind Tunnel, and 3) provide data for future validation studies. A data quality study revealed that the NFAC 40- by 80-Foot Wind Tunnel is an adequate acoustic environment to test the TTR rotor. For a given thrust and advance ratio, a shaft angle sweep was performed and acoustic measurements were compared against 1996 and 1999 XV-15 data in the NFAC 80- by 120-Foot Wind Tunnel; differences between the three tests are discussed.

40- by 80-FootWind Tunnel↗

NASA NTRS1992

Development of an analytical method to predict helicopter main rotor performance in icing conditions

Historically, certification of a helicopter for flight into known icing conditions was a problem. This is because of the current emphasis on flight testing for verification of system performance. Flight testing in icing conditions is difficult because, in addition to being dangerous and expensive, many times conditions which are sought after cannot be readily found in nature. The problem is compounded for helicopters because of their small range in comparison to many fixed wing aircraft. Thus, helicopters are forced to wait for conditions to occur in a certain region rather than seeking them out. These and other drawbacks to flight testing prompted extreme interest in developing validated alternatives to flight testing. One such alternative is theoretical prediction. It is desirable to have the ability to predict how a helicopter will perform when subjected to icing conditions. Herein, calculations are restricted to the main rotor, and are illustrated. The computational tool used to obtain performance is the lifting line analysis of B65. B65 incorporates experimental data into data banks in order to determine the section lift, drag, and moment characteristics of various airfoils at different Mach numbers and angles of attack. The local flow angle is calculated at user specified radial locations. This flow angle, along with the local Mach number is then cross referenced with the airfoil tables to obtain the local section characteristics. The local characteristics are then integrated together to obtain the entire rotor attributes. Once the clean performance is known, characterization of the type and shape of ice which accretes on the rotor blades is obtained using the analysis of LEWICE. The Interactive Boundary Layer (IBL) method then calculates the 2-D characteristics of the iced airfoil for input into the airfoil data bank of B65. Calculations are restricted to natural ice shedding and it is assumed that no de-icing takes place. Once the new lift, drag, and moment characteristics are known for the entire blade radius, this information is fed into B65, where the iced performance is then calculated.

Britton, Randall K.↗

NASA NTRS2015

Case Studies for the Statistical Design of Experiments Applied to Powered Rotor Wind Tunnel Tests

The application of statistical Design of Experiments (DOE) to helicopter wind tunnel testing was explored during two powered rotor wind tunnel entries during the summers of 2012 and 2013. These tests were performed jointly by the U.S. Army Aviation Development Directorate Joint Research Program Office and NASA Rotary Wing Project Office, currently the Revolutionary Vertical Lift Project, at NASA Langley Research Center located in Hampton, Virginia. Both entries were conducted in the 14- by 22-Foot Subsonic Tunnel with a small portion of the overall tests devoted to developing case studies of the DOE approach as it applies to powered rotor testing. A 16-47 times reduction in the number of data points required was estimated by comparing the DOE approach to conventional testing methods. The average error for the DOE surface response model for the OH-58F test was 0.95 percent and 4.06 percent for drag and download, respectively. The DOE surface response model of the Active Flow Control test captured the drag within 4.1 percent of measured data. The operational differences between the two testing approaches are identified, but did not prevent the safe operation of the powered rotor model throughout the DOE test matrices.

Overmeyer, Austin D.↗

NASA NTRS1944

Effect of Helicopter Performance of Modifications in Profile-Drag Characteristics of Rotor-Blade Airfoil Sections

Rough conventional, smooth conventional, and laminar-flow or low-drag sections were tested. The items covered are rotor thrust for fixed power in hovering, range and endurance at cruising speed, and power required at high-forward speed. Calculations indicated that a smooth conventional section gives marked performance gains. Smaller gains are obtainable by using a low-drag section. At high speeds or loads the low-drag section is inferior to the smooth conventional section.

Gustafson, F.B.↗

NASA NTRS1985

Free-Tip Rotor Wind Tunnel Test Results

A new rotor blade tip design called the free-tip has been proposed as a means to improve forward flight performance characteristics and reduce oscillatory loads. The free-tip design incorporates a tip that is free to pitch independently of the rest of the blade. Pitching about an axis forward of the quarter-chord, the tip weathervanes into its local wind, thus reducing angle of attack perturbations and the resulting oscillatory lift loadings. A nearly constant nose-up pitching moment is applied mechanically to the tip so that the tip, to maintain pitching equilibrium, produces nearly steady positive lift around the azimuth. A wind-tunnel test of a small-scale, 5.1 m diameter model rotor was conducted to obtain comparative forward flight performance and oscillatory loads data with the tips free and fixed. The free-up was shown to reduce power in trimmed flight over a wide range of advance ratio and thrust; at an advance ratio of 0.3 and C(sub L)/sigma of 0.08 the reduction is 12%. Oscillatory flapwise bending-moments and oscillatory pitch link loads are also reduced, but the oscillatory in-plane bending moments increase.

Stroub, Robert H.↗

NASA NTRS1975

Study of noise sources in a subsonic fan using measured blade pressures and acoustic theory

Sources of noise in a 1.4 m (4.6 ft) diameter subsonic tip speed propulsive fan running statically outdoors are studied using a combination of techniques. Signals measured with pressure transducers on a rotor blade are plotted in a format showing the space-time history of inlet distortion. Study of these plots visually and with statistical correlation analysis confirms that the inlet flow contains long, thin eddies of turbulence. Turbulence generated in the boundary layer of the shroud upstream of the rotor tips was not found to be an important noise source. Fan noise is diagnosed by computing narrowband spectra of rotor and stator sound power and comparing these with measured sound power spectra. Rotor noise is computed from spectra of the measured blade pressures and stator noise is computed using the author's stator noise theory. It is concluded that the rotor and stator sources contribute about equally at frequencies in the vicinity of the first three harmonics of blade passing frequency. At higher frequencies, the stator contribution diminishes rapidly and the rotor/inlet turbulence mechanism dominates. Two parametric studies are performed by using the rotor noise calculation procedure which was correlated with test. In the first study, the effects on noise spectrum and directivity are calculated for changes in turbulence properties, rotational Mach number, number of blades, and stagger angle. In the second study the influences of design tip speed and blade number on noise are evaluated.

Hanson, D. B.↗

NASA NTRS1978

Observations on the dynamic stall characteristics of advanced helicopter rotor airfoils

A significant amount of research was devoted to understanding the mechanism of dynamic stall delay as applicable to the flow environment of a helicopter rotor in forward flight. One aspect of such research deals with the unsteady characteristics of two-dimensional airfoil sections over a Mach number range from 0.3 to 9.6, since such characteristics can be meaningfully related to rotor performance and loads. This paper summarizes the results of several oscillatory tests carried out on conventional, transonic and BLC-equipped airfoils.

Dadone, L.↗

NASA NTRS1980

A flight investigation of blade section aerodynamics for a helicopter main rotor having NLR-1T airfoil sections

A flight investigation was conducted using a teetering-rotor AH-1G helicopter to obtain data on the aerodynamic behavior of main-rotor blades with the NLR-1T blade section. The data system recorded blade-section aerodynamic pressures at 90 percent rotor radius as well as vehicle flight state, performance, and loads. The test envelope included hover, forward flight, and collective-fixed maneuvers. Data were obtained on apparent blade-vortex interactions, negative lift on the advancing blade in high-speed flight and wake interactions in hover. In many cases, good agreement was achieved between chordwise pressure distributions predicted by airfoil theory and flight data with no apparent indications of blade-vortex interactions.

Morris, C. E. K., Jr.↗

NASA NTRS2016

Coaxial Rotor Flow Phenomena in Forward Flight

Coaxial rotors are nding use in advanced rotorcraft concepts. Combined with lift offset rotor technology, they offer a solution to the problems of dynamic stall and re-verse ow that often limit single rotor edgewise forward ight speeds. Lower tip speed means reduced high-speed impulsive noise. The need for an anti-torque tail rotor is eliminated, a major boon during operation in conned areas. However, the operation of two counter-rotating ro-tors in close proximity generates many possibilities for aerodynamic interactions between rotor blades, blades and vortices, and between vortices. The parameter de-sign space is very large, and requires efcient computations as well as basic experiments to explore important physics to determine performance, loads, and acoustics. Computations are done on the classic HarringtonDingeldein rotor test case from the 1950s using the ROTUNS Navier Stokes code. Two regimes are explored: very low advance ratio as a perturbation from hover, and high advance ratio. Flow eld properties from RotUNS are used with 2-D OVERFLOW computations to capture blade crossing effects including those of higher subsonic Mach numbers. Bladeblade and bladevortex intersection events are captured using a MatLab-based predictor.

Flow Phenomena↗

NASA NTRS2020

An Over-the-Rotor Liner Investigation with Configurations Enabled by Additive Manufacturing

This paper presents the results of an investigation of over-the-rotor acoustic liner configurations enabled by additive manufacturing. NASA Langley and Glenn Research Centers have collaborated on the usage of acoustic liners in the turbofan aircraft engine nacelle wall at or very near the tip of the rotor. These liners absorb rotor-alone and rotor-stator interaction noise and, due to their proximity to the rotor tips, serve as a pressure release to inhibit the amount of generated noise. Initial tests with a metallic foam liner demonstrated good acoustic results, but there was concern regarding the durability of the material. NASA then decided to explore configurations enabled by additive manufacturing via tests in the NASA Langley Normal Incidence Tube. Measured data for uniform-depth and variable-depth cores with narrow and wide chambers were compared with predictions via the NASA Langley impedance prediction model. As these configurations were intended for eventual use in an over-the-rotor application, it was necessary to add facesheets to the wide-chamber cores to avoid deleterious flow effects caused by open cavities. A number of facesheets were tested in combination with each wide-chamber core. Finally, it has been shown that grooves near the rotor tips cause an improvement in aerodynamic performance. A small set of grooves were fabricated such that they could be combined with the wide-chamber configurations. The results of these tests were subsequently used to guide designs for further testing in higher technology readiness level test rigs at NASA Glenn Research Center.

acoustic↗

NASA NTRS1989

Design of an active helicopter control experiment at the Princeton Rotorcraft Dynamics Laboratory

In an effort to develop an active control technique for reducing helicopter vibrations stemming from the main rotor system, a helicopter model was designed and tested at the Princeton Rotorcraft Dynamics Laboratory (PRDL). A description of this facility, including its latest data acquisition upgrade, are given. The design procedures for the test model and its Froude scaled rotor system are also discussed. The approach for performing active control is based on the idea that rotor states can be identified by instrumenting the rotor blades. Using this knowledge, Individual Blade Control (IBC) or Higher Harmonic Control (HHC) pitch input commands may be used to impact on rotor dynamics in such a way as to reduce rotor vibrations. Discussed here is an instrumentation configuration utilizing miniature accelerometers to measure and estimate first and second out-of-plane bending mode positions and velocities. To verify this technique, the model was tested, and resulting data were used to estimate rotor states as well as flap and bending coefficients, procedures for which are discussed. Overall results show that a cost- and time-effective method for building a useful test model for future active control experiments was developed. With some fine-tuning or slight adjustments in sensor configuration, prospects for obtaining good state estimates look promising.

Marraffa, Andrew M.↗

NASA NTRS1948

Full-Scale Investigation of Aerodynamic Characteristics of a Typical Single-Sotor Helicopter in Forward Flight

As part of the general helicopter research program being undertaken by the National Advisory Committee for Aeronautics to provide designers with fundamental rotor information, the forward-flight performance characteristics of a typical single-rotor helicopter, which is equipped with main and tail rotors, have been investigated in the Langley full-scale tunnel. The test conditions included operation of tip-speed ratios from 0.10 to 0.27 and at thrust coefficients from 0.0030 to 0.0060. Results obtained with production rotor were compared with those for an alternate set of blades having closer rib spacing and a smoother and more accurately contoured surface in order to evaluate the performance gains that are available by the use of rotor blades having an improved surface condition. The wind tunnel results are shown to be in fair agreement with the results of both flight tests and theoretical predictions.

Dingeldein, Richard C↗