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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 325 records · Page 18

Gear Mesh Loss-of-Lubrication Experiments and Analytical Simulation

An experimental program to determine the loss-of-lubrication (LOL) characteristics of spur gears in an aerospace simulation test facility has been completed. Tests were conducted using two different emergency lubricant types: (1) an oil mist system (two different misted lubricants) and (2) a grease injection system (two different grease types). Tests were conducted using a NASA Glenn test facility normally used for conducting contact fatigue. Tests were run at rotational speeds up to 10000 rpm using two different gear designs and two different gear materials. For the tests conducted using an air-oil misting system, a minimum lubricant injection rate was determined to permit the gear mesh to operate without failure for at least 1 hr. The tests allowed an elevated steady state temperature to be established. A basic 2-D heat transfer simulation has been developed to investigate temperatures of a simulated gear as a function of frictional behavior. The friction (heat generation source) between the meshing surfaces is related to the position in the meshing cycle, the load applied, and the amount of lubricant in the contact. Experimental conditions will be compared to those from the 2-D simulation.

Handschuh, Robert F.↗

Merging for Particle-Mesh Complex Particle Kinetic Modeling of the Multiple Plasma Beams

We suggest a merging procedure for the Particle-Mesh Complex Particle Kinetic (PMCPK) method in case of inter-penetrating flow (multiple plasma beams). We examine the standard particle-in-cell (PIC) and the PMCPK methods in the case of particle acceleration by shock surfing for a wide range of the control numerical parameters. The plasma dynamics is described by a hybrid (particle-ion-fluid-electron) model. Note that one may need a mesh if modeling with the computation of an electromagnetic field. Our calculations use specified, time-independent electromagnetic fields for the shock, rather than self-consistently generated fields. While a particle-mesh method is a well-verified approach, the CPK method seems to be a good approach for multiscale modeling that includes multiple regions with various particle/fluid plasma behavior. However, the CPK method is still in need of a verification for studying the basic plasma phenomena: particle heating and acceleration by collisionless shocks, magnetic field reconnection, beam dynamics, etc.

Lipatov, Alexander S.↗

Discrete Surface Evolution and Mesh Deformation for Aircraft Icing Applications

Robust, automated mesh generation for problems with deforming geometries, such as ice accreting on aerodynamic surfaces, remains a challenging problem. Here we describe a technique to deform a discrete surface as it evolves due to the accretion of ice. The surface evolution algorithm is based on a smoothed, face-offsetting approach. We also describe a fast algebraic technique to propagate the computed surface deformations into the surrounding volume mesh while maintaining geometric mesh quality. Preliminary results presented here demonstrate the ecacy of the approach for a sphere with a prescribed accretion rate, a rime ice accretion, and a more complex glaze ice accretion.

ice accretion↗

The Space-Time Conservative Schemes for Large-Scale, Time-Accurate Flow Simulations with Tetrahedral Meshes

Despite decades of development of unstructured mesh methods, high-fidelity time-accurate simulations are still predominantly carried out on structured, or unstructured hexahedral meshes by using high-order finite-difference, weighted essentially non-oscillatory (WENO), or hybrid schemes formed by their combinations. In this work, the space-time conservation element solution element (CESE) method is used to simulate several flow problems including supersonic jet/shock interaction and its impact on launch vehicle acoustics, and direct numerical simulations of turbulent flows using tetrahedral meshes. This paper provides a status report for the continuing development of the space-time conservation element solution element (CESE) numerical and software framework under the Revolutionary Computational Aerosciences (RCA) project. Solution accuracy and large-scale parallel performance of the numerical framework is assessed with the goal of providing a viable paradigm for future high-fidelity flow physics simulations.

Venkatachari, Balaji Shankar↗

Automated Generation of Finite-Element Meshes for Aircraft Conceptual Design

This paper presents a novel approach for automated generation of fully connected finite-element meshes for all internal structural components and skins of a given wing-body geometry model, controlled by a few conceptual-level structural layout parameters. Internal structural components include spars, ribs, frames, and bulkheads. Structural layout parameters include spar/rib locations in wing chordwise/spanwise direction and frame/bulkhead locations in longitudinal direction. A simple shell thickness optimization problem with two load conditions is used to verify versatility and robustness of the automated meshing process. The automation process is implemented in ModelCenter starting from an OpenVSP geometry and ending with a NASTRAN 200 solution. One subsonic configuration and one supersonic configuration are used for numerical verification. Two different structural layouts are constructed for each configuration and five finite-element meshes of different sizes are generated for each layout. The paper includes various comparisons of solutions of 20 thickness optimization problems, as well as discussions on how the optimal solutions are affected by the stress constraint bound and the initial guess of design variables.

Li, Wu↗

Baseline Experimental Results on the Effect of Oil Temperature on Shrouded Meshed Spur Gear Windage Power Loss

Rotorcraft gearbox efficiencies are reduced at increased surface speeds due to viscous and impingement drag on the gear teeth. This windage power loss can affect overall mission range, payload, and frequency of transmission maintenance. Experimental and analytical studies on shrouding for single gears have shown it be potentially effective in mitigating windage power loss. Efficiency studies on unshrouded meshed gears have shown the effect of speed, oil viscosity, temperature, load, lubrication scheme, etc. on gear windage power loss. The open literature does not cite data on shrouded meshed spur gears. Gear windage power loss test results are presented on shrouded meshed spur gears at elevated oil inlet temperatures and constant oil pressure both with and without shrouding. Shroud effectiveness is compared at four oil inlet temperatures. The results are compared to the available literature and follow-up work is outlined.

windage↗

Baseline Experimental Results on the Effect of Oil Temperature on Shrouded Meshed Spur Gear Windage Power Loss

Rotorcraft gearbox efficiencies are reduced at increased surface speeds due to viscous and impingement drag on the gear teeth. This windage power loss can affect overall mission range, payload, and frequency of transmission maintenance. Experimental and analytical studies on shrouding for single gears have shown it to be potentially effective in mitigating windage power loss. Efficiency studies on unshrouded meshed gears have shown the effect of speed, oil viscosity, temperature, load, lubrication scheme, etc. on gear windage power loss. The open literature does not contain experimental test data on shrouded meshed spur gears. Gear windage power loss test results are presented on shrouded meshed spur gears at elevated oil inlet temperatures and constant oil pressure both with and without shrouding. Shroud effectiveness is compared at four oil inlet temperatures. The results are compared to the available literature and follow-up work is outlined.

gear↗

The Jetting Phenomena in Meshed Spur Gears

Rotorcraft gearbox transmissions are required to efficiently transfer power from the turbine engine to the main and tail rotor blades. Losses in transmission efficiency impact mission payload and aircraft range. These systems are expected to deliver high power with high gear pitch line velocities. More recently, shrouding has been employed to reduce windage power losses associated with the high gear rotational speeds. However, recent experimental results from tests conducted by the authors show the negative impact of close clearance shrouds on windage power loss, particularly at the meshed region where flow is ejected, or jetted, from the collapsing tooth spaces. A literature review was conducted to gain further insight into the phenomenon of gear mesh jetting and strategies to mitigate and control the associated losses. An analysis was conducted on windage losses in the mesh region. Test results are given for a modified shroud configuration. Finally, a discussion on observed trends follows with suggestions on future research.

windage↗

The Jetting Phenomena in Meshed Spur Gears

Rotorcraft gearbox transmissions are required to efficiently transfer power from the turbine engine to the main and tail rotor blades. Losses in transmission efficiency impact mission payload and aircraft range. These systems are expected to deliver high power with high gear pitch line velocities. More recently, shrouding has been employed to reduce windage power losses associated with the high gear rotational speeds. However, recent experimental results from tests conducted by the authors show the negative impact of close clearance shrouds on windage power loss, particularly at the meshed region where flow is ejected, or jetted, from the collapsing tooth spaces. A literature review was conducted to gain further insight into the phenomenon of gear mesh jetting and strategies to mitigate and control the associated losses. An analysis was conducted on windage losses in the mesh region. Test results are given for a modified shroud configuration. Finally, a discussion on observed trends follows with suggestions on future research.

Gear↗

Applications of Parallel-Element, Embedded Mesh-Cap Acoustic Liner Concepts

This study explores progress achieved with 2DOF, 3DOF, and MDOF acoustic liners constructed with mesh caps embedded within a honeycomb core. These liner configurations offer potential for broadband noise reduction, and are suitable for conventional aircraft implementation. Samples for each configuration are tested in the NASA normal incidence tube and grazing flow impedance tube, with and without a wire mesh facesheet. Impedances based on these measured data compare favorably with those predicted using a transmission line impedance prediction model. Predicted impedances are then used as input for an aeroacoustic propagation code to compute axial acoustic pressure distributions in the grazing flow tube. These predicted distributions compare favorably with the corresponding measured distributions at frequencies away from the frequency of peak attenuation, but suffer slight degradation for frequencies very near the peak attenuation frequency, where the predicted results are sensitive to input impedance changes. As expected, the noise reduction frequency range increases as more degrees of freedom are included. Although the specific results achieved herein may differ from those that would be achieved with other 2DOF, 3DOF, and MDOF liners, this comparison highlights some of the key features that can be exploited in the design of parallel-element, embedded mesh-cap liners.

Jones, M. G.↗

Dynamic Smagorinsky Modeled Large-Eddy Simulations of Turbulence Using Tetrahedral Meshes

Eddy-resolving numerical computations of turbulent flows are emerging as viable alternatives to Reynolds Averaged Navier-Stokes (RANS) calculations for flows with an intrinsically steady mean state due to the advances in large-scale parallel computing. In these computations, medium to large turbulent eddies are resolved by the numerics while the smaller or subgrid scales are either modeled or taken care of by the inherent numerical dissipation. To advance the state of the art of unstructured-mesh turbulence simulation capabilities, large eddy simulations (LES) using the dynamic Smagorinsky model (DSM) on tetrahedral meshes are carried out with the space-time conservation element, solution element (CESE) method. In contrast to what has been reported in the literature, the present implementation of dynamic models allows for active backscattering without any ad-hoc limiting of the eddy viscosity calculated from the subgrid-scale model. For the benchmark problems involving compressible isotropic turbulence decay as well as the shock/turbulent boundary layer interaction benchmark problems, no numerical instability associated with kinetic energy growth is observed and the volume percentage of the backscattering portion accounts for about 38-40% of the simulation domain. A slip-wall model in conjunction with the implemented DSM is used to simulate a relatively high Reynolds number Mach 2.85 turbulent boundary layer over a 30° ramp with several tetrahedral meshes and a wall-normal spacing of either Δγ& = 10 or Δγ& = 20. The computed mean wall pressure distribution, separation region size, mean velocity profiles, and Reynolds stress agree reasonably well with experimental data.

CESE method↗

Synthetic Data Generation for 3D Mesh Prediction and Spatial Reasoning During Multi-Agent Robotic Missions

In-space assembly operations require accurate reasoning over the pose, location, and structural organization of both the autonomous agents and assembly materials. In a full six-degree-of-freedom space, an accurate understanding of the full three-dimensional structure of the object of interest greatly enriches information for pose estimation and collision planning. Current methods of predicting pose estimation require a priori understanding of the shape of the object. Additionally, visual information in the space environment is impacted by variations in contrast and illumination. Using synthetic data allows us to rapidly generate large datasets with in varying environments and lighting conditions.This work details the generation of synthetic data used to explore the use of a region-based convolutional neural networks to detect objects of interest and predict a voxel-based three-dimensional mesh in order to understand their full three-dimensional shape. This mesh provides useful spatial information during in-space assembly operations without requiring either the complexity of maintaining models over the progress of building an object or observations from multiple angles. The generated meshes are then compared to that of ground truth in order to measure its performance.

synthetic data↗

Synthetic Data Generation for 3D Mesh Prediction and Spatial Reasoning During Multi-Agent Robotic Missions

In-space assembly operations require accurate reasoning over the pose, location, and structural organization of both the autonomous agents and assembly materials. In a full six-degree-of-freedom space, an accurate understanding of the full three-dimensional structure of the object of interest greatly enriches information for pose estimation and collision planning. Current methods of predicting pose estimation require a priori understanding of the shape of the object. Additionally, visual information in the space environment is impacted by variations in contrast and illumination. Using synthetic data allows us to rapidly generate large datasets with in varying environments and lighting conditions. This work details the generation of synthetic data used to explore the use of a region-based convolutional neural networks to detect objects of interest and predict a voxel-based three-dimensional mesh in order to understand their full three-dimensional shape. This mesh provides useful spatial information during in-space assembly operations without requiring either the complexity of maintaining models over the progress of building an object or observations from multiple angles. The generated meshes are then compared to that of ground truth in order to measure its performance.

James Ecker↗

A thin-ply composite with embedded metallic mesh for a spaceborne antenna

This study presents a technique developed for embedding a conductive metallic mesh into the layup of thin-ply carbon fiber reinforced polymer (CFRP) composite material. Thermal cycling and subsequent mechanical testing on fabricated samples has been used to evaluate thin-ply composites as a crack mitigation technique. Furthermore, the construction of thin-ply CFRP composite tubes has been demonstrated for both straight segments and curved segments utilizing a novel sacrificial ceramic molding method. These prototypes represent the building blocks for a 1 m scale radiating element and are the first test articles for the evaluation of thin-ply CFRP composites with an embedded metallic mesh. The successful implementation of a CFRP composite with an embedded metallic mesh would enable ultra-lightweight conductive structures for future applications, such as antennas, requiring survival in cryogenic temperatures.

Sakovsky, Maria↗

Integral Velocity Sampling for Unsteady Rotor Models on Cartesian Meshes

An unsteady body-force rotor model utilizing integral velocity sampling is developed for Cartesian meshes with a focus on accurate performance predictions. In this approach, the rotors are modeled as body-force source terms, and integral sampling is used to define the local freestream velocity vector. The method is verified in two dimensions for airfoils, providing accurate angle of attack and freestream Mach number estimates even on relatively coarse meshes, and demonstrating excellent mesh convergence across a variety of source region thicknesses. Extensions of the model to three dimensions for both fixed and rotating wings are considered, with numerical experiments demonstrating the need for a spanwise-continuous representation of the induced velocity or angle of attack. The model provides reasonable spanwise lift distributions without any explicit tip-loss model. Comparisons to high-fidelity simulations and experimental data show excellent agreement for predictions of an isolated DJI Phantom 3 propeller in hover. Finally, simulations of the full aircraft in edgewise forward flight also compare well with wind tunnel data across a variety of pitch angles and propeller speeds.

ARMD↗

Anisotropic Mach Cone Aligned Mesh Adaptation for Low Boom Simulations

An automated off-body Mach cone aligned structured curvilinear grid generation procedure is presented for near-field computational fluid dynamics simulations. This procedure combines output-based indicators and mesh redistribution to perform anisotropic mesh adaptation while maintaining Mach cone alignment. Automation is achieved through a novel direction-based adaptation indicator formulation. The adaptation procedure is demonstrated on the JAXA Wing Body geometry and X-59 C608 demonstrator model from the Second and Third AIAA Sonic Boom Prediction Workshops, respectively. It is demonstrated that anisotropic mesh adaptation may result in a greater than fifty percent reduction in resource usage required to achieve the same level of accuracy as uniform and user constructed Mach cone aligned grids for near-field pressure signatures, ground-level overpressure signatures, and loudness metrics.

CST↗

Anisotropic Mach Cone Aligned Mesh Adaptation for Low Boom Simulations

An automated off-body Mach cone aligned structured curvilinear grid generation procedure is presented for near-field computational fluid dynamics simulations. This procedure combines output-based indicators and mesh redistribution to perform anisotropic mesh adaptation while maintaining Mach cone alignment. Automation is achieved through a novel direction-based adaptation indicator formulation. The adaptation procedure is demonstrated on the JAXA Wing Body geometry and X-59 C608 demonstrator model from the Second and Third AIAA Sonic Boom Prediction Workshops, respectively. It is demonstrated that anisotropic mesh adaptation may result in a greater than fifty percent reduction in resource usage required to achieve the same level of accuracy as uniform and user constructed Mach cone aligned grids for near-field pressure signatures, ground-level overpressure signatures, and loudness metrics.

CST↗

A method for bounding high-order finite element functions: Applications to mesh validity and bounds-preserving limiters

We introduce a novel method for bounding high-order multi-dimensional polynomials in finite element approximations. The method involves precomputing optimal piecewise-linear bounding boxes for polynomial basis functions, which can then be used to locally bound any combination of these basis functions. This approach can be applied to any element/basis type at any approximation order, can provide local (i.e., subcell) extremum bounds to a desired level of accuracy, and can be evaluated efficiently on-the-fly in simulations. Furthermore, we show that this approach generally yields more accurate bounds in comparison to traditional methods based on convex hull properties (e.g., Bernstein polynomials). Furthermore, the efficacy of this technique is shown in applications such as mesh validity checks and optimization for high-order curved meshes, where positivity of the element Jacobian determinant can be ensured throughout the entire element, and continuously bounds-preserving limiters for hyperbolic systems, which can enforce maximum principle bounds across the entire solution polynomial.

Bounding box↗