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NASA NTRS2010

Labyrinth Seal Flutter Analysis and Test Validation in Support of Robust Rocket Engine Design

High energy-density turbomachines, like the SSME turbopumps, utilize labyrinth seals, also referred to as knife-edge seals, to control leakage flow. The pressure drop for such seals is order of magnitude higher than comparable jet engine seals. This is aggravated by the requirement of tight clearances resulting in possible unfavorable fluid-structure interaction of the seal system (seal flutter). To demonstrate these characteristics, a benchmark case of a High Pressure Oxygen Turbopump (HPOTP) outlet Labyrinth seal was studied in detail. First, an analytical assessment of the seal stability was conducted using a Pratt & Whitney legacy seal flutter code. Sensitivity parameters including pressure drop, rotor-to-stator running clearances and cavity volumes were examined and modeling strategies established. Second, a concurrent experimental investigation was undertaken to validate the stability of the seal at the equivalent operating conditions of the pump. Actual pump hardware was used to construct the test rig, also referred to as the (Flutter Rig). The flutter rig did not include rotational effects or temperature. However, the use of Hydrogen gas at high inlet pressure provided good representation of the critical parameters affecting flutter especially the speed of sound. The flutter code predictions showed consistent trends in good agreement with the experimental data. The rig test program produced a stability threshold empirical parameter that separated operation with and without flutter. This empirical parameter was used to establish the seal build clearances to avoid flutter while providing the required cooling flow metering. The calibrated flutter code along with the empirical flutter parameter was used to redesign the baseline seal resulting in a flutter-free robust configuration. Provisions for incorporation of mechanical damping devices were introduced in the redesigned seal to ensure added robustness

El-Aini, Yehia↗

NASA NTRS1976

Study of flutter related computational procedures for minimum weight structural sizing of advanced aircraft

Results of a study of the development of flutter modules applicable to automated structural design of advanced aircraft configurations, such as a supersonic transport, are presented. Automated structural design is restricted to automated sizing of the elements of a given structural model. It includes a flutter optimization procedure; i.e., a procedure for arriving at a structure with minimum mass for satisfying flutter constraints. Methods of solving the flutter equation and computing the generalized aerodynamic force coefficients in the repetitive analysis environment of a flutter optimization procedure are studied, and recommended approaches are presented. Five approaches to flutter optimization are explained in detail and compared. An approach to flutter optimization incorporating some of the methods discussed is presented. Problems related to flutter optimization in a realistic design environment are discussed and an integrated approach to the entire flutter task is presented. Recommendations for further investigations are made. Results of numerical evaluations, applying the five methods of flutter optimization to the same design task, are presented.

Oconnell, R. F.↗

NASA NTRS1981

Transonic flutter study of a wind-tunnel model of an arrow-wing supersonic transport

A 1/20-size, low-speed flutter model of the SCAT-15F complete airplane was tested in a wind-tunnel on cables to simulate a near free-flying condition. Only the model wing and fuselage were flexible. Flutter boundaries were measured for a nominal configuration and a configuration with wing fins removed at Mach numbers M from 0.76 to 1.2. For both configurations, the transonic dip in the wing flutter dynamic pressure q boundary was relatively small and the minimum flutter q occurred near M = 0.92. Removing the wing fins increased the flutter q about 14 percent and changed the flutter mode from symmetric to antisymmetric. Vibration and flutter analyses were made using a finite-element structural representation and subsonic kernel-function aerodynamics. For the nominal configuration, the analysis (using calculated modal data) predicted the experimental flutter q levels within 10 percent but did not predict the correct flutter mode at the higher M. For the configuration without wing fins, the analysis predicted 16 to 36 percent unconservative (higher than experimental) flutter q levels and showed extreme sensitivity to mass shapes.

Ruhlin, C. L.↗

NASA NTRS1987

Flutter study of an advanced composite wing with external stores

A flutter test using a scaled model of an advanced composite wing for a Navy attack aircraft has been conducted in the NASA Langley Research Center Transonic Dynamics Tunnel. The model was a wall-mounted half-span wing with a semi-span of 6.63 ft. The wing had an aspect ratio of 5.31, taper ratio of 0.312, and quarter-chord sweep of 25 degrees. The model was supported in a manner that simulated the load path in the carry-through structure of the aircraft and the symmetric boundary condition at the fuselage centerline. The model was capable of carrying external stores from three pylon locations on the wing. Flutter tests were conducted for the wing with and without external stores. No flutter was encountered for the clean wing at test conditions which simulated the scaled airplane operating envelope. Flutter boundaries were obtained for several external store configurations. The flutter boundaries for the fuel tanks were nearly Mach number independent (occurring at constant dynamic pressure). To study the aerodynamic effect of the fuel tank stores, pencil stores (slender cylindrical rods) which had the same mass and pitch and yaw inertia as the fuel tanks were tested on the model. These pencil store configurations exhibited a transonic dip in the flutter dynamic pressure, indicating that the aerodynamic effect of the actual fuel tanks on flutter was significant. Several flutter analyses methods were used in an attempt to predict the flutter phenomenon exhibited during the wind-tunnel test. The analysis gave satisfactory predictions of flutter for the pencil store configurations, but unsatisfactory correlation for the actual fuel tank configurations.

Cole, Stanley R.↗

NASA NTRS2000

Test Cases for Flutter of the Benchmark Models Rectangular Wings on the Pitch and Plunge Apparatus

The supercritical airfoil was chosen as a relatively modem airfoil for comparison. The BOO12 model was tested first. Three different types of flutter instability boundaries were encountered, a classical flutter boundary, a transonic stall flutter boundary at angle of attack, and a plunge instability near M = 0.9 and for zero angle of attack. This test was made in air and was Transonic Dynamics Tunnel (TDT) Test 468. The BSCW model (for Benchmark SuperCritical Wing) was tested next as TDT Test 470. It was tested using both with air and a heavy gas, R-12, as a test medium. The effect of a transition strip on flutter was evaluated in air. The B64AOlO model was subsequently tested as TDT Test 493. Some further analysis of the experimental data for the BOO12 wing is presented. Transonic calculations using the parameters for the BOO12 wing in a two-dimensional typical section flutter analysis are given. These data are supplemented with data from the Benchmark Active Controls Technology model (BACT) given and in the next chapter of this document. The BACT model was of the same planform and airfoil as the BOO12 model, but with spoilers and a trailing edge control. It was tested in the heavy gas R-12, and was instrumented mostly at the 60 per cent span. The flutter data obtained on PAPA and the static aerodynamic test cases from BACT serve as additional data for the BOO12 model. All three types of flutter are included in the BACT Test Cases. In this report several test cases are selected to illustrate trends for a variety of different conditions with emphasis on transonic flutter. Cases are selected for classical and stall flutter for the BSCW model, for classical and plunge for the B64AOlO model, and for classical flutter for the BOO12 model. Test Cases are also presented for BSCW for static angles of attack. Only the mean pressures and the real and imaginary parts of the first harmonic of the pressures are included in the data for the test cases, but digitized time histories have been archived. The data for the test cases are available as separate electronic files. An overview of the model and tests is given, the standard formulary for these data is listed, and some sample results are presented.

Robert M Bennett↗

NASA NTRS2000

Test Cases for the Benchmark Active Controls: Spoiler and Control Surface Oscillations and Flutter

As a portion of the Benchmark Models Program at NASA Langley, a simple generic model was developed for active controls research and was called BACT for Benchmark Active Controls Technology model. This model was based on the previously-tested Benchmark Models rectangular wing with the NACA 0012 airfoil section that was mounted on the Pitch and Plunge Apparatus (PAPA) for flutter testing. The BACT model had an upper surface spoiler, a lower surface spoiler, and a trailing edge control surface for use in flutter suppression and dynamic response excitation. Previous experience with flutter suppression indicated a need for measured control surface aerodynamics for accurate control law design. Three different types of flutter instability boundaries had also been determined for the NACA 0012/PAPA model, a classical flutter boundary, a transonic stall flutter boundary at angle of attack, and a plunge instability near M = 0.9. Therefore an extensive set of steady and control surface oscillation data was generated spanning the range of the three types of instabilities. This information was subsequently used to design control laws to suppress each flutter instability. There have been three tests of the BACT model. The objective of the first test, TDT Test 485, was to generate a data set of steady and unsteady control surface effectiveness data, and to determine the open loop dynamic characteristics of the control systems including the actuators. Unsteady pressures, loads, and transfer functions were measured. The other two tests, TDT Test 502 and TDT Test 5 18, were primarily oriented towards active controls research, but some data supplementary to the first test were obtained. Dynamic response of the flexible system to control surface excitation and open loop flutter characteristics were determined during Test 502. Loads were not measured during the last two tests. During these tests, a database of over 3000 data sets was obtained. A reasonably extensive subset of the data sets from the first two tests have been chosen for Test Cases for computational comparisons concentrating on static conditions and cases with harmonically oscillating control surfaces. Several flutter Test Cases from both tests have also been included. Some aerodynamic comparisons with the BACT data have been made using computational fluid dynamics codes at the Navier-Stokes level (and in the accompanying chapter SC). Some mechanical and active control studies have been presented. In this report several Test Cases are selected to illustrate trends for a variety of different conditions with emphasis on transonic flow effects. Cases for static angles of attack, static trailing-edge and upper-surface spoiler deflections are included for a range of conditions near those for the oscillation cases. Cases for trailing-edge control and upper-surface spoiler oscillations for a range of Mach numbers, angle of attack, and static control deflections are included. Cases for all three types of flutter instability are selected. In addition some cases are included for dynamic response measurements during forced oscillations of the controls on the flexible mount. An overview of the model and tests is given, and the standard formulary for these data is listed. Some sample data and sample results of calculations are presented. Only the static pressures and the first harmonic real and imaginary parts of the pressures are included in the data for the Test Cases, but digitized time histories have been archived. The data for the Test Cases are also available as separate electronic files.

Bennett, Robert M.↗

NASA NTRS1997

Flutter Boundary Identification From Simulation Time Histories

While there has been much recent progress in simulating nonlinear aeroelastic systems, and in predicting many of the aeroelastic phenomena of concern in transport aircraft design (i.e. transonic flutter buckets), the utility of a simulation in generating an understanding of the flutter behavior is limited. This is due in part to the high cost of generating these simulations; and the implied limitation on the number of conditions that can be analyzed, but there are also some difficulties introduced by the very nature of a simulation. Flutter engineers have traditionally worked in the frequency domain, and are accustomed to describing the flutter behavior of an airplane in terms of its V-G and V-F (or Q-G and Q-F) plots and flutter mode shapes. While the V-G and V-F plots give information about how the dynamic response of an airplane changes as the airspeed is increased, the simulation only gives information about one isolated condition (Mach, airspeed, altitude, etc.). Therefore, where a traditional flutter analysis can let the engineer determine an airspeed at which an airplane becomes unstable, while a simulation only serves as a binary check: either the airplane is fluttering at this condition, or it is not. In this document, a new technique is described in which system identification is used to easily extract modal frequencies and damping ratios from simulation time histories, and shows how the identified parameters can be used to determine the variation in frequency and dampin,o ratio as the airspeed is changed. This technique not only provides the flutter engineer with added insight into the aeroelastic behavior of the airplane, but it allows calculation of flutter mode shapes, and allows estimation of flutter boundaries while minimizing the number of simulations required.

Baker, Myles↗

NASA NTRS1975

Stabilizer flutter investigated by flight test

Flight flutter tests were conducted on an experimental airplane which resulted in the successful prediction of a limited amplitude stabilizer flutter at supersonic speeds. The flutter obtained was unusual in that fore and aft bending of the stabilizer carry-through structure contributed to the flutter condition. During flight tests the impending flutter condition was observed from force per unit amplitude, damping coefficient, and frequency measurements. A description is given of the physical and operational characteristics of the test equipment and telemetering facilities. A flutter analysis using measured modes and incompressible two-dimensional strip air forces yielded a conservative flutter speed. Sled tests of a similar stabilizer configuration had lead to the conclusion that flutter would not be encountered. Certain overall conclusions are reached regarding this particular flight flutter testing program and the need for a concerted research effort in this field.

Baird, E. F.↗

NASA NTRS1976

Wind tunnel investigation of supersonic wing-tail flutter

A flutter model, consisting of a wing, horizontal tail, and splitter plate/fuselage mechanism, was tested in a 4-foot transonic tunnel in the Mach number range 1.1 to 1.3. Two types of flutter were encountered during the testing: a wing-tail flutter bending-torsion flutter mode. The wing-tail flutter speed was found to be a minimum at M = 1.2 for the configuration tested. Recorded model test data were digitized for a power spectral density (PSD) analysis and Random Decrement (Randomdec) analysis. Comparisons between the frequency and damping obtained from the PSD plots and the Randomdec signatures agreed very well. A limited flutter analysis was conducted using a Mach box unsteady aerodynamics method which accounted for interference and airfoil thickness. Analytical comparisons with experimental flutter speeds agreed well. The analyses assuming zero thickness predicted flutter speeds higher than those measured, ranging from 1 percent at M = 1.12 to 8 percent at M = 1.28. With the airfoil thickness included, the correlation was improved such that predicted flutter speeds for all cases investigated were within 2 percent of experimental speeds.

Huttsell, L. J.↗

NASA NTRS1991

Active flutter suppression - Control system design and experimental validation

The synthesis and experimental validation of an active flutter suppression controller for the Active Flexible Wing wind-tunnel model is presented. The design is accomplished with traditional root locus and Nyquist methods using interactive computer graphics tools and with extensive use of simulation-based analysis. The design approach uses a fundamental understanding of the flutter mechanism to formulate a simple controller structure to meet stringent design specifications. Experimentally, the flutter suppression controller succeeded in simultaneous suppression of two flutter modes, significantly increasing the flutter dynamic pressure despite errors in flutter dynamic pressure and flutter frequency in the mathematical model. The flutter suppression controller was also successfully operated in combination with a roll maneuver controller to perform flutter suppression during rapid rolling maneuvers.

Waszak, Martin R.↗

NASA NTRS1992

Design and experimental validation of a flutter suppression controller for the active flexible wing

The synthesis and experimental validation of an active flutter suppression controller for the Active Flexible Wing wind tunnel model is presented. The design is accomplished with traditional root locus and Nyquist methods using interactive computer graphics tools and extensive simulation based analysis. The design approach uses a fundamental understanding of the flutter mechanism to formulate a simple controller structure to meet stringent design specifications. Experimentally, the flutter suppression controller succeeded in simultaneous suppression of two flutter modes, significantly increasing the flutter dynamic pressure despite modeling errors in predicted flutter dynamic pressure and flutter frequency. The flutter suppression controller was also successfully operated in combination with another controller to perform flutter suppression during rapid rolling maneuvers.

Waszak, Martin R.↗

NASA NTRS1997

A Presentation on Robust Flutter Margin Analysis and a Flutterometer

This paper documents an invited presentation given to The Boeing Company, Seattle, Washington, on September 9, 1997. The audience consisted of structural dynamic and flight test engineers from the Boeing Commercial Airplane Group who were interested in discussing research which may be applied to future flight flutter test programs. A method to compute robust flutter margins is described which is a significant departure from traditional methods. This method uses the structured singular value, mu, to compute a flutter margin which directly accounts for modeling errors such that a worst-case flutter margin is computed with respect to those errors. This method may be applied in several ways. A post-flight application uses data sets from multiple test points to compute worst-case flutter margins and a worst-case flight envelope. An on-line implementation computes flutter margins at each test point to track the flutter margins during a flight test. This on-line implementation is the basis for a flutterometer flight test tool that displays the distance to flutter at a given test point. Such a tool was not previously possible using traditional flutter flight test analysis methods. The F/A-18 System Research Aircraft was used to demonstrate these applications using flight data recorded from test points throughout the flight envelope.

Lind, Rick C.↗

NASA NTRS1959

Experimental Investigation of Flutter of Buckled Curved Panels Having Longitudinal Stringers at Transonic and Supersonic Speeds

Panel-flutter tests have been made at transonic and supersonic speeds With particular reference to buckled curved panels with longitudinal stringers. Other panel configurations were also tested in an attempt to determine effects of skin thickness, curvature, stringers, buckling, pressure differential, and Mach number on the dynamic pressure necessary to start flutter. For buckled curved panels with longitudinal stringers, the dynamic pressure required to start flutter was increased by increasing the skin thickness and increasing the pressure differential across the panel. There was no apparent effect of Mach number variation from 1.3 to 2.0. None of the curved panels failed because of flutter although the dynamic pressure at the start of flutter was exceeded by a factor of 3 in many cases. curved panels and four flat panels failed because of flutter. The flat panels fluttered at lower dynamic pressures than the curved panels and four flat panels failed because of flutter.

Tuovila, W. J.↗

NASA NTRS1973

Experimental investigation of orthotropic panel flutter at arbitrary yaw angles, and comparison with theory

Flutter characteristics for yaw angles between 15 deg and 90 deg were determined experimentally for two types of corrugation-stiffened panels: those with weak twisting stiffness and those with strong twisting stiffness. By mounting the panels on a remotely controlled turntable, good definition of the flutter boundaries was obtained by rotating the panels into and out of flutter. Flutter tests were conducted at M = 2 and M = 1.6. Before testing, vibration tests and analyses were also performed. The experimental flutter data is compared with flutter theory for orthotropic panels utilizing quasi-steady aerodynamics. Five different corrugated panels were tested consisting of one single skin panel having a length-to-width ratio of 5 on clamped supports and four different square double skin panels on discrete flexible supports. The investigation indicated that flutter speed for corrugated panels is highly dependent on yaw angle. Reasonable flutter correlation between analysis and test was obtained for moderate yaw angles, but extreme sensitivity to structural parameters made the correlation at large yaw angles uncertain.

Shyprykevich, P.↗

NASA NTRS1974

Some tunnel-wall effects on transonic flutter

Significant effects of wind-tunnel walls were observed on the transonic flutter boundaries of wall-mounted models during two flutter model research studies. In these studies, flutter experiments with cantilevered SST-type wing models were conducted in three different wind tunnels. The experimental results are compared to flutter boundaries calculated for the models in free air. The results indicate that transonic flutter boundaries can be affected by tunnel-wall interference, tunnel resonances, and shock-wave reflections, and that flutter model data accuracy is a function of model/tunnel size and tunnel wall porosity. However, models within the recommended size limits should give accurate results in transonic tunnels with normal ventilation. A flutter trend analysis for a two-dimensional wing-demonstrating tunnel wall and resonance effects on flutter are also presented.

Ruhlin, C. L.↗

NASA NTRS1977

F-16 flutter model studies with external wing stores

The flutter prevention and clearance task for the F-16 airplane is being accomplished in a combined analysis, wind-tunnel dynamic model test, and flight flutter test program. This paper presents highlight results from transonic flutter model studies. The flutter model was constructed to support the flutter prevention and clearance program from preliminary design through flight flutter tests. The model tests were conducted in NASA's Langley Transonic Dynamics Tunnel. The large full-span free-flying model is shown to be an effective tool in defining airplane flutter characteristics by demonstrating freedom from flutter for most configurations and by defining optimum solutions for a few troublesome configurations.

Foughner, J. T., Jr.↗

NASA NTRS1979

The development of the DAST I remotely piloted research vehicle for flight testing an active flutter suppression control system

The development of the DAST I (drones for aerodynamic and structural testing) remotely piloted research vehicle is described. The DAST I is a highly modified BQM-34E/F Firebee II Supersonic Aerial Target incorporating a swept supercritical wing designed to flutter within the vehicle's flight envelope. The predicted flutter and rigid body characteristics are presented. A description of the analysis and design of an active flutter suppression control system (FSS) designed to increase the flutter boundary of the DAST wing (ARW-1) by a factor of 20% is given. The design and development of the digital remotely augmented primary flight control system and on-board analog backup control system is presented. An evaluation of the near real-time flight flutter testing methods is made by comparing results of five flutter testing techniques on simulated DAST I flutter data. The development of the DAST ARW-1 state variable model used to generate time histories of simulated accelerometer responses is presented. This model uses control surface commands and a Dryden model gust as inputs. The feasibility of the concept of extracting open loop flutter characteristics from closed loop FSS responses was examined. It was shown that open loop characteristics can be determined very well from closed loop subcritical responses.

Grose, D. L.↗

NASA NTRS1980

Passive control of wing/store flutter

This paper presents results for a passive flutter suppression approach known as the decoupler pylon. The decoupler pylon dynamically isolates the wing from store pitch inertia effects by means of soft-spring/damper elements assisted by a low-frequency feedback-control system which minimizes static pitch deflections of the store due to maneuvers and changing flight conditions. Wind-tunnel tests and analyses show that this relatively simple pylon suspension system provides substantial increases in flutter speed and reduces the sensitivity of flutter to changes in store inertia and center-of-gravity location. Flutter characteristics of F-16 and YF-17 flutter models equipped with decoupler pylon-mount stores are presented and compared with results obtained on the same model configurations using active flutter suppression systems. These studies show both passive and active concepts to be effective in suppressing wing/store flutter. Also presented are data showing the influence of pylon stiffness nonlinearities on wing/store flutter.

Reed, W. H., III↗