X-57 “Maxwell” High-Lift Propeller Testing and Model Development
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A low Reynolds number, high subsonic mach number flight regime is fairly uncommon in aeronautics. Most flight vehicles do not fly under these aerodynamic conditions. However, recently there have been a number of proposed aircraft applications (such as high altitude observation platforms and Mars aircraft) that require flight within this regime. One of the main obstacles to flight under these conditions is the ability to reliably generate sufficient thrust for the aircraft. For a conventional propulsion system, the operation and design of the propeller is the key aspect to its operation. Due to the difficulty in experimentally modeling the flight conditions in ground-based facilities, it has been proposed to conduct propeller experiments from a high altitude gliding platform (APEX). A preliminary design of a propeller experiment under the low Reynolds number, high mach number flight conditions has been devised. The details of the design are described as well as the potential data that will be collected.
Reactivity and expansion characteristics of Aerozine-50 and nitrogen tetroxide from vacuum chamber tests
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Values of total drag coefficient were measured for four round-nosed bodies of revolution in free flight at Mach numbers from 0.6 to 1.5 and Reynolds numbers from 10 x 10(6) to 50 x 10(6). The bodies were designed by rounding off the sharp, fineness-ratio-3.56 nose of a previously tested configuration. The nose radii tested were 27.4, 38.7, 80.6, and 100 percent of the maximum body radius and corresponded to values of 0.075, 0.150, 0.650, and 1.000, respectively, for the ratio of nose-sphere frontal area to body frontal area. The body having least bluntness did not differ appreciably in drag from the pointed-nose body. The others showed marked increases in supersonic drag with increasing bluntness. (author)
Decelerators (IADs) have traditionally been tested in wind tunnels. As the limitations of these test facilities are reached, other avenues must be pursued. The IAD being tested is a Supersonic IAD (SIAD), which attaches just aft of the heatshield around the perimeter of an entry body. This 'attached torus' SIAD is meant to improve the accuracy of landing for robotic class missions to Mars and allow for potentially increased payloads. The SIAD Design Verification (SDV) test aims to qualify the SIAD by applying a targeted aerodynamic load to the vehicle. While many test architectures were researched, a rocket sled track was ultimately chosen to be the most cost effective way to achieve the desired dynamic pressures. The Supersonic Naval Ordnance Research Track (SNORT) at the Naval Air Warfare Center Weapons Division (NAWCWD) China Lake is a four mile test track, traditionally used for warhead and ejection seat testing. Prior to SDV, inflatable drag bodies have been tested on this particular track. Teams at Jet Propulsion Laboratory (JPL) and NAWCWD collaborate together to design and fabricate one of the largest sleds ever built. The SDV sled is comprised of three individual sleds: a Pusher Sled which holds the solid booster rockets, an Item Sled which supports the test vehicle, and a Camera Sled that is pushed in front for in-situ footage and measurements. The JPL-designed Test Vehicle has a full-scale heatshield shape and contains all instrumentation and inflation systems necessary to inflate and test a SIAD. The first campaign that is run at SNORT tested all hardware and instrumentation before the SIAD was ready to be tested. For each of the three tests in this campaign, the number of rockets and top speed was increased and the data analyzed to ensure the hardware is safe at the necessary accelerations and aerodynamic loads.
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The investigation described in this report was made primarily to afford a comparison between propeller tests in the new propeller research tunnel and flight tests and small model tests on propellers. Three wood propellers which had been previously tested in flight on a VE-7 airplane, and of which models had also been tested in a wind tunnel, were tested again on a VE-7 airplane in the propeller research tunnel. The results of these tests are in fair agreement with those of the flight and model tests. Tests were also made with the tail surfaces removed, and with both the wing and tail surfaces removed. It was found that the effect of the tail surfaces on the propeller characteristics was negligible, but that the wings reduced the maximum propulsive efficiency about 5 percent. (author)
This paper describes a variable-pitch propeller testing and aerodynamic modeling methodology for electric vertical takeoff and landing (eVTOL) aircraft using wind tunnel testing. Propellers used for eVTOL aircraft propulsion systems experience a wide range of operating conditions resulting in significant variation of axial thrust and torque, as well as off-axis forces and moments, across a typical flight envelope. An experimental design is developed to collect informative wind tunnel data in an efficient manner using response surface methods. System identification methods are then applied to isolated propeller wind tunnel data to develop a mathematical model of the propeller valid throughout the transition envelope of a vectored-thrust eVTOL aircraft. Multiple explanatory variable definitions are postulated and compared using modeling and prediction performance metrics. Modeling results validated against data withheld from the modeling process indicate good predictive capability and agree with theoretical expectations. All identified propeller models are provided, which allows the models to be used in future eVTOL aircraft flight dynamics simulations.
Tests of swirl recovery vanes designed for use in conjunction with advanced high speed propellers were carried out at the NASA Lewis Research Center. The eight bladed 62.23 cm vanes were tested with a 62.23 cm SR = 7A high speed propeller in the NASA Lewis 2.44 x 1.83 m Supersonic Wind Tunnel for a Mach number range of 0.60 to 0.80. At the design operating condition for cruise of Mach 0.80 at an advance ratio of 3.26, the vane contribution to the total efficiency approached 2 percent. At lower off-design Mach numbers, the vane efficiency is even higher, approaching 4.5 percent for the Mach 0.60 condition. Use of the swirl recovery vanes essentially shifts the peak of the high speed propeller efficiency to a higher operating speed. This allows a greater degree of freedom in the selection of rpm over a wider operating range. Another unique result of the swirl recovery vane configuration is their essentially constant torque split between the propeller and the swirl vanes over a wide range of operating conditions for the design vane angle.
Solid propellant rocket vehicles
Tests were conducted in the Langley full-scale tunnel to determine the aerodynamic performance and acoustic characteristics of four different pusher-propeller configurations on a twin boom, general aviation airplane. The propellers included a 2-blade free propeller, two 3-blade shrouded propellers, and a 5-blade shrouded propeller. The tests were conducted for a range of airplane angles of attack from about 0 deg to 16 deg for test speeds from 0 to about 36 m/sec and for a range of propeller blade angles and rotation speeds. The free propeller provided the best aerodynamic propulsive performance. For forward flight conditions, the free propeller noise levels were lower than those of the shrouded propellers. In the static conditions the free propeller noise levels were as low as those for the shrouded propellers, except for the propeller in-plane noise where the shrouded propeller noise levels were lower.
Tests have been made at the Langley Aeronautical Laboratory on a 6000-horsepower propeller dynamometer installed at a ground test facility to determine the effect of a half-scale model of the Wright Aeronautical Development Center 30,000-horsepower whirl rig upon the aerodynamic characteristics of a three-blade NACA 10-(3)(062)-045 propeller. The model of the whirl rig was mounted in front of the 6000-horsepower propeller dynamometer. Static propeller tests were made for 0deg, 5deg, 10deg, 15deg, and 20deg blade angles over a range of rotational speeds from 600 to 2200 rpm in 100-rpm increments. Measurements were made of propeller thrust and torque, stresses in the propeller blades, and static and total pressures over the surface of the model. Propeller thrust and torque were increased up to 33 percent by the presence of the model of the whirl rig, but the average increase was from 5 to 10 percent. Blade vibratory stresses were small.
Test of 10-foot diameter, four and six blade single-rotating and dual-rotating propellers were conducted in the NACA propeller-research tunnel. The propellers were mounted at the front end of a streamline body incorporating spinners to house the hub portions. The effect of a symmetrical wing mounted in the slipstream ranged from 20 degrees to 65 degrees setting corresponds to airplane speeds greater than 500 miles per hour. The results indicate that dual-rotating propellers were from 0 to 6 percent more efficient than single-rotating ones; but, when the propellers operated in the presence of a wing, the gain was reduced by about one-half. Other advantages of dual-rotating propellers were found to include greater power absorption and greater efficiency at the low V/nD operating range of high-pitch propellers.
Dynamometer tests of propellers under static thrust conditions
Tests of 2-blade, adjustable-pitch, counterrotating tandem model propellers, adjusted to absorb equal power at maximum efficiency, were made at Stanford University. The characteristics, for 15 degrees, 25 degrees, 35 degrees, and 45 degrees pitch settings at 0.75 R of the forward propeller and for 8 1/2%, 15% and 30% diameter spacings, were compared with those of 2-blade and 4-blade propellers of the same blade form. The tests showed that the efficiency of the tandem propellers was from 0.5% to 4% greater than that of a 4-blade propeller and, at the high pitch settings, not appreciable inferior to that of a 2-blade propeller. It was found that the rear tandem propeller should be set at a pitch angle slightly less than that of the forward propeller to realize the condition of equal power at maximum efficiency. Under this condition the total power absorbed by the tandem propellers was from 3% to 9% more than that absorbed by the 4-blade propeller and about twice that absorbed by a 2-blade propeller.