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NASA NTRS1995

SRM Internal Flow Test and Computational Fluid Dynamic Analysis: Major Task Summaries - Volume 1

During the four year period of performance for NASA contract, NASB-39095, ERC has performed a wide variety of tasks to support the design and continued development of new and existing solid rocket motors and the resolution of operational problems associated with existing solid rocket motor's at NASA MSFC. This report summarizes the support provided to NASA MSFC during the contractual period of performance. The report is divided into three main sections. The first section presents summaries for the major tasks performed. These tasks are grouped into three major categories: full scale motor analysis, subscale motor analysis and cold flow analysis. The second section includes summaries describing the computational fluid dynamics (CFD) tasks performed. The third section, the appendices of the report, presents detailed descriptions of the analysis efforts as well as published papers, memoranda and final reports associated with specific tasks. These appendices are referenced in the summaries. The subsection numbers for the three sections correspond to the same topics for direct cross referencing.

Whitesides, R. Harold↗

NASA NTRS2018

Computational Fluid Dynamics Analysis of the Stall Characteristics of a Wing Design Based on Prandtl's Minimum Induced Drag

Stall characteristics of a wing whose design was based on Prandtl’s minimum induced drag analysis is presented. Flow field is resolved using RANS CFD (Computational Fluid Dynamics) solver OVERFLOW-2. Both in freestream and in ground effect are analyzed. In addition, effect of low-Mach preconditioner on the stall characteristic is presented. Results show that simulations that lack preconditioner predicts higher stall angle as well as much more benign behavior near the stall angle. Stall analysis in freestream show that flow begins to separate at the inboard region. The flow at the tip remains attached until approximately 19.0 degrees angle of attack.

PRANDTL↗

NASA NTRSDate not supplied

Time-Accurate Computational Fluid Dynamics Analysis of a Supersonic Turbine to Assess Structural Mode Excitation

Gas turbines can experience significant unsteady loading during operation which can cause damage such as blade cracking or bearing wear. While computational fluid dynamics (CFD) modeling of full three-dimensional gas turbine flow to verify meanline design performance is standard practice within the industry, the use of time-accurate CFD makes it possible to assess the unsteady loading which can be especially problematic at operating conditions where unsteady fluid loading aligns with structural modes. The Fluid Dynamics branch (ER42) at NASA Marshall Space Flight Center has developed a time-accurate CFD analysis methodology using the unstructured, density-based, Loci-CHEM solver which is capable of simulating the relative motion required for turbomachinery applications through sliding interface meshes. The highly-parallel unstructured solver allows for full three-dimensional, time-accurate simulation of turbines including upstream and downstream components such as manifolds, nozzles, and stators, any of which could excite a turbine structural mode. Recently, Loci-CHEM was used to analyze the FASTRAC supersonic turbine to assess the loading on the rotor. Overall performance and time-averaged loading on the rotor was computed, including the axial force over the entire rotor disk which is required for force balance calculations on the turbopump. The FASTRAC turbine has supersonic nozzles upstream of the rotor that result in significant unsteady loading on the rotor blades at multiples of the nozzle pass frequency. The unsteady blade pressure loading was decomposed into the frequency domain for direct use in structural forced response analysis. Utilizing this type of CFD analysis coupled with structural analysis has proven to be a valuable tool in identifying structural modes that are being excited by unsteady fluid loading.

M.V. Fischels↗

NASA NTRSDate not supplied

Time-Accurate Computational Fluid Dynamics Analysis of a Supersonic Turbine to Assess Structural Mode Excitation

M V Fischels↗

NASA NTRS1989

Computational fluid dynamics analysis of space shuttle main propulsion feed line 17-inch disconnect valves

A steady incompressible three-dimensional (3-D) viscous flow analysis was conducted for the Space Shuttle Main Propulsion External Tank (ET)/Orbiter (ORB) propellant feed line quick separable 17-inch disconnect flapper valves for liquid oxygen (LO2) and liquid hydrogen (LH2). The main objectives of the analysis were to predict and correlate the hydrodynamic stability of the flappers and pressure drop with available water test data. Computational Fluid Dynamics (CFD) computer codes were procured at no cost from the public domain, and were modified and extended to carry out the disconnect flow analysis. The grid generator codes SVTGD3D and INGRID were obtained. NASA Ames Research Center supplied the flow solution code INS3D, and the color graphics code PLOT3D. A driver routine was developed to automate the grid generation process. Components such as pipes, elbows, and flappers can be generated with simple commands, and flapper angles can be varied easily. The flow solver INS3D code was modified to treat interior flappers, and other interfacing routines were developed, which include a turbulence model, a force/moment routine, a time-step routine, and initial and boundary conditions. In particular, an under-relaxation scheme was implemented to enhance the solution stability. Major physical assumptions and simplifications made in the analysis include the neglect of linkages, slightly reduced flapper diameter, and smooth solid surfaces. A grid size of 54 x 21 x 25 was employed for both the LO2 and LH2 units. Mixing length theory applied to turbulent shear flow in pipes formed the basis for the simple turbulence model. Results of the analysis are presented for LO2 and LH2 disconnects.

Kandula, Max↗

NASA NTRS1993

Axisymmetric computational fluid dynamics analysis of a film/dump-cooled rocket nozzle plume

Prediction of convective base heating rates for a new launch vehicle presents significant challenges to analysts concerned with base environments. The present effort seeks to augment classical base heating scaling techniques via a detailed investigation of the exhaust plume shear layer of a single H2/O2 Space Transportation Main Engine (STME). Use of fuel-rich turbine exhaust to cool the STME nozzle presented concerns regarding potential recirculation of these gases to the base region with attendant increase in the base heating rate. A pressure-based full Navier-Stokes computational fluid dynamics (CFD) code with finite rate chemistry is used to predict plumes for vehicle altitudes of 10 kft and 50 kft. Levels of combustible species within the plume shear layers are calculated in order to assess assumptions made in the base heating analysis.

Tucker, P. K.↗

NASA NTRS1996

Design of a Subscale Propellant Slag Evaluation Motor Using Two-Phase Fluid Dynamic Analysis

Small pressure perturbations in the Space Shuttle Reusable Solid Rocket Motor (RSRM) are caused by the periodic expulsion of molten aluminum oxide slag from a pool that collects in the aft end of the motor around the submerged nozzle nose during the last half of motor operation. It is suspected that some motors produce more slag than others due to differences in aluminum oxide agglomerate particle sizes that may relate to subtle differences in propellant ingredient characteristics such as particle size distributions or processing variations. A subscale motor experiment was designed to determine the effect of propellant ingredient characteristics on the propensity for slag production. An existing 5 inch ballistic test motor was selected as the basic test vehicle. The standard converging/diverging nozzle was replaced with a submerged nose nozzle design to provide a positive trap for the slag that would increase the measured slag weights. Two-phase fluid dynamic analyses were performed to develop a nozzle nose design that maintained similitude in major flow field features with the full scale RSRM. The 5 inch motor was spun about its longitudinal axis to further enhance slag collection and retention. Two-phase flow analysis was used to select an appropriate spin rate along with other considerations, such as avoiding bum rate increases due to radial acceleration effects. Aluminum oxide particle distributions used in the flow analyses were measured in a quench bomb for RSRM type propellants with minor variations in ingredient characteristics. Detailed predictions for slag accumulation weights during motor bum compared favorably with slag weight data taken from defined zones in the subscale motor and nozzle. The use of two-phase flow analysis proved successful in gauging the viability of the experimental program during the planning phase and in guiding the design of the critical submerged nose nozzle.

Whitesides, R. Harold↗

NASA NTRS1989

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.↗

NASA NTRS1994

Computational fluid dynamics analysis in support of the simplex turbopump design

Simplex is a turbopump that is being developed at NASA/Marshall Space Flight Center (MSFC) by an in-house team. The turbopump consists of a single-stage centrifugal impeller, vaned-diffuser pump powered by a single-stage, axial, supersonic, partial admission turbine. The turbine is driven by warm gaseous oxygen tapped off of the hybrid motor to which it will be coupled. Rolling element bearings are cooled by the pumping fluid. Details of the configuration and operating conditions are given by Marsh. CFD has been used extensively to verify one-dimensional (1D) predictions, assess aerodynamic and hydrodynamic designs, and to provide flow environments. The complete primary flow path of the pump-end and the hot gas path of the turbine, excluding the inlet torus, have been analyzed. All CFD analyses conducted for the Simplex turbopump employed the pressure based Finite Difference Navier-Stokes (FDNS) code using a standard kappa-epsilon turbulence model with wall functions. More detailed results are presented by Garcia et. al. To support the team, loading and temperature results for the turbine rotor were provided as inputs to structural and thermal analyses, and blade loadings from the inducer were provided for structural analyses.

Garcia, Roberto↗

NASA NTRS2003

Comparison of Experimental Data and Computations Fluid Dynamics Analysis for a Three Dimensional Linear Plug Nozzle

A three dimensional linear plug nozzle of area ratio 12.79 was designed by EADS Space Transportation (former Astrium Space Infrastructure). The nozzle was tested within the German National Technology Program 'LION' in a cold air wind tunnel by TU Dresden. The experimental hardware and test conditions are described. Experimental data was obtained for the nozzle without plug side wall fences at a nozzle pressure ratio of 116 and then with plug side wall fences at NPR 110. Schlieren images were recorded and axial profiles of plug wall static pressures were measured at several spanwise locations and on the plug base. Detailed CFD analysis was performed for these nozzle configurations at NPR 116 by NASA MSFC. The CFD exhibits good agreement with the experimental data. A detailed comparison of the CFD results and the experimental plug wall pressure data are given. Comparisons are made for both the without and with plug side wall fence configurations. Numerical results for density gradient are compared to experimental Schlieren images. Experimental nozzle thrust efficiencies are calculated based on the CFD results. The CFD results are used to illustrate the plug nozzle fluid dynamics. The effect of the plug side wall is emphasized.

Ruf, J. H.↗

NASA NTRS1997

Computational Fluid Dynamics Analysis Method Developed for Rocket-Based Combined Cycle Engine Inlet

Renewed interest in hypersonic propulsion systems has led to research programs investigating combined cycle engines that are designed to operate efficiently across the flight regime. The Rocket-Based Combined Cycle Engine is a propulsion system under development at the NASA Lewis Research Center. This engine integrates a high specific impulse, low thrust-to-weight, airbreathing engine with a low-impulse, high thrust-to-weight rocket. From takeoff to Mach 2.5, the engine operates as an air-augmented rocket. At Mach 2.5, the engine becomes a dual-mode ramjet; and beyond Mach 8, the rocket is turned back on. One Rocket-Based Combined Cycle Engine variation known as the "Strut-Jet" concept is being investigated jointly by NASA Lewis, the U.S. Air Force, Gencorp Aerojet, General Applied Science Labs (GASL), and Lockheed Martin Corporation. Work thus far has included wind tunnel experiments and computational fluid dynamics (CFD) investigations with the NPARC code. The CFD method was initiated by modeling the geometry of the Strut-Jet with the GRIDGEN structured grid generator. Grids representing a subscale inlet model and the full-scale demonstrator geometry were constructed. These grids modeled one-half of the symmetric inlet flow path, including the precompression plate, diverter, center duct, side duct, and combustor. After the grid generation, full Navier-Stokes flow simulations were conducted with the NPARC Navier-Stokes code. The Chien low-Reynolds-number k-e turbulence model was employed to simulate the high-speed turbulent flow. Finally, the CFD solutions were postprocessed with a Fortran code. This code provided wall static pressure distributions, pitot pressure distributions, mass flow rates, and internal drag. These results were compared with experimental data from a subscale inlet test for code validation; then they were used to help evaluate the demonstrator engine net thrust.

Source record↗

NASA NTRS1980

Fluid dynamic analysis of the space shuttle main engine high pressure oxidizer turbopump slinger seal

The details of the flow on the bladed side of a centrifugal type dynamic shaft seal utilized to contain liquid oxygen in the Space Shuttle Main Engine high pressure oxidizer turbopump were clarified. The governing equations are solved to predict the pressure and temperature gradients and to aid in investigating the nature of the liquid-vapor interface. Recommendations for design improvements are discussed.

Voss, J. S.↗

NASA NTRS1985

SPAR improved structural-fluid dynamic analysis capability

The results of a study whose objective was to improve the operation of the SPAR computer code by improving efficiency, user features, and documentation is presented. Additional capability was added to the SPAR arithmetic utility system, including trigonometric functions, numerical integration, interpolation, and matrix combinations. Improvements were made in the EIG processor. A processor was created to compute and store principal stresses in table-format data sets. An additional capability was developed and incorporated into the plot processor which permits plotting directly from table-format data sets. Documentation of all these features is provided in the form of updates to the SPAR users manual.

Pearson, M. L.↗

NASA NTRS1991

Computational fluid dynamic analysis of liquid rocket combustion instability

The paper presents a computational analysis of liquid rocket combustion instability. Consideration is given to both a fully nonlinear unsteady calculation as well as a new CFD-based linearized stability analysis. An analytical solution for the linear stability problem in a constant area combustion chamber with uniform mean flow is developed to verify the numerical analyses.

Venkateswaran, Sankaran↗

NASA NTRS1995

SRM Internal Flow Tests and Computational Fluid Dynamic Analysis: RSRM Full Scale Motor Analyses - Volume 2

The purpose of the RSRM Nozzle Slag Ejection Precursor Test is to investigate the effect that slag ejection from the RSRM nozzle has on the chamber pressure and trust of the SRB's. In past firings of the Reusable Solid Rocket Motor (RSRM) both static test and flight motors have shown small pressure perturbations occurring primarily between 65 and 80 seconds. A joint NASA/Thiokol team investigation concluded that the cause of the pressure perturbations was the periodic ingestion and ejection of molten aluminum oxide slag from the cavity around the submerged nozzle nose which tends to trap and collect individual aluminum oxide droplets from the approach flow. The conclusions of the team were supported by numerous data and observations from special tests including high speed photographic films, real time radiography, plume calorimeters, accelerometers, strain gauges, nozzle TVC system force gauges, and motor pressure and thrust data. A simplistic slag ballistics model was formulated to relate a given pressure perturbation to a required slag quantity. Also, a cold flow model using air and water was developed to provide data on the relationship between the slag flow rate and the chamber pressure increase. Both the motor and the cold flow model exhibited low frequency oscillations in conjunction with periods of slag ejection. Motor and model frequencies were related to scaling parameters. The data indicate that there is a periodicity to the slag entrainment and ejection phenomena which is possibly related to organized oscillations from instabilities in the dividing streamline shear layer which impinges on the underneath surface of the nozzle.

Source record↗

NASA NTRS1995

SRM Internal Flow Tests and Computational Fluid Dynamic Analysis: Cold Flow Analyses and CFD Analysis Capability Development - Volume 4

An evaluation of the effect of model inlet air temperature drift during a test run was performed to aid in the decision on the need for and/or the schedule for including heaters in the SRMAFTE. The Sverdrup acceptance test data was used to determine the drift in air temperature during runs over the entire range of delivered flow rates and pressures. The effect of this temperature drift on the model Reynolds number was also calculated. It was concluded from this study that a 2% change in absolute temperature during a test run could be adequately accounted for by the data analysis program. A handout package of these results was prepared and presented to ED35 management.

Source record↗

NASA NTRS2001

SRM Internal Flow Tests and Computational Fluid Dynamic Analysis: CFD RSRM Full-Scale Analyses - Volume 2

This document presents the full-scale analyses of the CFD RSRM. The RSRM model was developed with a 20 second burn time. The following are presented as part of the full-scale analyses: (1) RSRM embedded inclusion analysis; (2) RSRM igniter nozzle design analysis; (3) Nozzle Joint 4 erosion anomaly; (4) RSRM full motor port slag accumulation analysis; (5) RSRM motor analysis of two-phase flow in the aft segment/submerged nozzle region; (6) Completion of 3-D Analysis of the hot air nozzle manifold; (7) Bates Motor distributed combustion test case; and (8) Three Dimensional Polysulfide Bump Analysis.

Source record↗

NASA NTRS2005

Computational Fluid Dynamics Analysis for the Orbiter LH2 Feedline Flowliner

In phase II, additional inducer rotations are simulated in order to understand the root cause of the flowliner crack problem. CFD results confirmed that there is a strong unsteady interaction between the backflow regions caused by the LPFTP inducer and secondary flow regions in the bellows cavity through the flowliner slots. It is observed that the swirl on the duct side of the downstream flowliner is stronger than on the duct side of the upstream flowliner. Due to this swirl, there are more significant unsteady flow interactions through the downstream slots than those observed in the upstream slots. Averaged values of the local velocity at the slots were provided to the NESC-ITA flow physics acoustics team to guide them in designing the acoustics experiment. A parametric study was performed to compare the flow field in the flowliner area when one upstream slot and one corresponding downstream slot were enlarged. No significant differences were observed between the flow field obtained from the enlarged slot configuration when compared with the original configuration. More cases must be analyzed with various enlarged slot configurations to generalize this observation. The flow through the A1 test stand and the flow through the orbiter fuel feedline manifold were simulated without the LPFTP. It was observed that incoming flow to the flowliner and inducer was more uniform in the A1 test stand then in the orbiter manifold. Additionally, each engine LPFTP in the orbiter receives significantly different velocity distributions. Because of the differences observed in the computed results, it is not possible for the A1 test stand to represent the three different engine feedlines simultaneously.

Kiris, Cetin C.↗