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Multiphase Computational Fluid Dynamics Simulation of Ignition Overpressure and Plume-Water Interaction in the SLS Scale Model Acoustics Test
The solid rocket boosters (SRBs) on the Space Launch System (SLS) generate powerful ignition overpressure (IOP) waves that can potentially damage the vehicle and surrounding ground structures. Based on historical Shuttle experience, the IOP will be mitigated by utilizing an IOP/Sound Suppression (SS) water system which sprays water in and around the SRB and RS-25 engine plumes. However, the complex multiphase physics of the resulting plume-water interaction can lead to undesirable effects, such as high velocity water spray onto the engine nozzles and SRB nozzle side loads. Prior to launch, insight into this environment can be achieved through scale model testing and predictive computational fluid dynamics (CFD) modeling. The Scale Model Acoustic Test (SMAT) was conducted at Marshall Space Flight Center to provide the data necessary to develop the SLS liftoff acoustic environments by using a 5% scale SLS vehicle, fully integrated with a scaled IOP/SS water system, mobile launcher (ML), and tower. NASA engineers have put forth significant effort in validating the Loci/CHEM-Real Fluids multiphase CFD solver on a wet hold down test from the SMAT series. In this paper, the IOP acoustics and plume-water interactions predicted by the CFD model are compared and validated against the experiment, enabling relatively inexpensive, rapid turnaround for multiphase launch environment analyses to support future flights and design evolutions of SLS and other launch vehicles.
CFD Simulation of Ignition Overpressure and Plume-Water Interaction in the SLS Scale Model Acoustics Test
The solid rocket boosters (SRBs) on the Space Launch System (SLS) generate powerful ignition overpressure (IOP) waves that can potentially damage the vehicle and surrounding ground structures. Based on historical Shuttle experience, the IOP will be mitigated by utilizing an IOP/Sound Suppression (SS) water system which sprays water in and around the SRB and RS-25 engine plumes. However, the complex multiphase physics of the resulting plume-water interaction can lead to undesirable effects, such as high velocity water spray onto the engine nozzles and SRB nozzle side loads. Prior to launch, insight into this environment can be achieved through scale model testing and predictive computational fluid dynamics (CFD) modeling. The Scale Model Acoustic Test (SMAT) was conducted at Marshall Space Flight Center to provide the data necessary to develop the SLS liftoff acoustic environments by using a 5% scale SLS vehicle, fully integrated with a scaled IOP/SS water system, mobile launcher (ML), and tower. NASA engineers have put forth significant effort in validating the Loci/CHEM-Real Fluids multiphase CFD solver on a wet hold down test from the SMAT series. In this paper, the IOP acoustics and plume-water interactions predicted by the CFD model are compared and validated against the experiment, enabling relatively inexpensive, rapid turnaround for multiphase launch environment analyses to support future flights and design evolutions of SLS and other launch vehicles.
An Initial Electric Motor Rotor Vibration Model
Ongoing integration of outrunner brushless electric motors into drones and Advanced Air Mobility aircraft presents a need for accurate acoustic predictions derived from prediction of the motor rotor vibrations. In outrunner motors, the external rotor vibrates and drives the acoustic field. At resonant frequencies of the rotor, the rotor displacements will be the largest. The vibrations can lead to acoustic tones that are relevant to the overall acoustic design of these types of vehicles. This study performs a finite element analysis to assess the modes in two electric motor rotors. This model is then refined into a simple parameterized geometry that can make the same predictions for motors of the same class. A parametric sweep and least-squares-curve fit to the finite element analysis data results in a series of simple curves that can predict the mode shapes and frequencies that are likely to appear in this class of motors without the need for any simulation. The simulations are validated by comparison to acoustic and experimental modal-analysis data.
An Initial Electric Motor Rotor Vibration Model
Ongoing integration of outrunner brushless electric motors into drones and Advanced Air Mobility aircraft presents a need for accurate acoustic predictions derived from prediction of the motor rotor vibrations. In outrunner motors, the external rotor vibrates and drives the acoustic field. At resonant frequencies of the rotor, the rotor displacements will be the largest. The vibrations can lead to acoustic tones that are relevant to the overall acoustic design of these types of vehicles. This study performs a finite element analysis to assess the modes in two electric motor rotors. This model is then refined into a simple parameterized geometry that can make the same predictions for motors of the same class. A parametric sweep and least-squares-curve fit to the finite element analysis data results in a series of simple curves that can predict the mode shapes and frequencies that are likely to appear in this class of motors without the need for any simulation. The simulations are validated by comparison to acoustic and experimental modal-analysis data.
Computation of Feedback Aeroacoustic System by the CE/SE Method
It is well known that due to vortex shedding in high speed flow over cutouts, cavities, and gaps, intense noise may be generated. Strong tonal oscillations occur in a feedback cycle in which the vortices shed from the upstream edge of the cavity convect downstream and impinge on the cavity lip, generating acoustic waves that propagate upstream to excite new vortices. Numerical simulation of such a complicated process requires a scheme that can: (1) resolve acoustic waves with low dispersion and numerical dissipation, (2) handle nonlinear and discontinuous waves (e.g. shocks), and (3) have an effective (near field) nonreflecting boundary condition (NRBC). The new space time conservation element and solution element method, or CE/SE for short, is a numerical method that meets the above requirements.
Acoustic and Aero-Mixing Experimental Results for Fluid Shield Scale Model Nozzles
The principle objectives of this investigation are to evaluate the acoustic and aerodynamic characteristics of fluid shield nozzle concept and to assess Far 36, Stage 3 potential for fluid shield nozzle with Flade Cycle. Acoustic data for nine scale model nozzle configurations are obtained. The effects of simulated flight and geometric and aerothermodynamic flow variables on the acoustic behavior of the fluid shield are determined. The acoustic tests are aimed at studying the effect of: (1) shield thickness, (2) wrap angle, (3) mass flow and velocity ratios between shield and core streams at constant cycle specific thrust (i.e., mixed velocity), (4) porous plug, and (5) subsonic shield. Shadowgraphs of six nozzle configurations are obtained to understand the plume flowfield features. Static pressure data on suppressor chutes in the core stream (shielded and unshielded) sides and on plug surface are acquired to determine the impact of fluid shield on base drag of the 36-chute suppressor nozzle and the thrust augmentation due to the plug, respectively.
Direct Numerical Simulation of Hypersonic Turbulent Boundary Layer inside an Axisymmetric Nozzle
As a first step toward a study of acoustic disturbance field within a conventional, hypersonic wind tunnel, direct numerical simulations (DNS) of a Mach 6 turbulent boundary layer on the inner wall of a straight axisymmetric nozzle are conducted and the results are compared with those for a flat plate. The DNS results for a nozzle radius to boundary-layer thickness ratio of 5:5 show that the turbulence statistics of the nozzle-wall boundary layer are nearly unaffected by the transverse curvature of the nozzle wall. Before the acoustic waves emanating from different parts of the nozzle surface can interfere with each other and undergo reflections from adjacent portions of the nozzle surface, the rms pressure fluctuation beyond the boundary layer edge increases toward the nozzle axis, apparently due to a focusing effect inside the axisymmetric configuration. Spectral analysis of pressure fluctuations at both the wall and the freestream indicates a similar distribution of energy content for both the nozzle and the flat plate, with the peak of the premultiplied frequency spectrum at a frequency of [(omega)(delta)]/U(sub infinity) approximately 6.0 inside the free stream and at [(omega)(delta)]/U(sub infinity) approximately 2.0 along the wall. The present results provide the basis for follow-on simulations involving reverberation effects inside the nozzle.
Development of a Broadband Acoustic Emulator to Mature Propulsion Noise Reduction (CFANS-BB)
A simulator to artificially generate turbofan broadband signatures using the ANCF (Advanced Noise Control Fan) test article is presented. [Development of a Broadband Acoustic Emulator to Mature Propulsion Noise Reduction (CFANS-BB: Configurable Fan Artificial Noise Source- Broadband)]
Modeling the near-field ionospheric disturbances during earthquakes
We present the latest development of the Wave Perturbation-Global Ionosphere-Thermosphere Model (WP-GITM), a threedimensional physics-based numerical model for seismic/tsunami-ionosphere coupling via atmospheric acoustic-gravity waves. WP-GITM was previously applied to simulate the ionospheric perturbations resulted from the epicentral crustal movement by assuming spherical acoustic-gravity waves originated from a point source, which was specified by the seismic measurement at a single location nearby the epicenter. In this work, we extend WP-GITM to include the effects of Rayleigh surface waves and adapt WP-GITM to utilize seismic measurements from more than one location in the attempt to capture the radiation pattern of the seismic source. We apply the new WP-GITM to model the near-field co-seismic ionospheric perturbations during the 16 September 2015 Illapel earthquake. The comparison between the simulated ionospheric total electron content perturbations and the GPS observations shows promising results.
Far-field noise and internal modes from a ducted propeller at simulated aircraft takeoff conditions
The ducted propeller offers structural and acoustic benefits typical of conventional turbofan engines while retaining much of the aeroacoustic benefits of the unducted propeller. A model Advanced Ducted Propeller (ADP) was tested in the NASA Lewis Low-Speed Anechoic Wind Tunnel at a simulated takeoff velocity of Mach 0.2. The ADP model was designed and manufactured by the Pratt and Whitney Division of United Technologies. The 16-blade rotor ADP was tested with 22- and 40-vane stators to achieve cut-on and cut-off criterion with respect to propagation of the fundamental rotor-stator interaction tone. Additional test parameters included three inlet lengths, three nozzle sizes, two spinner configurations, and two rotor rub strip configurations. The model was tested over a range of rotor blade setting angles and propeller axis angles-of-attack. Acoustic data were taken with a sideline translating microphone probe and with a unique inlet microphone probe which identified inlet rotating acoustic modes. The beneficial acoustic effects of cut-off were clearly demonstrated. A 5 dB fundamental tone reduction was associated with the long inlet and 40-vane sector, which may relate to inlet duct geometry. The fundamental tone level was essentially unaffected by propeller axis angle-of-attack at rotor speeds of at least 96 percent design.
Far-field noise and internal modes from a ducted propeller at simulated aircraft takeoff conditions
The ducted propeller offers structural and acoustic benefits typical of conventional turbofan engines while retaining much of the aeroacoustic benefits of the unducted propeller. A model Advanced Ducted Propeller (ADP) was tested in the NASA Lewis Low-Speed Anechoic Wind Tunnel at a simulated takeoff velocity of Mach 0.2. The ADP model was designed and manufactured by the Pratt and Whitney Division of United Technologies. The 16-blade rotor ADP was tested with 22- and 40-vane stators to achieve cut-on and cut-off criterion with respect to propagation of the fundamental rotor-stator interaction tone. Additional test parameters included three inlet lengths, three nozzle sizes, two spinner configurations, and two rotor rub strip configurations. The model was tested over a range of rotor blade setting angles and propeller axis angles-of-attack. Acoustic data were taken with a sideline translating microphone probe and with a unique inlet microphone probe which identified inlet rotating acoustic modes. The beneficial acoustic effects of cut-off were clearly demonstrated. A 5 dB fundamental tone reduction was associated with the long inlet and 40-vane sector, which may relate to inlet propeller axis angle-of-attack at rotor speeds of at least 96 percent design.
Effects of simulated flight on the structure and noise of underexpanded jets
Mean plume static and pitot pressures and far-field acoustic pressure were measured for an underexpanded convergent nozzle in simulated flight. Results show that supersonic jet mixing noise behaves in flight in the same way that subsonic jet mixing noise does. Regarding shock-associated noise, the frequencies of both screech and peak broadband shock noise were found to decrease with flight speed. The external flow determines the dominant screech mode over a wide range of nozzle pressure rations. Change in the screech mode strongly affects both the development of the downstream shock structure and the characteristic frequency of the broadband shock-associated noise. When no mode change occurs, the main effect of the external flow is to stretch the axial development of the shock cells.
Noise of a simulated installed model counterrotation propeller at angle-of-attack and takeoff/approach conditions
Acoustic results for two model counterrotation propellers are presented. The propellers were tested over a range of rotational speeds and propeller axis angles of attack in both the baseline configuration and the installed configuration consisting of a simulated upstream nacelle support pylon and fuselage section. Acoustic data were taken with a polar microphone probe attached to the downstream propeller housing, capable of surveying directivities at several azimuthal locations. The forward and aft rotor power coefficients and fundamental rotor-alone tone levels are found to be directly controlled by propeller axis angle of attack. The second-order rotor-alone tones are strongly influenced by the upstream pylon wake at 80 percent speed; however, rotor-alone mechanisms control the tone level at 90 percent speed, while rotor-rotor interaction tones are essentially unaffected by the presence of the simulated installation.
On the scaling of small-scale jet noise to large scale
An examination was made of several published jet noise studies for the purpose of evaluating scale effects important to the simulation of jet aeroacoustics. Several studies confirmed that small conical jets, one as small as 59 mm diameter, could be used to correctly simulate the overall or perceived noise level (PNL) noise of large jets dominated by mixing noise. However, the detailed acoustic spectra of large jets are more difficult to simulate because of the lack of broad-band turbulence spectra in small jets. One study indicated that a jet Reynolds number of 5 x 10(exp 6) based on exhaust diameter enabled the generation of broad-band noise representative of large jet mixing noise. Jet suppressor aeroacoustics is even more difficult to simulate at small scale because of the small mixer nozzles with flows sensitive to Reynolds number. Likewise, one study showed incorrect ejector mixing and entrainment using a small-scale, short ejector that led to poor acoustic scaling. Conversely, fairly good results were found with a longer ejector and, in a different study, with a 32-chute suppressor nozzle. Finally, it was found that small-scale aeroacoustic resonance produced by jets impacting ground boards does not reproduce at large scale.
Coupled multi-disciplinary simulation of composite engine structures in propulsion environment
A computational simulation procedure is described for the coupled response of multi-layered multi-material composite engine structural components which are subjected to simultaneous multi-disciplinary thermal, structural, vibration, and acoustic loadings including the effect of hostile environments. The simulation is based on a three dimensional finite element analysis technique in conjunction with structural mechanics codes and with acoustic analysis methods. The composite material behavior is assessed at the various composite scales, i.e., the laminate/ply/constituents (fiber/matrix), via a nonlinear material characterization model. Sample cases exhibiting nonlinear geometrical, material, loading, and environmental behavior of aircraft engine fan blades, are presented. Results for deformed shape, vibration frequency, mode shapes, and acoustic noise emitted from the fan blade, are discussed for their coupled effect in hot and humid environments. Results such as acoustic noise for coupled composite-mechanics/heat transfer/structural/vibration/acoustic analyses demonstrate the effectiveness of coupled multi-disciplinary computational simulation and the various advantages of composite materials compared to metals.
Coupled multi-disciplinary simulation of composite engine structures in propulsion environment
A computational simulation procedure is described for the coupled response of multi-layered multi-material composite engine structural components which are subjected to simultaneous multi-disciplinary thermal, structural, vibration, and acoustic loadings including the effect of hostile environments. The simulation is based on a three dimensional finite element analysis technique in conjunction with structural mechanics codes and with acoustic analysis methods. The composite material behavior is assessed at the various composite scales, i.e., the laminate/ply/constituents (fiber/matrix), via nonlinear material characterization model. Sample cases exhibiting nonlinear geometrical, material, loading, and environmental behavior of aircraft engine fan blades, are presented. Results for deformed shape, vibration frequency mode shapes, and acoustic noise emitted from the fan blade, are discussed for their coupled effect in hot and humid environments. Results such as acoustic noise for coupled composite-mechanics/heat transfer/structural/vibration/acoustic analyses demonstrate the effectiveness of coupled multi-disciplinary computational simulation the various advantages of composite materials compared to metals.
On the Computation of Sound by Large-Eddy Simulations
The effect of the small scales on the source term in Lighthill's acoustic analogy is investigated, with the objective of determining the accuracy of large-eddy simulations when applied to studies of flow-generated sound. The distribution of the turbulent quadrupole is predicted accurately, if models that take into account the trace of the SGS stresses are used. Its spatial distribution is also correct, indicating that the low-wave-number (or frequency) part of the sound spectrum can be predicted well by LES. Filtering, however, removes the small-scale fluctuations that contribute significantly to the higher derivatives in space and time of Lighthill's stress tensor T(sub ij). The rms fluctuations of the filtered derivatives are substantially lower than those of the unfiltered quantities. The small scales, however, are not strongly correlated, and are not expected to contribute significantly to the far-field sound; separate modeling of the subgrid-scale density fluctuations might, however, be required in some configurations.