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The use of a sensitivity equation method to computer derivatives for optimization based design algorithms are discussed. The problem of designing an optimal forebody simulator is used to motivate the algorithm and to illustrate the basic ideas. Finally, how an existing computational fluid dynamics (CFD) code can be modified to compute sensitivities and a numerical example is presented.
A process is presented by which aeroelastic analysis is performed by using an advanced computational fluid dynamics (CFD) code coupled with an advanced computational structural dynamics (CSD) code. The process is demonstrated on an F/A-18 Stabilator using NASTD (an in-house McDonnell Douglas Aerospace East CFD code) coupled with NASTRAN. The process is also demonstrated on an aeroelastic research wing (ARW-2) using ENSAERO (an in-house NASA Ames Research Center CFD code) coupled with a finite element wing-box structures code. Good results have been obtained for the F/A-18 Stabilator while results for the ARW-2 supercritical wing are still being obtained.
Numerical predictions of the acoustic characteristics of an Active Twist Rotor (ATR), using two methods to compute the rotor blade aerodynamics and elastic blade motion are compared to experimental data from a wind tunnel test in the NASA Langley Transonic Dynamics Tunnel (TDT) in 2000. The first method, a loosely coupled iterative method, utilizes the Computational Fluid Dynamics (CFD) code OVERFLOW 2 and the Computational Structural Dynamics (CSD) code CAMRAD II. The second method utilizes the CAMRAD II free-wake model only. The harmonic active-twist control to the main rotor blade system is identified with three parameters - harmonic actuation frequency, actuation amplitude, and control phase angle. The resulting aerodynamics and blade motion data from the two methods are then used in the acoustics code PSU-WOPWOP to predict acoustic pressure on a spherical array of equally spaced observers surrounding the rotor. This spherical distribution of pressure is used to compute the sound power level representing baseline and actuated conditions. Sound power levels for three categories of noise are defined as - blade-vortex interaction sound power level (BVIPWL), low frequency sound power level (LFPWL), and overall sound power level, OAPWL. Comparisons with measured data indicate the CFD/CSD analysis successfully captures the trends in sound power levels and the effects of active-twist control at advance ratios of 0.14 and 0.17. The free-wake model predictions show inconsistent sound power levels relative to the trends in the experimental and CFD data. This paper presents the first ever comparison between CFD/CSD acoustic predictions for an active-twist rotor and experimental measurements.
A multidisciplinary design optimization procedure which couples formal multiobjectives based techniques and complex analysis procedures (such as computational fluid dynamics (CFD) codes) developed. The procedure has been demonstrated on a specific high speed flow application involving aerodynamics and acoustics (sonic boom minimization). In order to account for multiple design objectives arising from complex performance requirements, multiobjective formulation techniques are used to formulate the optimization problem. Techniques to enhance the existing Kreisselmeier-Steinhauser (K-S) function multiobjective formulation approach have been developed. The K-S function procedure used in the proposed work transforms a constrained multiple objective functions problem into an unconstrained problem which then is solved using the Broyden-Fletcher-Goldfarb-Shanno (BFGS) algorithm. Weight factors are introduced during the transformation process to each objective function. This enhanced procedure will provide the designer the capability to emphasize specific design objectives during the optimization process. The demonstration of the procedure utilizes a computational Fluid dynamics (CFD) code which solves the three-dimensional parabolized Navier-Stokes (PNS) equations for the flow field along with an appropriate sonic boom evaluation procedure thus introducing both aerodynamic performance as well as sonic boom as the design objectives to be optimized simultaneously. Sensitivity analysis is performed using a discrete differentiation approach. An approximation technique has been used within the optimizer to improve the overall computational efficiency of the procedure in order to make it suitable for design applications in an industrial setting.
It is established that Computational Fluid Dynamics (CFD) code validation is an integral part of all flow testing. Specific attention is given to the development of new methods/instruments to obtain time varying 3-D data. Additionally, a discussion concerning wind tunnels and small test facilities is presented. All results and data are presented in viewgraph form.
This paper describes the parallel version of the three-dimensional, chemically reacting, computational fluid dynamics (CFD) code, SPARK. This work was performed on the Intel iPSC/860-based parallel computers. The SPARK code utilizes relatively simple explicit numerical algorithms, but models complex chemical reactions. The code solves the equations over a regular structured mesh so a simple dam decomposition is used to assign work to the individual processors. The explicit nature of the algorithm, combined with the computational intensity of the chemistry calculations, results in a very low communication-to-computation ratio when compared to typical CFD codes. The efficiency of the parallel code is examined and shown to be about 65 percent when the problem size is scaled with the number of processors. Two low-angle wall-jet injection cases are solved to demonstrate the capability of the parallel code for solving large problems efficiently.
The System Thermal Hydraulics (STH) code SAM has been coupled to the Computational Fluid Dynamics (CFD) code Simcenter STAR-CCM+ utilizing a hybrid domain overlapping method with an explicit coupling in time. The coupling aims to extend the STH code’s applicability to scenarios where local momentum and energy transfers are important yet difficult for STH codes to capture, such as three-dimensional (3D) mixing. The coupling method’s numerical stability was verified in the past against two closed-loop configurations, and it was validated against a double T-junction experiment with 3D scalar mixing. In the present work, the coupling method is validated against the TALL-3D STH/CFD coupling benchmark facility. TALL-3D is a three-legged, liquid-metal facility with a large, pool-type enclosure (test section) that exhibits 3D flow effects to be modeled by a CFD code. The rest of the system exhibits approximately 1D behavior well-predicted by an STH code. First, the present STAR-CCM+ CFD model of the 3D test section is validated against experimental data. Then, the SAM-STARCCM+ coupled model is validated against six different TALL-3D steady states, including SAM standalone model results for comparison. Lastly, the SAM-STARCCM+ coupled model is validated against two TALL-3D transients, one exhibiting flow reversal in the test section and one exhibiting nonlinear, Limit Cycle Oscillations (LCO). For the first transient, the SAM-STARCCM+ coupled model properly predicts an increase in the test section’s inlet temperature during flow reversal, and this is not predicted by the SAM standalone model. Following flow reversal, the SAM-STARCCM+ coupled model better-predicts the initial flow recovery and following oscillations as the system approaches a final natural circulation state. For the second transient, no true final steady state is observed due to LCO. Neither the SAM-STARCCM+ coupled model nor the SAM standalone model can perfectly capture the experiment’s changing oscillation frequency during the transient. However, the SAM-STARCCM+ coupled model does reproduce the oscillatory feedback observed in the system. This is a significant achievement as the SAM-STARCCM+ coupled model only uses an explicit coupling in time, as opposed to a semi-implicit coupling. In comparison, previous STH/CFD coupling efforts of the TALL-3D facility required semi-implicit coupling to obtain similar results.
Adjoint shape optimization has enabled physics-based optimal designs for aerodynamic surfaces. Additive manufacturing (AM) makes it possible to manufacture complex shapes. However, there has been a gap between optimal and manufacturable surfaces due to the inherent limitations of commercial computational fluid dynamics (CFD) codes to implement geometric constraints during adjoint computation. In such cases, the design sensitivities are exported and used to perform constrained shape modifications using parametric information stored in computer aided design (CAD) files to satisfy manufacturability constraints. However, modifying the design using adjoint methods in CFD solvers and performing constrained shape modification in CAD can lead to inconsistencies due to different shape parameterization schemes. This paper describes a method to enable the simultaneous optimization of the fluid domain and impose AM manufacturability constraints, resolving one of the key issues of geometry definition for isogeometric analysis. Similar to a grid convergence study, the proposed method verifies the consistencies between shape parameterization techniques present within commercial CAD and CFD software during mesh movement as a part of the adjoint shape optimization routine. By identifying the appropriate parameters essential to a shape optimization study, the error metric between the different parameterization techniques converges to demonstrate sufficient consistencies for justifiable exchange of data between CAD and CFD. For the identified shape optimization parameters, the error metric to measure the deviation between the two parameterization schemes lies within the AM laser-powder bed fusion (L-PBF) process tolerance. Additionally, comparison for subsequent objective function calculations between iterations of the optimization loop showed acceptable differences within 1% variation between the modified geometries obtained using the two parameterization schemes. This method provides justification for the use of multiphysics guided adjoint design sensitivities computed in CFD software to perform shape modifications in CAD to incorporate AM manufacturability constraints during the shape optimization loop such that optimal designs are also additively manufacturable.
Research on the computational fluid dynamics (CFD) code evaluation with emphasis on supercomputing in reacting flows is discussed. Advantages of unstructured grids, multigrids, adaptive methods, improved flow solvers, vector processing, parallel processing, and reduction of memory requirements are discussed. As examples, researchers include applications of supercomputing to reacting flow Navier-Stokes equations including shock waves and turbulence and combustion instability problems associated with solid and liquid propellants. Evaluation of codes developed by other organizations are not included. Instead, the basic criteria for accuracy and efficiency have been established, and some applications on rocket combustion have been made. Research toward an ultimate goal, the most accurate and efficient CFD code, is in progress and will continue for years to come.
The task of developing a computational fluid dynamics (CFD) code to accurately model the mold filling phase of a casting operation was accomplished in a systematic manner. First the state-of-the-art was determined through a literature search, a code search, and participation with casting industry personnel involved in consortium startups. From this material and inputs from industry personnel, an evaluation of the currently available codes was made. It was determined that a few of the codes already contained sophisticated CFD algorithms and further validation of one of these codes could preclude the development of a new CFD code for this purpose. With industry concurrence, ProCAST was chosen for further evaluation. Two benchmark cases were used to evaluate the code's performance using a Silicon Graphics Personal Iris system. The results of these limited evaluations (because of machine and time constraints) are presented along with discussions of possible improvements and recommendations for further evaluation.
We develop the methodology of coupling two different computational fluid dynamic (CFD) codes, OpenNCC and Glenn-HT, in order to investigate the unsteady flow fields inside the combustor and around the first-stage stator of a high-pressure turbine (HPT) from the energy efficient engine (E 3 ) program. In our coupling strategy, OpenNCC, a time accurate unstructured mesh multi-phase combustion CFD code, is applied to the combustor region and Glenn-HT, a structured mesh CFD code designed for turbine applications, is utilized inside the HPT region. As a proof of concept, we first simulate the three-dimensional airflow over the backward facing step and compared the predicted pressure coefficient against experimental data. We then considered a Jet-A/Air combustor with the NASA single learn direct injector (LDI) as a reacting flow test case. Here, Glenn-HT is used in the downstream of the combustor and assumes that the working fluid is a single gas (i.e., air) where the properties of the gas are taken from time- and area-averaged values at the combustor exit. A fully coupled combustor-turbine simulation using both OpenNCC and Glenn-HT was conducted on the E 3 combustor and a detailed analysis done pertaining to how a realistic combustor outflow affects migration of hot-streaks and its impact on the aerodynamic behavior inside the HPT. It is found that the combustion dynamics (i.e., the switching main and pilot flame strength) significantly alters the aerodynamic behavior inside the HPT including hot-streak migration. Variations of the temperature and the velocity magnitude in the passage could be up to ±75 and ±15. These large variations are an important part of the combustor-turbine interactions, which are overlooked by a single component simulation of the HPT while imposing the steady inflow boundary condition at the HPT inlet. Finally, it is observed the strong density gradient associated with the hot-streaks and the pressure gradient at the passage significantly enhances the baroclinic torque, affecting the vorticity field.
The aim is to develop a 3-D computational fluid dynamics (CFD) code for the analysis of fluid flow in cylindrical seals and evaluation of the dynamic forces on the seals. This code is expected to serve as a scientific tool for detailed flow analysis as well as a check for the accuracy of the 2D industrial codes. The features necessary in the CFD code are outlined. The initial focus was to develop or modify and implement new techniques and physical models. These include collocated grid formulation, rotating coordinate frames and moving grid formulation. Other advanced numerical techniques include higher order spatial and temporal differencing and an efficient linear equation solver. These techniques were implemented in a 2D flow solver for initial testing. Several benchmark test cases were computed using the 2D code, and the results of these were compared to analytical solutions or experimental data to check the accuracy. Tests presented here include planar wedge flow, flow due to an enclosed rotor, and flow in a 2D seal with a whirling rotor. Comparisons between numerical and experimental results for an annular seal and a 7-cavity labyrinth seal are also included.
OVERFLOW is an overset, structured computational fluid dynamics (CFD) code written in Fortran which is widely used in the government, industry, and academia. Over the last several years the OVERFLOW developers have been working to port miniapps based on computationally expensive parts of OVERFLOW to run on GPUs, primarily using OpenACC. This effort started at our first hackathon in 2019 and since then the OVERFLOW team has attended two additional hackathons (virtually). These hackathon environments have provided a great place to collaborate with others and learn from experts. These learning experiences enabled porting two miniapps to run effectively on NVIDIA GPUs using OpenACC. The first miniapp focused on motifs found in the solver itself and the final ported version runs three times fast ona single V100 compared to a 40 core, dual-socket Intel Skylake node. The speed up in this solverminiapp required multiple design changes including increasing the amount of parallelism available and the amount of work performed in each kernel. The second miniapp focused on overset MPI communication, also saw significant speedups over the CPU implementation using a CUDA-aware MPI implementation through OpenACC. This presentation will discuss our experience at the hackathons, our process of porting the miniapps to run on the GPUs, and several lessons learned throughout.
A rotor section aerodynamics design package is developed by coupling Constrained Direct Iterative Surface Curvature (CDISC) design method with the FPX rotor code. The coupling between the CDISC design and the FPX flow analysis is fully automated. The CDISC design method employs a predictor-corrector procedure iteratively to determine a surface geometry which produces a target pressure distribution, where the target pressure distributions is either pre-defined or automatically generated through flow and geometry constraints. The FPX code is an eXtended Full-Potential rotor Computational Fluid Dynamics (CFD) code, which solves the three-dimensional unsteady full-potential equation in a strong conservative form using an implicit approximate factorization finite-difference scheme with entropy and viscosity corrections. Application of the CDISC design method coupled with the FPX rotor code is made for rotor blades in hovering motions. Several design examples are presented to demonstrate the capability of the new package in rotor section design.
Electron beam freeform fabrication (EBF3) is a member of an emerging class of direct manufacturing processes known as solid freeform fabrication (SFF); another member of the class is the laser deposition process. Successful application of the EBF3 process requires precise control of a number of process parameters such as the EB power, speed, and metal feed rate in order to ensure thermal management; good fusion between the substrate and the first layer and between successive layers; minimize part distortion and residual stresses; and control the microstructure of the finished product. This is the only effort thus far that has addressed computer simulation of the EBF3 process. The models developed in this effort can assist in reducing the number of trials in the laboratory or on the shop floor while making high-quality parts. With some modifications, their use can be further extended to the simulation of laser, TIG (tungsten inert gas), and other deposition processes. A solid mechanics-based finite element code, ABAQUS, was chosen as the primary engine in developing these models whereas a computational fluid dynamics (CFD) code, Fluent, was used in a support role. Several innovative concepts were developed, some of which are highlighted below. These concepts were implemented in a number of new computer models either in the form of stand-alone programs or as user subroutines for ABAQUS and Fluent codes. A database of thermo-physical, mechanical, fluid, and metallurgical properties of stainless steel 304 was developed. Computing models for Gaussian and raster modes of the electron beam heat input were developed. Also, new schemes were devised to account for the heat sink effect during the deposition process. These innovations, and others, lead to improved models for thermal management and prediction of transient/residual stresses and distortions. Two approaches for the prediction of microstructure were pursued. The first was an empirical approach involving the computation of thermal gradient, solidification rate, and velocity (G,R,V) coupled with the use of a solidification map that should be known a priori. The second approach relies completely on computer simulation. For this purpose a criterion for the prediction of morphology was proposed, which was combined with three alternative models for the prediction of microstructure; one based on solidification kinetics, the second on phase diagram, and the third on differential scanning calorimetry data. The last was found to be the simplest and the most versatile; it can be used with multicomponent alloys and rapid solidification without any additional difficulty. For the purpose of (limited) experimental validation, finite element models developed in this effort were applied to three different shapes made of stainless steel 304 material, designed expressly for this effort with an increasing level of complexity. These finite element models require large computation time, especially when applied to deposits with multiple adjacent beads and layers. This problem can be overcome, to some extent, by the use of fast, multi-core computers. Also, due to their numerical nature coupled with the fact that solid mechanics- based models are being used to represent the material behavior in liquid and vapor phases as well, the models have some inherent approximations that become more pronounced when dealing with multi-bead and multi-layer deposits.
A new code for the simulation of full (forebody and base region) flowfields about bluff bodies in the hypersonic regime of severe planetary entry is described. The present 'maximally conservative, maximally differenced' formulation of the unsteady compressible Navier-Stokes equations for 2-D axisymmetric 3-D flow is contrasted for stability with previous formulations of Viviand, Kutler, et al, and Thomas and Lombard. Discrete metric relations peculiar to the axisymmetric finite volume formulation are presented along with a general discussion of their relations to and consequences of failure to close computational cells. A computational mesh of curvilinear coordinate topology singular in the flow regime is presented that permits aligned capturing of the major physical features of the complex flowfield.
Gradient-based optimization requires accurate derivatives of the objective function and constraints. These gradients may have previously been obtained by manual differentiation of analysis codes, symbolic manipulators, finite-difference approximations, or existing automatic differentiation (AD) tools such as ADIFOR (Automatic Differentiation in FORTRAN). Each of these methods has certain deficiencies, particularly when applied to complex, coupled analyses with many design variables. Recently, a new AD tool called ADJIFOR (Automatic Adjoint Generation in FORTRAN), based upon ADIFOR, was developed and demonstrated. Whereas ADIFOR implements forward-mode (direct) differentiation throughout an analysis program to obtain exact derivatives via the chain rule of calculus, ADJIFOR implements the reverse-mode counterpart of the chain rule to obtain exact adjoint form derivatives from FORTRAN code. Automatically-generated adjoint versions of the widely-used CFL3D computational fluid dynamics (CFD) code and an algebraic wing grid generation code were obtained with just a few hours processing time using the ADJIFOR tool. The codes were verified for accuracy and were shown to compute the exact gradient of the wing lift-to-drag ratio, with respect to any number of shape parameters, in about the time required for 7 to 20 function evaluations. The codes have now been executed on various computers with typical memory and disk space for problems with up to 129 x 65 x 33 grid points, and for hundreds to thousands of independent variables. These adjoint codes are now used in a gradient-based aerodynamic shape optimization problem for a swept, tapered wing. For each design iteration, the optimization package constructs an approximate, linear optimization problem, based upon the current objective function, constraints, and gradient values. The optimizer subroutines are called within a design loop employing the approximate linear problem until an optimum shape is found, the design loop limit is reached, or no further design improvement is possible due to active design variable bounds and/or constraints. The resulting shape parameters are then used by the grid generation code to define a new wing surface and computational grid. The lift-to-drag ratio and its gradient are computed for the new design by the automatically-generated adjoint codes. Several optimization iterations may be required to find an optimum wing shape. Results from two sample cases will be discussed. The reader should note that this work primarily represents a demonstration of use of automatically- generated adjoint code within an aerodynamic shape optimization. As such, little significance is placed upon the actual optimization results, relative to the method for obtaining the results.
Powerful computer codes undergoing development. Report reviews development of computational fluid dynamics (CFD) for prediction of airflow around rotary wings of helicopters. Reviews progress in following endeavors: Prediction and verification of flows under various operating conditions; calculation of interactions between rotor blades and vortexes; analysis of viscous, transonic flows about airfoils; and study of formation of vortexes at tips of rotors.