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Computer structural optimization is applied to the design of Space Shuttle main engine turbopump blades. The optimization is implemented by the program SSME/STAEBL. A general description of this program is given. Design optimization studies for typical blade designs are presented.
One of the propulsion concepts being investigated for future cruise missiles is advanced unducted propfans. To support the evaluation of this technology applied to the cruise missile, a joint DOD and NASA test project was conducted to design and then test the characteristics of the propfans on a 0.55-scale, cruise missile model in a NASA wind tunnel. The configuration selected for study is a counterrotating rearward swept propfan. The forward blade row, having six blades, rotates in a counterclockwise direction, and the aft blade row, having six blades, rotates in a clockwise direction, as viewed from aft of the test model. Figures show the overall cruise missile and propfan blade configurations. The objective of this test was to evaluate propfan performance and suitability as a viable propulsion option for next generation of cruise missiles. This paper details the concurrent computer aided design, engineering, and manufacturing of the carbon fiber/epoxy propfan blades as the NASA Lewis Research Center.
A new inverse inviscid method suitable for the design of rotating blade sections lying on an arbitrary axisymmetric stream-surface with varying streamtube width is presented. The geometry of the axisymmetric stream-surface and the streamtube width variation with meridional distance, the number of blades, the inlet flow conditions, the rotational speed and the suction and pressure side velocity distributions as functions of the normalized arc-length are given. The flow is considered irrotational in the absolute frame of reference and compressible. The output of the computation is the blade section that satisfies the above data. The method solves the flow equations on a (phi 1, psi) potential function-streamfunction plane for the velocity modulus, W and the flow angle beta; the blade section shape can then be obtained as part of the physical plane geometry by integrating the flow angle distribution along streamlines. The (phi 1, psi) plane is defined so that the monotonic behavior of the potential function is guaranteed, even in cases with high peripheral velocities. The method is validated on a rotating turbine case and used to design new blades. To obtain a closed blade, a set of closure conditions were developed and referred.
The aerodynamic, acoustic, and aeromechanical performance of counterrotating blade concepts were evaluated both theoretically and experimentally. Analytical methods development and design are addressed. Utilizing the analytical methods which evolved during the conduct of this work, aerodynamic and aeroacoustic predictions were developed, which were compared to NASA and GE wind tunnel test results. The detailed mechanical design and fabrication of five different composite shell/titanium spar counterrotating blade set configurations are presented. Design philosophy, analyses methods, and material geometry are addressed, as well as the influence of aerodynamics, aeromechanics, and aeroacoustics on the design procedures. Blade fabrication and quality control procedures are detailed; bench testing procedures and results of blade integrity verification are presented; and instrumentation associated with the bench testing also is identified. Additional hardware to support specialized testing is described, as are operating blade instrumentation and the associated stress limits. The five counterrotating blade concepts were scaled to a tip diameter of 2 feet, so they could be incorporated into MPS (model propulsion simulators). Aerodynamic and aeroacoustic performance testing was conducted in the NASA Lewis 8 x 6 supersonic and 9 x 15 V/STOL (vertical or short takeoff and landing) wind tunnels and in the GE freejet anechoic test chamber (Cell 41) to generate an experimental data base for these counterrotating blade designs. Test facility and MPS vehicle matrices are provided, and test procedures are presented. Effects on performance of rotor-to-rotor spacing, angle-of-attack, pylon proximity, blade number, reduced-diameter aft blades, and mismatched rotor speeds are addressed. Counterrotating blade and specialized aeromechanical hub stability test results are also furnished.
Analyses were performed on a high-speed composite blade set for the Department of Defense Propfan Missile Interactions Project. The final design iteration, which resulted in the CM2D-2 blade design, is described in this report. Mode shapes, integral order excitation, and stress margins were examined. In addition, geometric corrections were performed to compensate for blade deflection under operating conditions with respect to the aerodynamic design shape.
The concept of a one-bladed horizontal-axis wind turbine has been of interest to wind turbine designers for many years. Many designs and economic analyses of one-bladed wind turbines have been undertaken by both United States and European wind energy groups. The analyses indicate significant economic advantages but at the same time, significant dynamic response concerns. In an effort to develop a broad data base on wind turbine design and operations, the NASA Wind Energy Project Office has tested a one-bladed rotor at the NASA/DOE Mod-O Wind Turbine Facility. This is the only known test on an intermediate-sized one-bladed rotor in the United States. The 15.2-meter-radius rotor consists of a tip-controlled blade and a counterweight assembly. A rigorous test series was conducted in the Fall of 1985 to collect data on rotor performance, drive train/generator dynamics, structural dynamics, and structural loads. This report includes background information on one-bladed rotor concepts, and Mod-O one-bladed rotor test configuration, supporting design analysis, the Mod-O one-blade rotor test plan, and preliminary test results.
A comprehensive anaytical design procedure for the installation of simple pendulums on the blades of a helicopter rotor to suppress the root reactions is presented. A frequency response anaysis is conducted of typical rotor blades excited by a harmonic variation of spanwise airload distributions as well as a concentrated load at the tip. The results presented included the effect of pendulum tuning on the minimization of the hub reactions. It is found that a properly designed flapping pendulum attenuates the root out-of-plane force and moment whereas the optimum designed lead-lag pendulum attenuates the root in-plane reactions. For optimum pendulum tuning the parameters to be determined are the pendulum uncoupled natural frequency, the pendulum spanwise location and its mass. It is found that the optimum pendulum frequency is in the vicinity of the excitation frequency. For the optimum pendulum a parametric study is conducted. The parameters varied include prepitch, pretwist, precone and pendulum hinge offset.
The topic of validating structural optimization methods by use of experimental results is addressed. The need for validating the methods as a way of effecting a greater and an accelerated acceptance of formal optimization methods by practicing engineering designers is described. The range of validation strategies is defined which includes comparison of optimization results with more traditional design approaches, establishing the accuracy of analyses used, and finally experimental validation of the optimization results. Examples of the use of experimental results to validate optimization techniques are described. The examples include experimental validation of the following: optimum design of a trussed beam; combined control-structure design of a cable-supported beam simulating an actively controlled space structure; minimum weight design of a beam with frequency constraints; minimization of the vibration response of helicopter rotor blade; minimum weight design of a turbine blade disk; aeroelastic optimization of an aircraft vertical fin; airfoil shape optimization for drag minimization; optimization of the shape of a hole in a plate for stress minimization; optimization to minimize beam dynamic response; and structural optimization of a low vibration helicopter rotor.
An investigation was carried out to complete the preliminary development of a combined perturbation/optimization procedure and associated computational code for designing optimized blade-to-blade profiles of turbomachinery blades. The overall purpose of the procedures developed is to provide demonstration of a rapid nonlinear perturbation method for minimizing the computational requirements associated with parametric design studies of turbomachinery flows. The method combines the multiple parameter nonlinear perturbation method, successfully developed in previous phases of this study, with the NASA TSONIC blade-to-blade turbomachinery flow solver, and the COPES-CONMIN optimization procedure into a user's code for designing optimized blade-to-blade surface profiles of turbomachinery blades. Results of several design applications and a documented version of the code together with a user's manual are provided.
A variable pitch fan actuation system was designed which incorporates a remote nacelle-mounted blade angle regulator. The regulator drives a rotating fan-mounted mechanical actuator through a flexible shaft and differential gear train. The actuator incorporates a high ratio harmonic drive attached to a multitrack spherical cam which changes blade pitch through individual cam follower arms attached to each blade trunnion. Detail design parameters of the actuation system are presented. These include the following: design philosophies, operating limits, mechanical, hydraulic and thermal characteristics, mechanical efficiencies, materials, weights, lubrication, stress analyses, reliability and failure analyses.
The development of structural models for composite rotor blades is summarized. The models are intended for use in design analysis for the purpose of exploring the potential of elastic tailoring. The research was performed at the Center for Rotary Wing Aircraft Technology.
The design of large wind power systems in Germany is reviewed with attention given to elaboration of the total wind energy system, aerodynamic design of the rotor blade, and wind loading effects. Particular consideration is given to the development of composite glass fiber/plastic or carbon fiber/plastic rotor blades for such installations.
Rotor blade modifications for high weight flow, low pressure ratio turbine
The feasibility to incorporate an active higher harmonic control (HHC) system on an OH-6A rotorcraft was demonstrated. The introduction of continuously modulated low amplitude 4P feathering showed potential for reducing rotor transmitted oscillatory loads. The design implementation of this system on a baseline OH-6A required generation of a hydraulic power system, control actuator placement and design integration of an electronic subsystem comprised of an electronic control unit (ECU) and digital microcomputer. Various placements of the HHC actuators in the primary control system are evaluated. Assembly drawings of the actuator concepts and control rigging are presented. The advantages of generating both hydraulic power and 4F control motions in the nonrotating system is confirmed.
A solid blade version of a single-stage, axial-flow turbine was investigated to determine its performance over a range of speeds from 0 to 105 percent of equivalent design speed and over a range of total to static pressure ratios from 1.62 to 5.07. The results of this investigation will be used as a baseline for comparison with those obtained from a cooled version of this turbine.
A supersonic tip speed single stage fan was modified with the intent of reducing multiple pure tone (MPT) or buzz saw noise. There were three modifications to the blades from the original design. The modifications to the blade resulted in an increase in cascade throat area causing the shock to start at a lower corrected fan speed. The acoustic results without acoustically absorbing liners showed substantial reduction in multiple pure tone levels. However, an increase in the blade passing frequency noise at takeoff fan speed accompanied the MPT reduction. The net result however, was a reduction in the maximum 1000-foot (304.8 m) altitude level flyover PNL. For the case with acoustic treatment in the inlet outer wall, the takeoff noise increased relative to an acoustically treated baseline. This was largely due to the increased blade passing frequency noise which was not effectively reduced by the liner.
Aerodynamic design parameters are presented along the overall and blade element performance, of an axial flow compressor rotor designed to study the effects of blade solidity on efficiency and stall margin. At design speed the peak efficiency was 0.844 and occurred at an equivalent weight flow of 63.5 lb/sec with a total pressure ratio of 1.801. Design efficiency, pressure ratio, and weight flow 0.814, 1.65, and 65.3(41.1 lb/sec/sq ft of annulus area), respectively. Stall margin for design speed was 6.4 percent based on the weight flow and pressure ratio values at peak efficiency and just prior to stall.
Design and performance of axial-flow pump rotor with blade tip diffusion factor of 0.66