Optimizing advanced propeller designs by simultaneously updating flow variables and design parameters
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A method has been studied for predicting the acoustic field of the SR-3 transonic propfan using flow data generated by two versions of the NASPROP-E computer code. Since the flow fields calculated by the solvers include the shock-wave system of the propeller, the nonlinear quadrupole noise source term is included along with the monopole and dipole noise sources in the calculation of the acoustic near field. Acoustic time histories in the near field are determined by transforming the azimuthal coordinate in the rotating, blade-fixed coordinate system to the time coordinate in a nonrotating coordinate system. Fourier analysis of the pressure time histories is used to obtain the frequency spectra of the near-field noise.
The SR-7A propeller was acoustically tested with and without downstream swirl recovery vanes to determine if any extra noise was caused by the interaction of the propeller wakes and vortices with these vanes. No additional noise was observed at the cruise condition over the angular range tested. The presence of the swirl recovery vanes did unload the propeller and some small peak noise reductions were observed from lower propeller loading noise. The propeller was also tested alone to investigate the behavior of the peak propeller noise with helical tip Mach number. As observed before on other propellers, the peak noise first rose with helical tip Mach number and then leveled off or decreased at higher helical tip Mach numbers. Detailed pressure-time histories indicate that a portion of the primary pressure pulse is progressively cancelled by a secondary pulse as the helical tip Mach number is increased. This cancellation appears to be responsible for the peak noise behavior at high helical tip Mach numbers.
The SR-7A propeller was acoustically tested with and without downstream swirl recovery vanes to determine if any extra noise was caused by the interaction of the propeller wakes and vortices with these vanes. No additional noise was observed at the cruise condition over the angular range tested. The presence of the swirl recovery vanes did unload the propeller and some small peak noise reductions were observed from lower propeller loading noise. The propeller was also tested alone to investigate the behavior of the peak propeller noise with helical tip Mach number. As observed before on other propellers, the peak noise first rose with helical tip Mach number and then leveled off or decreased at higher helical tip Mach numbers. Detailed pressure-time histories indicate that a portion of the primary pressure pulse is progressively cancelled by a secondary pulse as the helical tip Mach number is increased. This cancellation appears to be responsible for the peak noise behavior at high helical tip Mach numbers.
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Recent results of aerodynamic and acoustic research on both single rotation and counterrotation propellers are reviewed. Data and analytical results are presented for three propellers: SR-7A, the single rotation design used in the NASA Propfan Test Assessment (PTA) flight program; CRP-X1, the initial 5+5 Hamilton Standard counterrotating design; and F7-A7, the 8+8 counterrotating G.E. design used in the proof of concept Unducted Fan (UDF) engine. In addition to propeller efficiencies, cruise and takeoff noise, and blade pressure data, off-design phenomena involving formation of leading edge vortexes are described. Aerodynamic and acoustic computational results derived from 3-D Euler and acoustic radiation codes are presented. Research on unsteady flows which are particularly important for understanding counterrotation interaction noise, unsteady loading effects on acoustics, and flutter or forced response is described. The first results of 3-D unsteady Euler solutions are illustrated for a single rotation propeller at angle of attack and for a counterrotation propeller. Basic experimental and theoretical results from studies on the unsteady aerodynamics of oscillating cascades are outlined.
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A three-dimensional Euler solver is coupled with a three-dimensional structural dynamics model to investigate flutter of propfans. An implicit-explicit hybrid scheme is used to reduce computational time for the solution of Euler equations. The aeroelastic equations are formulated in normal modes and are solved for flutter in frequency domain. The required generalized forces are obtained using a pulse response method. Computations show that the instability is dominated by the second mode frequency as was observed in experiment.
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Advanced counter-rotation propellers have been indicated as possibly generating an unacceptable amount of noise for the people living near an airport. This report has explored ways to reduce this noise level, which is treated as being caused by the interaction of the upstream propeller wakes and vortices with the downstream propeller. The noise reduction techniques fall into two categories: (1) reducing the strength of the wakes and vortices, and (2) reducing the response of the downstream blades to them. The noise from the wake interaction was indicated as being reduced by increased propeller spacing and decreased blade drag coefficient. The vortex-interaction noise could be eliminated by having the vortex pass over the tips of the downstream blade, and it could be reduced by increased spacing or decreased initial circulation. The downstream blade response could be lessened by increasing the reduced frequency parameter omega or by phasing of the response from different sections to have a mutual cancellation effect. Uneven blade to blade spacing for the downstream blading was indicated as having a possible effect on the annoyance of counter-rotation propeller noise. Although there are undoubtedly additional methods of noise reduction not covered in this report, the inclusion of the design methods discussed would potentially result in a counter-rotation propeller that is acceptably quiet.
The time-marching Navier-Stokes code PARC3D was used to study the 3D viscous flow associated with an advanced ducted propeller subsonic inlet at take-off operating conditions. At a free stream Mach number of 0.2, experimental data for the inlet-with-propeller test model indicated that the airflow was attached on the cowl windward lip at an angle of attack of 25 deg became unstable at 29 deg, and separated at 30 deg. An experimental study with a similar inlet and without propeller (through-flow) indicated that flow separation occurred at an angle of attack a few degrees below the value observed when the inlet was tested with the propeller, indicating the propeller's favorable effect on inlet performance. In the present numerical study, flow blockage analogous to the propeller was modeled via a PARC3D computational boundary condition (BC), the 'screen BC', based on 1-1/2 dimension actuator disk theory. The application of the screen BC in this numerical study provided results similar to those of past experimental efforts in which either the blockage device or the propeller was used.
A time marching Navier-Stokes code called PARC3D was used to study the 3-D viscous flow associated with an advanced ducted propeller (ADP) subsonic inlet at take-off operating conditions. At a free stream Mach number of 0.2, experimental data for the inlet-with-propeller test model indicated that the airflow was attached on the cowl windward lip at an angle of attack of 25 degrees became unstable at 29 degrees, and separated at 30 degrees. An experimental study with a similar inlet and with no propeller (through-flow) indicated that flow separation occurred at an angle of attack a few degrees below the value observed when the inlet was tested with the propeller. This tends to indicate that the propeller exerts a favorable effect on the inlet performance. During the through-flow experiment a stationary blockage device was used to successfully simulate the propeller effect on the inlet flow field at angles of attack. In the present numerical study, this flow blockage was modeled via a PARC3D computational boundary condition (BC) called the screen BC. The principle formulation of this BC was based on the one-and-half dimension actuator disk theory. This screen BC was applied at the inlet propeller face station of the computational grid. Numerical results were obtained with and without the screen BC. The application of the screen BC in this numerical study provided results which are similar to the results of past experimental efforts in which either the blockage device or the propeller was used.
Several advanced-design propellers, previously tested in the wind tunnel at the Lewis Research Center, have been tested in flight at the Dryden Flight Research Facility. The flight-test propellers were mounted on a pylon on the top of the fuselage of a JetStar airplane. Acoustic data for the advanced-design SR-2 and SR-3 propellers at Mach numbers to 0.8 and helical-tip Mach numbers to 1.15 are presented; maximum blade-passage frequency sound-pressure levels are also compared.
Advanced turboprop-powered aircraft have the potential to reduce fuel consumption by 15 to 30 percent as compared with an equivalent technology turbofan-powered aircraft. An important obstacle to the use of advanced design propellers is the cabin noise generated at Mach numbers up to .8 and at altitudes up to 35,000 feet. As part of the NASA Aircraft Energy Efficiency Program, the near-field acoustic characteristics on a series of advanced design propellers are investigated. Currently, Dryden Flight Research Center is flight testing a series of propellers on a JetStar airplane. The propellers used in the flight test were previously tested in wind tunnels at the Lewis Research Center. Data are presented showing the narrow band spectra, acoustic wave form, and acoustic contours on the fuselage surface. Additional flights with the SR-3 propeller and other advanced propellers are planned in the future.
Advanced design propellers on a JetStar aircraft were tested at NASA Ames Research Center's Dryden Flight Research Facility. A calibration of the flow field at the test location to obtain local Mach number and flow direction was performed. A pitot-static probe and flow direction vane installation was installed and tested at Mach 0.3 to 0.8 and altitudes from 3000 m (10,000 ft) to 9100 m (30,000 ft). Local Mach number and flow direction relationships were obtained and related to their noseboom counterparts. Effects of varying angles of sideslip to + or - 3 deg. were investigated.
An advanced lightweight insulation system suitable for use in long duration, low pressure planetary orbiter-type motor applications was developed. Experiments included the screening of various filler and binder materials with optimization studies combining the best of each. Small scale test motor data were used to judge the degree of success.