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NASA NTRS2017

Comprehensive Analysis Modeling of Small-Scale UAS Rotors

Multicopter unmanned aircraft systems (UAS), or drones, have continued their explosive growth in recent years. With this growth comes demand for increased performance as the limits of existing technologies are reached. In order to better design multicopter UAS aircraft, better performance prediction tools are needed. This paper presents the results of a study aimed at using the rotorcraft comprehensive analysis code CAMRAD II to model a multicopter UAS rotor in hover. Parametric studies were performed to determine the level of fidelity needed in the analysis code inputs to achieve results that match test data. Overall, the results show that CAMRAD II is well suited to model small-scale UAS rotors in hover. This paper presents the results of the parametric studies as well as recommendations for the application of comprehensive analysis codes to multicopter UAS rotors.

Analysis↗

NASA NTRS2016

Aerodynamic Analysis of the Elytron 2S Experimental Tiltwing Aircraft

The Elytron 2S is a prototype aircraft concept to allow VTOL capabilities together with fixed wing aircraft performance. It has a box wing design with a centrally mounted tilt-wing supporting two rotors. This paper explores the aerodynamic characteristics of the aircraft using computational fluid dynamics in hover and low speed forward flight, as well as analyzing the unique control system in place for hover. The results are then used to build an input set for NASA Design and Analysis if Rotorcraft software allowing trim and flight stability and control estimations to be made with SIMPLIFLYD.

Elytron 2S↗

NASA NTRS2018

Generation of Performance Model for the Aeolian Wind Tunnel (AWT) Rotor at Reduced Pressure

The NASA Jet Propulsion Laboratory (JPL) designed the Mars Helicopter (MH) in collaboration with AeroVironment Inc., NASA Ames Research Center, and NASA Langley Research Center to explore the possibility of a vertical takeoff and landing (VTOL) Unmanned Aerial Vehicle (UAV) for flight on Mars. A 40-inch-diameter Aeolian Wind Tunnel (AWT) rotor, roughly approximating the proposed MH design by JPL, was tested in forward flight at Mars atmospheric pressure at the NASA Ames Planetary Aeolian Laboratory (PAL) in support of MH research efforts. This report describes the generation of the rotor model used to correlate with that experimental effort as reported by Ament and Koning. The 40-inch-diameter rotor was 3D-scanned and transformed into an airfoil deck. The scanned rotor airfoil sections are analyzed using C81 Generator (C81Gen) to generate the sectional aerodynamic coefficients for comprehensive analyses. A mid-fidelity computational fluid dynamics (CFD) simulation using Rotorcraft CFD (RotCFD) is pursued to efficiently estimate rotor hover and forward flight performance. Simulations at two pressures, 7 mbar (approximate Martian atmospheric pressure) and 1018 mbar (1 atmosphere), are performed to gain an understanding of the performance differences and Reynolds number effects observed. Experimental 1-atmosphere thrust for single- and dual-rotor isolated hover cases correlate well with the modeled rotor. Performance results at reduced pressure (7 mbar) show a drastic decrease in lift for equivalent RPMs tested at 1 atmosphere. Although this is primarily due to pressure reduction, Reynolds number effects also contribute to this decrease, as airfoil lift and drag coefficients are affected when compared with 1-atmosphere results. Further, simulated rotor power coefficient shows drastic increases at reduced pressures, attributed to laminar boundary layer separation, as described in Koning et al. for the MH rotor analysis. PAL experimental Martian Surface Wind Tunnel (MARSWIT) results are presented in the paper by Ament and Koning. The very low Reynolds number range is currently not well understood and presents various challenges for both experimentation and simulation.

Koning, Witold J. F.↗

NASA NTRS2017

Design and Control of an Experimental Tilt-Wing Aircraft

In this project, work has been done in the field of conceptual design of experimental tiltrotors. The main tools that have been used are NDARC (NASA Design and Analysis of Rotorcraft) and SIMPLI-FLYD. NDARC is a conceptual design tool for rotorcraft, and it is used to find trim points under various flight conditions. SIMPLI-FLYD is an integrated collection of software tools that enables a flight dynamics and control assessment of the rotorcraft vehicle design generated from NDARC. Two different tiltrotors have been investigated. Initially, work was done with the Bell XV- 15 tiltrotor. NDARCs ability to correctly model the tiltwing transition between airplane mode and hover mode was looked into. In addition, data from old flight tests were compared to the NDARC output, to see how accurately performance could be predicted. After the XV-15 analysis, an NDRARC model of a novel tiltwing concept from Elytron Aircraft was written and analyzed together with SIMPLI-FLYD. Elytron 2S is an experimental tiltwing aircraft, consisting of a joined-wing design with a small central wing for the proprotor. An alternative approach to hover control is used, where the typical rotor hub and swash plate are substituted for linear actuators controlling pitch, yaw and roll. The objective with the analysis of Elytron is to obtain a more complete understanding of the maneuverability and possible performance of this alternative aircraft configuration.

Conceptual Design↗

NASA NTRS2016

A Study of Coaxial Rotor Performance and Flow Field Characteristics

As a precursor to studying the acoustics of a coaxial rotor system, the aerodynamics and flow field of a coaxial rotor were simulated to better understand the interaction between the two rotors. RotUNS, an unsteady Navier-Stokes solver that uses a simplified blade aerodynamics model, was used to predict coaxial rotor performance in hover and forward flight. RotUNS steady hover calculations showed improved performance compared to blade element momentum theory. Prior to examining the complex 3D flow field of a coaxial rotor in detail, two airfoils traveling in opposite directions with a vertical separation distance equivalent to the separation between the upper and lower rotor of the coaxial system were simulated. The pressure field generated by the two airfoils aided our interpretation of the more complex coaxial rotor system flow field. The pressure fields above, between, and below the coaxial rotor system were then examined for different azimuth positions of the upper and lower rotor blades.

Barbely, Natasha L.↗

NASA NTRS2019

Correlation of Full-Scale Isolated Proprotor Performance and Loads

A full-scale isolated proprotor test is currently being conducted in the USAF National Full-Scale Aerodynamics Complex (NFAC) 40- by 80-Foot Wind Tunnel at NASA Ames. The test article is a 3-bladed research rotor derived from the right-hand rotor of the AW609; this rotor was manufactured by Bell Helicopter under contract to NASA. In this paper, this research rotor is referred to as "699". The test, nearly completed, is an integral part of the initial checkout test of the newly developed Tiltrotor Test Rig (TTR), whose purpose is to test advanced, full-scale proprotors in the NFAC. Figure 1 shows the TTR/699 installed in the 40- by 80-Foot test section. The TTR rotor axis is horizontal and the rig rotates in yaw on the wind tunnel turntable for conversion (transition) and helicopter mode testing. To date, a substantial amount of wind tunnel test data has already been acquired. The completed operational conditions include hover, airplane mode (cruise, wind tunnel airspeed V=61 to 267 knots), and the helicopter and conversion conditions (with a comprehensive sweep of the TTR yaw angle ranging, to date, from 90-deg yaw helicopter mode to 30-deg yaw conversion mode, at varying airspeeds). This 699 proprotor performance and loads correlation study uses these newly acquired wind tunnel test data. This paper represents the third analytical study, coming after two earlier analytical studies on the TTR/699; that is, a 2018 paper on pre-test predictions of 699 performance and loads, Ref. 1, and an upcoming January 2019 paper on aeroelastic stability analysis of the TTR/699 installed in the 40- by 80-Foot Wind Tunnel, Ref. 2. Reference 8 will present an overview of the entire TTR/699 test program. For completeness, Ref. 3 addresses the development and initial testing of the TTR. Background information on the TTR effort at NASA Ames can be found at the Aeromechanics website: https://rotorcraft.arc.nasa.gov/Research/Facilities/ttr.html. To the authors' knowledge, the full-scale results presented in this paper are the first of their kind. A literature survey brought up several existing correlation studies, but these were either based on small-scale test data (for example, the studies performed by the University of Maryland) or full-scale aircraft flight test data (for example, flight tests conducted by Bell Helicopter). Separately, the 2009 NASA study involving the JVX rotor is relevant (see Ref.4). The JVX is closely similar to the 699 in size and aerodynamics, and is accordingly a good reference for performance calculations. In Ref. 1 (as mentioned above), pre-test reality checks of the current analytical model were made by comparing JVX and 699 predictions in hover and forward flight (airplane mode).

Isolated Proprotor Performance↗

NASA NTRS2019

Correlation of Full-Scale Isolated Proprotor Performance and Loads

A full-scale isolated proprotor test was recently conducted in the USAF National Full-Scale Aerodynamics Complex (NFAC) at NASA Ames Research Center. The test article was a 3-bladed research rotor derived from the right-hand rotor of the AW609. For this test, the NASA Tiltrotor Test Rig (TTR) and rotor were installed in the 40- by 80-foot test section. This paper presents correlations between data and predictions of rotor performance and blade moments using the newly acquired test data and the comprehensive analysis CAMRAD II. The operational conditions covered in this analytical study are: hover (actually, low speed vertical climb), cruise (airplane mode), conversion, and helicopter mode. Mean and 1/2 peak-to-peak quantities (hpp) are correlated; time-history correlation for the helicopter condition is also included. The correlation is reasonable to good. Also, the hover calculations turned out to be useful in providing reality checks on the test hardware such as: a) the functioning of the blade strain gages and b) calibration of the measurement of the collective pitch hardware. The time-history correlation shows that, compared to the rolled-up wake model, the multiple-trailer wake model improves the correlation slightly; the longitudinal cyclic correlation is reasonable but the lateral cyclic correlation is not good, and the collective is predicted well by the rolled-up wake model; the flap moment correlation is reasonable; the pitch link load and lag moment are underpredicted; and the torsion moment correlation is poor and needs further study.

Kottapalli, Sesi↗

NASA NTRS2019

Extraction of Dynamic Inflow Models for Coaxial and Tandem Rotors from CFD Simulations

The dynamic inflow coupling with rotor/body dynamics is crucial in the analysis of stability and control law design for helicopters. Over the past several decades, finite-state inflow models for single rotor configurations in hover, forward flight, and maneuver have developed (Ref.1-3). By capturing the interference effects between rotors, the extension of pressure potential finite state inflow model has promising result for coaxial rotor configuration (Ref.4-6). Recently, the focus of the dynamic inflow modeling has shifted to tandem rotor configurations (Ref.7, 8). The development of the dynamic inflow models for tandem rotor configuration still have some limitations due to the lack of knowledge of rotor-to-rotor interference, and rotor-wake interference. Experimental methods, and computational fluid dynamics methods are commonly used to understand the rotor performance and rotor airload variations, and measure or predict inflow velocity distributions at the rotor desk. The inflow distributions are subsequently used to improve the dynamic inflow models. Tandem rotor configurations have been studied experimentally and computationally for several decades (Ref.9-12). Sweet (Ref.10) observed that a tandem rotor with 76-percent-radius overlap required 14% more induced power at hovering condition, relative to an isolated rotor of equivalent disk area. Sweet also found that, above a shaft-to-shaft distance of 1.03 diameter, the performance of the tandem rotor was nearly the same as two isolated rotors. The objective of the present study is to apply computational fluid dynamics simulations of tandem rotors for the extraction of dynamic inflow models. The extended methodology is first validated by comparing the computed induced power against test data. Subsequently inflow distributions and wake structures are analyzed.

Extraction of Dynamic Inflow Models↗

NASA NTRS2020

Control Force Compensation in Ground-Based Flight Simulators

This paper presents the results of a study that investigated if controller force compensations accounting for the inertial force and moment due to the aircraft motion during flight have a significant effect on pilot control behavior and performance. Seven rotorcraft pilots performed a side-step and precision hovering task in light turbulence in the Vertical Motion Simulator. The effects of force compensation were examined for two different simulated rotorcraft: linear and UH-60 dynamics with two different force gradient of the lateral stick control. Four motion configurations were used: large motion, hexapod motion, fixed-base motion, and fixed-base motion with compensation. Control-input variables and task performance such as the time to translate to the designated hover position, station-keeping position errors, and handling qualities ratings were used as measures. Control force compensation enabled pilot control behavior and performance more similar to that under high- or medium-fidelity motion to some extent only. Control force compensation did not improve overall task performance considering both rotorcraft models at the same time. The control force compensation had effects on the linear model with lighter force gradient, but only a minimal effect on pilots? control behavior and task performance for the UH-60 model, which had a higher force gradient. This suggests that the control force compensation has limited benefits for controllers that have higher stiffness.

Chung, William W.↗

NASA NTRS2020

Control Force Compensation in Ground-Based Flight Simulators

Chung, William↗

NASA NTRS2020

Acoustic Optimization for Anti-Phase Asymmetric Rotor

This investigation seeks to optimize the implementation of anti-phase alternating trailing edge (TE) patterns for rotor noise suppression. The design objective is to maximize reduction of noise perceived by the community while maintaining the aerodynamic thrust. Computations using a three-dimensional Unsteady-Reynolds-Averaged-Navier-Stokes (URANS) with k-w Shear Stress Transport (SST) turbulence model and Ffowcs-Williams and Hawkings (FW-H) formula are used to obtain aerodynamic thrust and far-field noise level. A parametric acoustic study of 13 configurations of KDE rotor with variable alternating trailing edge period, alternating trailing edge length, and trailing edge deflection angle is conducted. The best design candidate for the KDE rotor has a four-period TE waveform which results in a reduction in far-field noise level of 2.1 dB in the hover condition and a reduction of 1.1 dB in the forward flight condition at 9.7 m/s. A further parametric acoustic study is conducted for a different rotor manufactured by APC. Six APC rotor design candidates are simulated. The best design candidate 4H for the APC rotor results in a reduction in far-field noise level of 4.0 dB in the hover condition and a reduction of 1.3 dB in the forward flight condition at 9.7 m/s. A series of acoustic experiments in the Penn State University (PSU) anechoic chamber have been conducted. In the forward flight condition at 9.7 m/s, the APC anti-phase 4H rotor offers clear evidence of noise suppression capability across a wide range of the azimuthal angle. In the broadband frequency range of 2000-4000 Hz, the APC anti-phase 4H rotor produces as much as 6 dB noise reduction. The experimental results appear to confirm the noise suppression capability of the proposed anti-phase rotor design concepts.

Xiong, Juntao↗

NASA NTRS2019

High-Fidelity Multidisciplinary Sensitivity Analysis Framework for Multipoint Rotorcraft Optimization

A multidisciplinary, gradient-based sensitivity-analysis methodology is evaluated for optimization of rotorcraft configurations. The tightly coupled discipline models include physics-based fluid dynamics and rotorcraft comprehensive analysis. A discretely-consistent adjoint method accounts for sensitivities of the unsteady flow and unstructured, dynamic, over set grids, while sensitivities of structural responses to aerodynamic loads are computed using a complex-variable method. The methodology is applied to optimize the shape of UH-60A Blackhawk helicopter blades for hover and forward flight conditions. The objective of the multipoint design is to simultaneously increase the rotorcraft figure of merit in a hover flight and reduce the rotor power in a forward flight. Trimmed loose-coupling solutions for the baseline configuration are used to initiate the tight-coupling multidisciplinary analysis. Target thrust and rolling and pitching moments are enforced as optimization constraints. The optimized configuration improves the optimization metrics at both design points. The improved performance and all constraints are maintained over many revolutions beyond the optimization interval, satisfying the required flight conditions. Computational cost of the optimization cycle is assessed in a high-performance computing environment and found affordable for design of rotorcraft in general level-flight conditions.

Wang, Li↗

NASA NTRSDate not supplied

Fundamental Aeroelastic Analysis of an Urban Air Mobility Rotor

A computational investigation was conducted of the aeroelastic characteristics of a representative rotor typical of aircraft for Urban Air Mobility. A rotorcraft comprehensive analysis was used to examine the aeroelastic characteristics of the model, both in hover and in forward flight. Throughout the study, parameters examined included rotor rotational speed, forward flight speed, blade torsion stiffness, and chordwise locations of the blade elastic axis and center of gravity. Three sets of airfoil properties were analyzed: NACA 0012, VR8, and VR12. For hover, the effect of dynamic inflow was studied via a comparison of uniform inflow and dynamic inflow models. Thrust coefficient and blade tip twist were analyzed to ascertain performance characteristics, and eigen analysis was employed to determine stability. For the forward flight cases, rpm and forward flight speed were swept separately, and the effect of each on performance and stability was assessed. Thrust coefficient and mean drag coefficient were used to evaluate performance of the rotor, and eigen analysis was invoked to study rotor stability. Forward flight stability results generated via a constant coefficient analysis were compared with results generated via Floquet Theory.

Fundamental Aeroelastic Analysis↗

NASA NTRSDate not supplied

Structural Design and Aeromechanical Analysis of Unconventional Blades for Future Mars Rotorcraft

The structural design for rotor blades with thin, unconventional airfoils for Earth-based testing is obtained using three-Dimensional (3D) aeromechanical analysis. This analysis is in support of the NASA ROAMX project. The outer mold was provided by NASA, but the internal structural design was developed at the University of Maryland and is presented here, along with a thorough aeromechanical analysis. The main objectives are to verify the structural integrity of the design and understand the unique aeroelastic behavior of the non-conventional airfoils designed for low-Reynolds number and high-Mach number flow. Six different blade models are considered, with the pitch axis varied from quarter-chord to mid-chord to determine the effect of C.G. offset on natural frequencies, blade deformations, root loads, and 3D stresses. All six blade designs are first studied under rotation in pure vacuum, and significant reductions in root loads and 3D stresses are achieved by moving the pitch axis closer to mid-chord to reduce the C.G. offset. Based on the vacuum analysis, the blade design with the pitch axis at 40% chord is selected for aerodynamic analysis. The blade control load, airloads, deformations, and 3D stresses are studied for steady hover. Dynamic control load and dynamic 3D stresses are studied for unsteady hover achieved using cyclic. Significant elastic twist is observed due to the trapeze effect and propeller moment, affecting the spanwise distribution of aerodynamic loads on the blades. However, the effect of aerodynamic loads on 3D stresses and the blade control load is found to be minimum. The dynamic control load is found to increase significantly due to inertial coupling from the C.G. offset. The dynamic stresses also increase, although still have factors of safety greater than two for both tensile and compressive stress.

Structural Design↗

NASA NTRS2023

Structural Design and Aeromechanical Analysis of Unconventional Blades for Future Mars Rotorcraft

The structural design for rotor blades with thin, unconventional airfoils for Earth-based testing is obtained using three-Dimensional (3D) aeromechanical analysis in support of the NASA ROAMX project. The outer mold line was provided by NASA, but the internal structural design was developed at the University of Maryland and is presented here along with a thorough aeromechanical analysis. The main objectives are to verify the structural integrity of the design and understand the unique aeroelastic behavior of the non-conventional airfoils designed for low-Reynolds number and high subsonic Mach number. Four different blade models are considered, with the pitch axis varied from quarter-chord to mid-chord to determine the effect of C.G. offset on natural frequencies, blade deformations, root loads, and 3D stresses. First, torsional stability is calculated for each of the designs – especially important due to the low Lock number on Mars. All four blade designs are studied under rotation in vacuum, and significant reductions in root loads and 3D stresses are achieved by moving the pitch axis closer to mid-chord to reduce the C.G. offset. Based on the vacuum analysis, the blade design with the pitch axis at 40% chord is selected for aeromechanical analysis. The blade control load, airloads, deformations, and 3D stresses are studied for steady hover. Dynamic control load and dynamic 3D stresses are studied for unsteady hover achieved using cyclic. Significant elastic twist is observed due to the trapeze effect and propeller moment, affecting the spanwise distribution of aerodynamic loads on the blades. The dynamic control load is found to increase significantly due to inertial coupling from the C.G. offset. The dynamic stresses also increase, although still have factors of safety greater than two for both tensile and compressive stress.

Structural Design↗

NASA NTRSDate not supplied

Predicted Performance Effects of Blade Elasticity on Testing of Rotors for Mars

The Rotor Optimization for the Advancement of Mars Exploration project (ROAMX) has designed and manufactured a set of rotor blades optimized for hover on Mars. These blades will soon be tested for hover performance in the NASA Ames Research Center Planetary Aeolian Laboratory, a large vacuum chamber capable of rotor testing at reduced pressures. To match the tip Mach numbers during this testing with the tip Mach numbers that would be experienced in the Martian atmosphere, the rotor will be spun faster in the vacuum chamber than it would be spun on Mars. While this accomplishes the goal of simulating the tip Mach numbers of Mars operations, the elevated RPM may have undesired consequences for performance, due to elastic deflections of the blades. The purpose of this paper is to use CAMRAD II, a rotorcraft comprehensive analysis code, to predict the effect on performance of blade elasticity at elevated RPM in the vacuum chamber environment. Results are presented for different thrust conditions and different rotor speeds, and comparisons are made between rigid and elastic blade predictions. Overall, the CAMRAD II analysis suggests that blade elasticity does influence rotor performance in the operating conditions of interest, although the effect is moderate enough to conclude that the PAL testing will be a good simulation of Mars operation.

Blade elasticity↗

NASA NTRSDate not supplied

Simulation of the Rotorwash Induced by a Quadrotor Urban Air Taxi in Ground Effect

A rotorcraft hovering near the ground causes downwash and outwash. The impact of these induced velocities on urban air mobility operations has not been extensively quantified. This paper explores the opportunity of using CFD to perform dedicated studies on the aerodynamics of rotorcraft in ground effect (IGE). For this purpose, we compare load and flow predictions obtained with the high-fidelity CFD solver OVERFLOW and with a medium-fidelity vortex particle-mesh (VPM) method, for a single rotor IGE. We show that the computational cost of high-fidelity simulation makes it impractical to sweep through a large number of configurations or operating conditions. However, a small set of cases can be used to verify a medium-fidelity tool. The latter provides a better trade-off between “accuracy” and computational intensity, which enables numerous, longer simulations at a more affordable cost. As an example, the outwash flow is computed for two different designs of a quadrotor air taxi in hover and reveals the existence of increased velocities between the rotors. This work illustrates how CFD can help identify dangerous areas for passengers and ground personnel when they approach the vehicle.

HECC↗

NASA NTRSDate not supplied

A Field-Deployable Wireless Data Acquisition System for Ground-Test Arrays

This paper describes the development, characterization, and deployment of a field-deployable wireless data acquisition system for ground-test arrays, applicable in noise-source localization or beamforming measurements such as those encountered during airframe noise flyover measurement tests. The system design is enabled by commercially available, low-power Internet of Things (IoT) processors and Wi-Fi communication components. Time is synchronized across the array wirelessly by leveraging the Coordinated Universal Time (UTC) time provided by the Global Positioning System (GPS). Initial laboratory characterization of the system demonstrated its ability to meet acoustic bandwidth, dynamic range, time synchronization, environmental, and battery life requirements for typical ground-test array deployments. A successful system deployment at NASA Langley was performed that included measurement of a suspended elevated static noise source, and Uncrewed Aerial System (UAS) vehicle measurements using a quadcopter operated both in hover mode and forward flight. Beamform analysis of the acquired data showed an excellent ability of the array to extract accurate sound pressure levels from the suspended source. Synchronization of the array and vehicle GPS timecodes allowed the ability to extract acoustic signatures from the UAS vehicle during hover and forward flight maneuvers over the array. These results validate that the use of a high channel count wireless array is advantageous in airframe and propulsion noise flyover test campaigns.

wireless↗