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NASA NTRS2002

Comparison Made of Operating Characteristics of Spiral Bevel Gears Manufactured Using Different Methods

Spiral bevel gears are important components on all current rotorcraft drive systems. These components are required to operate at high speeds, high loads, and for an extremely large number of load cycles. In this application, spiral bevel gears are used to redirect the shaft from the horizontal gas turbine engine to the vertical rotor. Because of the high expense of manufacturing these gears, methods that can achieve the same level of performance at reduced cost are highly desirable to aerospace gear manufacturers. Gears manufactured for aerospace applications use high-quality materials and are manufactured to tight tolerances. Special manufacturing machine tools and computer numerically controlled coordinate measurement systems have enabled rotorcraft drive system manufacturers to produce extremely high-quality gears during their normal production. Because of low production rates for rotorcraft, these gears are manufactured in small batches, and thus are unable to benefit from the economics of high production numbers as in other industries. In this investigation, two different manufacturing methods, face-milled and face-hobbed, were used to fabricate spiral bevel gears. For face-milled spiral bevel gears, grinding of the contacting surfaces is the final manufacturing step. At least two different specialty machines are needed to generate the teeth for face-milled spiral bevel gears. For face-hobbed gears, hard cutting is the final manufacturing process. The same machine is used to rough cut and finish cut the gears. This study compared the operational behavior of face-milled spiral bevel gears with that of face-hobbed spiral bevel gears. Test hardware was manufactured to fit within NASA Glenn Research Center's Spiral Bevel Test Facility and to aerospace quality standards. Tests were conducted for stress, vibration, and noise. A comparison of the results attained indicated that the face-hobbed gears had a lower alternating stress level with a more even distribution of loading across the teeth, and slightly reduced levels of vibration and noise. Results of this study show that the face-hobbed method is a viable and lower-cost alternative for producing aerospace-quality spiral-bevel gears.

Handschuh, Robert F.↗

NASA NTRS2022

Conceptual Design of a Tiltduct Reference Vehicle for Urban Air Mobility

NASA is establishing a fleet of conceptual air vehicle designs to support research and development for Urban Air Mobility (UAM). This fleet of vehicles will enable examination of the sensitivity of UAM vehicle designs to technology assumptions, identify key research and development needs for UAM aircraft, and provide the UAM community with reference vehicles that are publicly available and based upon known assumptions. To date, five six-passenger UAM reference vehicles have been published: a single-main-rotor helicopter, a side-by-side helicopter, a quadrotor, a lift-plus-cruise, and a tiltwing. To increase the breadth of vehicle technologies encapsulated in the fleet of NASA UAM reference vehicles, this paper establishes a tiltduct vehicle as an addition to the fleet. The fleet will continue to evolve as future analyses and trade studies are performed. The tiltduct UAM reference vehicle has six tilting ducted proprotors. This paper describes the initial configuration downselection; discusses ducted proprotor design rules of thumb as they applied to the conceptual design of the reference vehicle; describes the vehicle sizing, trade studies, and tuning of models performed; and finally, compares the resulting tiltduct vehicle against the other six-passenger NASA UAM reference vehicles. The high-level analyses performed for this study did not indicate significant differences in performance between the tiltduct and tiltwing reference vehicles, and so vehicle performance alone may not be a key driver in the selection of a tiltduct vehicle over a tiltwing vehicle. However, if ducts are found to have significant acoustical benefits, then acoustical priorities may provide a compelling reason to incorporate ducted proprotors. One significant limitation of the design presented in this paper is that the ducted proprotor performance was tuned based upon performance characteristics observed during historical tests with disk loadings (defined as thrust divided by proprotor disk area) of 125-250 lb/ft$^2$. The tiltduct vehicle designed in this study has a disk loading of 30 lb/ft$^2$, to be more representative of UAM vehicles; further studies to understand performance of ducted proprotors at representative disk loadings are warranted.

Tiltduct↗

NASA NTRS1991

Tiltrotor research aircraft composite blade repairs: Lessons learned

The XV-15, N703NA Tiltrotor Research Aircraft located at the NASA Ames Research Center, Moffett Field, California, currently uses a set of composite rotor blades of complex shape known as the advanced technology blades (ATBs). The main structural element of the blades is a D-spar constructed of unidirectional, angled fiberglass/graphite, with the aft fairing portion of the blades constructed of a fiberglass cross-ply skin bonded to a Nomex honeycomb core. The blade tip is a removable laminate shell that fits over the outboard section of the spar structure, which contains a cavity to retain balance weights. Two types of tip shells are used for research. One is highly twisted (more than a conventional helicopter blade) and has a hollow core constructed of a thin Nomex-honeycomb-and-fiberglass-skin sandwich; the other is untwisted with a solid Nomex honeycomb core and a fiberglass cross-ply skin. During initial flight testing of the blades, a number of problems in the composite structure were encountered. These problems included debonding between the fiberglass skin and the honeycomb core, failure of the honeycomb core, failures in fiberglass splices, cracks in fiberglass blocks, misalignment of mated composite parts, and failures of retention of metal fasteners. Substantial time was spent in identifying and repairing these problems. Discussed here are the types of problems encountered, the inspection procedures used to identify each problem, the repairs performed on the damaged or flawed areas, the level of criticality of the problems, and the monitoring of repaired areas. It is hoped that this discussion will help designers, analysts, and experimenters in the future as the use of composites becomes more prevalent.

Espinosa, Paul S.↗

NASA NTRS1992

Tiltrotor Research Aircraft composite blade repairs - Lessons learned

Espinosa, Paul S.↗

NASA NTRS2014

Computational Aerodynamic Simulations of a 1215 ft/sec Tip Speed Transonic Fan System Model for Acoustic Methods Assessment and Development

Computational Aerodynamic simulations of a 1215 ft/sec tip speed transonic fan system were performed at five different operating points on the fan operating line, in order to provide detailed internal flow field information for use with fan acoustic prediction methods presently being developed, assessed and validated. The fan system is a sub-scale, low-noise research fan/nacelle model that has undergone extensive experimental testing in the 9- by 15-foot Low Speed Wind Tunnel at the NASA Glenn Research Center. Details of the fan geometry, the computational fluid dynamics methods, the computational grids, and various computational parameters relevant to the numerical simulations are discussed. Flow field results for three of the five operating points simulated are presented in order to provide a representative look at the computed solutions. Each of the five fan aerodynamic simulations involved the entire fan system, which for this model did not include a split flow path with core and bypass ducts. As a result, it was only necessary to adjust fan rotational speed in order to set the fan operating point, leading to operating points that lie on a fan operating line and making mass flow rate a fully dependent parameter. The resulting mass flow rates are in good agreement with measurement values. Computed blade row flow fields at all fan operating points are, in general, aerodynamically healthy. Rotor blade and fan exit guide vane flow characteristics are good, including incidence and deviation angles, chordwise static pressure distributions, blade surface boundary layers, secondary flow structures, and blade wakes. Examination of the flow fields at all operating conditions reveals no excessive boundary layer separations or related secondary-flow problems.

Tweedt, Daniel L.↗

NASA NTRS2001

Analysis of Measured and Predicted Acoustics From an XV-15 Flight Test

Flight acoustic and vehicle state data from an XV-15 acoustic flight test are examined. Flight predictions using TiltRotor Aeroacoustic Code (TRAC) are performed for a level flight (repeated) and four descent conditions (including a blade vortex interaction (BVI)). The assumptions and procedures used for TRAC flight predictions as well as the variability in flight measurements, which are used for input and comparison to predictions, are investigated in detail. Differences were found in the measured vehicle airspeed, altitude, glideslope, and vehicle orientation (yaw, pitch, and roll angle) between each of the repeat runs. These differences violate some of the prediction assumptions and significantly impacted the resulting acoustic predictions. Multiple acoustic pulses, with a variable time between the pulses, were found in the measured acoustic time histories for the repeat runs. These differences could be attributed in part to the variability in vehicle orientation. Acoustic predictions that used the measured vehicle orientation for the repeat runs captured this multiple pulse variability. Thickness noise was found to be dominant on approach for all the cases, except the BVI condition. After the aircraft passed overhead, broadband noise and low frequency loading noise were dominant. The predicted LowSPL time histories compared well with measurement on approach to the array for the non-BVI conditions and poorly for the BVI condition. Accurate prediction of the lift share between the rotor and fuselage must be known in order to improve predictions. At a minimum, measurements of the rotor thrust and tip-path-plane angle are critical to further develop accurate flight acoustic prediction capabilities.

Boyd, D. Douglas, Jr.↗

DOE OSTI2019

UAV-Based High Resolution Thermal Imaging for Vegetation Monitoring, and Plant Phenotyping Using ICI 8640 P, FLIR Vue Pro R 640, and thermoMap Cameras

The growing popularity of Unmanned Aerial Vehicles (UAVs) in recent years, along with decreased cost and greater accessibility of both UAVs and thermal imaging sensors, has led to the widespread use of this technology, especially for precision agriculture and plant phenotyping. There are several thermal camera systems in the market that are available at a low cost. However, their efficacy and accuracy in various applications has not been tested. In this study, three commercially available UAV thermal cameras, including ICI 8640 P-series (Infrared Cameras Inc., USA), FLIR Vue Pro R 640 (FLIR Systems, USA), and thermoMap (senseFly, Switzerland) have been tested and evaluated for their potential for forest monitoring, vegetation stress detection, and plant phenotyping. Mounted on multi-rotor or fixed wing systems, these cameras were simultaneously flown over different experimental sites located in St. Louis, Missouri (forest environment), Columbia, Missouri (plant stress detection and phenotyping), and Maricopa, Arizona (high throughput phenotyping). Thermal imagery was calibrated using procedures that utilize a blackbody, handheld thermal spot imager, ground thermal targets, emissivity and atmospheric correction. A suite of statistical analyses, including analysis of variance (ANOVA), correlation analysis between camera temperature and plant biophysical and biochemical traits, and heritability were utilized in order to examine the sensitivity and utility of the cameras against selected plant phenotypic traits and in the detection of plant water stress. In addition, in reference to quantitative assessment of image quality from different thermal cameras, a non-reference image quality evaluator, which primarily measures image focus that is based on the spatial relationship of pixels in different scales, was developed. Our results show that (1) UAV-based thermal imaging is a viable tool in precision agriculture and (2) the three examined cameras are comparable in terms of their efficacy for plant phenotyping. Overall, accuracy, when compared against field measured ground temperature and estimating power of plant biophysical and biochemical traits, the ICI 8640 P-series performed better than the other two cameras, followed by FLIR Vue Pro R 640 and thermoMap cameras. Our results demonstrated that all three UAV thermal cameras provide useful temperature data for precision agriculture and plant phenotying, with ICI 8640 P-series presenting the best results among the three systems. Cost wise, FLIR Vue Pro R 640 is more affordable than the other two cameras, providing a less expensive option for a wide range of applications.

47 OTHER INSTRUMENTATION↗

NASA NTRS2014

Computational Aerodynamic Simulations of a 1484 ft/sec Tip Speed Quiet High-Speed Fan System Model for Acoustic Methods Assessment and Development

Computational Aerodynamic simulations of a 1484 ft/sec tip speed quiet high-speed fan system were performed at five different operating points on the fan operating line, in order to provide detailed internal flow field information for use with fan acoustic prediction methods presently being developed, assessed and validated. The fan system is a sub-scale, low-noise research fan/nacelle model that has undergone experimental testing in the 9- by 15-foot Low Speed Wind Tunnel at the NASA Glenn Research Center. Details of the fan geometry, the computational fluid dynamics methods, the computational grids, and various computational parameters relevant to the numerical simulations are discussed. Flow field results for three of the five operating points simulated are presented in order to provide a representative look at the computed solutions. Each of the five fan aerodynamic simulations involved the entire fan system, which includes a core duct and a bypass duct that merge upstream of the fan system nozzle. As a result, only fan rotational speed and the system bypass ratio, set by means of a translating nozzle plug, were adjusted in order to set the fan operating point, leading to operating points that lie on a fan operating line and making mass flow rate a fully dependent parameter. The resulting mass flow rates are in good agreement with measurement values. Computed blade row flow fields at all fan operating points are, in general, aerodynamically healthy. Rotor blade and fan exit guide vane flow characteristics are good, including incidence and deviation angles, chordwise static pressure distributions, blade surface boundary layers, secondary flow structures, and blade wakes. Examination of the computed flow fields reveals no excessive or critical boundary layer separations or related secondary-flow problems, with the exception of the hub boundary layer at the core duct entrance. At that location a significant flow separation is present. The region of local flow recirculation extends through a mixing plane, however, which for the particular mixing-plane model used is now known to exaggerate the recirculation. In any case, the flow separation has relatively little impact on the computed rotor and FEGV flow fields.

Tweedt, Daniel L.↗

DOE OSTI2018

Advanced High Torque Density Magnetically Geared Generator

The objective of this research project was to investigate the fundamental torque density limitations of multistage flux focusing magnetic gears and magnetically geared direct-drive generators for wind turbines. Magnetic gears create non-contact speed amplification by modulating the air-gap magnetic field harmonics created by magnetic rotors. By integrating a stator into the magnetic gear structure a very high torque density direct-drive generator can be created. Magnetic geared systems offer unique capabilities that are currently not available using existing mechanically geared systems, such as overload protection. Magnetic gears also offer the potential for higher reliability, higher efficiency and quieter operation than is currently achievable using a mechanically geared generator. By increasing reliability and design life magnetic gears could decrease the overall life-cycle costs when compared with equivalent mechanical or direct-drive drivetrains. This research project investigated and experimentally testing two sub-scale magnetic gearboxes (0.12 m diameter) and two large diameter magnetic gearboxes (0.56m and 0.63m diameter). The goal of the project was to demonstrate a torque density >300Nm/L for a multistage magnetic gearbox with integrated stator. A nested multistage magnetic gear structure was first proposed and studied. However, it was shown that the nested design greatly increased mechanical complexity and therefore a two-stage series typology was utilized. A multi-stage magnetic gear with a 59:1 gear ratio was successfully experimentally tested. A peak torque of 4.25 kN·m was measured and this resulted in an overall active region torque density of 141 N·m/L (when including support rings). The torque density was significantly reduced from what was computed using 2-D electromagnetic analysis. This reduction was due to the 3-D edge effects, increased power losses and the inclusion of additional mechanical support rings as well as other mechanical assembly design changes. At large diameters contiguous lamination parts could not be fabricated and so a segmented laminated rotor design had to be used. This reduced the mechanical strength of the design when compared to small diameter magnetic gears and resulted in the need for the addition of mechanical support rings to prevent deflection. The final experimentally tested design also had a high torque ripple and the power loss within the magnetic gear did not change significantly with load. This therefore resulted in the efficiency being high only at peak loads. Despite not experimentally achieving the 2-D calculated high torque density the analysis has shown that the problems encountered with the scaling can be overcome with careful design changes. For example, understanding the unique mechanical deflection requirements during the electromagnetic design of the large diameter magnetic gears is key to achieving both a high torque density based on the electromagnetic analysis and a high torque density based on the mechanical support needs. Furthermore, ensuring that end plates are made of non-conductive material and minimizing other conductive support elements within the magnetic structure is a key requirement for reducing eddy current losses. In summary, if the mechanical design can be made more robust and eddy current loss mitigation strategies are used in the mechanical design phase then the magnetic gear is capable of being scaled up whilst operating at a very high torque density. This will then enable it to be potentially performance and cost competitive with alternative direct-drive and mechanically geared wind turbine drivetrains.

17 WIND ENERGY↗

NASA NTRS2001

Ultrasonic Resonance Spectroscopy of Composite Rings for Flywheel Rotors

Flywheel energy storage devices comprising multilayered composite rotor systems are being studied extensively for utilization in the International Space Station. These composite material systems were investigated with a recently developed ultrasonic resonance spectroscopy technique. The system employs a swept frequency approach and performs a fast Fourier transform on the frequency spectrum of the response signal. In addition. the system allows for equalization of the frequency spectrum, providing all frequencies with equal amounts of energy to excite higher order resonant harmonics. Interpretation of the second fast Fourier transform, along with equalization of the frequency spectrum, offers greater assurance in acquiring and analyzing the fundamental frequency, or spectrum resonance spacing. The range of frequencies swept in a pitch-catch mode was varied up to 8 MHz, depending on the material and geometry of the component. Single and multilayered material samples, with and without known defects, were evaluated to determine how the constituents of a composite material system affect the resonant frequency. Amplitude and frequency changes in the spectrum and spectrum resonance spacing domains were examined from ultrasonic responses of a flat composite coupon, thin composite rings, and thick composite rings. Also, the ultrasonic spectroscopy responses from areas with an intentional delamination and a foreign material insert, similar to defects that may occur during manufacturing malfunctions, were compared with those from defect-free areas in thin composite rings. A thick composite ring with varying thickness was tested to investigate the full-thickness resonant frequency and any possible bulk interfacial bond issues. Finally, the effect on the frequency response of naturally occurring single and clustered voids in a composite ring was established.

Harmon, Laura M.↗

NASA NTRS2014

Computational Aerodynamic Simulations of an 840 ft/sec Tip Speed Advanced Ducted Propulsor Fan System Model for Acoustic Methods Assessment and Development

Computational Aerodynamic simulations of an 840 ft/sec tip speed, Advanced Ducted Propulsor fan system were performed at five different operating points on the fan operating line, in order to provide detailed internal flow field information for use with fan acoustic prediction methods presently being developed, assessed and validated. The fan system is a sub-scale, lownoise research fan/nacelle model that has undergone extensive experimental testing in the 9- by 15- foot Low Speed Wind Tunnel at the NASA Glenn Research Center, resulting in quality, detailed aerodynamic and acoustic measurement data. Details of the fan geometry, the computational fluid dynamics methods, the computational grids, and various computational parameters relevant to the numerical simulations are discussed. Flow field results for three of the five operating conditions simulated are presented in order to provide a representative look at the computed solutions. Each of the five fan aerodynamic simulations involved the entire fan system, excluding a long core duct section downstream of the core inlet guide vane. As a result, only fan rotational speed and system bypass ratio, set by specifying static pressure downstream of the core inlet guide vane row, were adjusted in order to set the fan operating point, leading to operating points that lie on a fan operating line and making mass flow rate a fully dependent parameter. The resulting mass flow rates are in good agreement with measurement values. The computed blade row flow fields for all five fan operating points are, in general, aerodynamically healthy. Rotor blade and fan exit guide vane flow characteristics are good, including incidence and deviation angles, chordwise static pressure distributions, blade surface boundary layers, secondary flow structures, and blade wakes. Examination of the computed flow fields reveals no excessive boundary layer separations or related secondary-flow problems. A few spanwise comparisons between computational and measurement data in the bypass duct show that they are in good agreement, thus providing a partial validation of the computational results.

Tweedt, Daniel L.↗

NASA NTRS2014

Propulsion Electric Grid Simulator (PEGS) for Future Turboelectric Distributed Propulsion Aircraft

NASA Glenn Research Center, in collaboration with the aerospace industry and academia, has begun the development of technology for a future hybrid-wing body electric airplane with a turboelectric distributed propulsion (TeDP) system. It is essential to design a subscale system to emulate the TeDP power grid, which would enable rapid analysis and demonstration of the proof-of-concept of the TeDP electrical system. This paper describes how small electrical machines with their controllers can emulate all the components in a TeDP power train. The whole system model in Matlab/Simulink was first developed and tested in simulation, and the simulation results showed that system dynamic characteristics could be implemented by using the closed-loop control of the electric motor drive systems. Then we designed a subscale experimental system to emulate the entire power system from the turbine engine to the propulsive fans. Firstly, we built a system to emulate a gas turbine engine driving a generator, consisting of two permanent magnet (PM) motors with brushless motor drives, coupled by a shaft. We programmed the first motor and its drive to mimic the speed-torque characteristic of the gas turbine engine, while the second motor and drive act as a generator and produce a torque load on the first motor. Secondly, we built another system of two PM motors and drives to emulate a motor driving a propulsive fan. We programmed the first motor and drive to emulate a wound-rotor synchronous motor. The propulsive fan was emulated by implementing fan maps and flight conditions into the fourth motor and drive, which produce a torque load on the driving motor. The stator of each PM motor is designed to travel axially to change the coupling between rotor and stator. This feature allows the PM motor to more closely emulate a wound-rotor synchronous machine. These techniques can convert the plain motor system into a unique TeDP power grid emulator that enables real-time simulation performance using hardware-in-the-loop (HIL).

electric power grid emulator↗

NASA NTRS2018

Design and Development of a Laboratory-Scale Ice Adhesion Testing Device

When an aircraft traverses through clouds containing supercooled water droplets, in-flight icing can occur that negatively affects vehicle performance by increasing weight and drag leading to loss of lift. Super-cooled water droplets present in clouds that impact vehicle surfaces can lead to inflight icing any time during the year.1 Most events occur at temperatures ranging from 0 to -20degC. Ice generated on the aircraft can vary between clear/glaze, rime, and mixed (Fig. 1) depending on air temperature (-5 to -20degC), liquid water content (0.3-0.6 g/m3), and droplet size (median volumetric diameter of 15-40 μm). Current strategies to remove ice are based on active technologies such as pneumatic boots, heated surfaces, and deicing agents (i.e., ethylene- and propylene-based glycols). The latter have potential environmental concerns. A passive approach to mitigate accreting ice that is actively being investigated are protective coatings. An ice mitigating coating could potentially be used as a stand-alone material, but more likely in combination with an active approach. In the latter scenario, potential reduction in power consumption by the active approach may be realized. To determine the ice adhesion strength of impact ice that is representative of the aircraft environment is not a trivial matter. Test methods utilizing slowly formed ice (i.e., freezer ice) do not accurately simulate this environment. Likewise, some testing methodologies involve sample relocation from the icing environment to the test chamber that can result in thermal shock to the sample, thus affecting the results. The Adverse Environment Rotor Test Stand (AERTS) located at Pennsylvania State University (PSU) has been demonstrated to simulate impact icing conditions within the icing envelope for the determination of ice adhesion shear strength (IASS) without removal/relocation of the sample.2 Due to the confidence in results obtained from AERTS, this instrument is in high demand and requires a significant amount of lead time and capital investment to obtain IASS results. As a solution for quickly and economically screening coatings in a controlled manner under impact icing conditions, a laboratory-scale ice adhesion test and dead blades were then removed from the rotor/blade assembly to obtain the final mass. The IASS of the live blade was determined from the difference in mass (before and after testing) of the live and dead blades, the ice shed area, and the rpm of the shed event. The same live blade sample was tested in triplicate at all three test temperatures. Surface roughness was determined using a Bruker Dektak XT Stylus Profilometer. Measurements were conducted using a 12.5 μm tip at a vertical range of 65.5 μm with an applied force of 3 mg. Data were collected over a 1.0 mm length at a resolution of 0.056 μm/point. Five single line scans at different locations were collected and processed using a two-point leveling subtraction. The resultant Ra (arithmetic roughness) and Rq (root mean square roughness) average values were calculated.

Smith, Joseph G., Jr.↗

NASA NTRS1996

High-Temperature Magnetic Bearings for Gas Turbine Engines

Magnetic bearings are the subject of a new NASA Lewis Research Center and U.S. Army thrust with significant industry participation, and coordination with other Government agencies. The NASA/Army emphasis is on high-temperature applications for future gas turbine engines. Magnetic bearings could increase the reliability and reduce the weight of these engines by eliminating the lubrication system. They could also increase the DN (diameter of the bearing times rpm) limit on engine speed and allow active vibration cancellation systems to be used--resulting in a more efficient, "more electric" engine. Finally, the Integrated High-Performance Turbine Engine Technology (IHPTET) Program, a joint Department of Defense/industry program, identified a need for a hightemperature (as high as 1200 F) magnetic bearing that could be demonstrated in a phase III engine. This magnetic bearing is similar to an electric motor. It has a laminated rotor and stator made of cobalt steel. Wound around the stator are a series of electrical wire coils that form a series of electric magnets around the circumference. The magnets exert a force on the rotor. A probe senses the position of the rotor, and a feedback controller keeps it in the center of the cavity. The engine rotor, bearings, and case form a flexible structure that contains a large number of modes. The bearing feedback controller, which could cause some of these modes to become unstable, could be adapted to varying flight conditions to minimize seal clearances and monitor the health of the system. Cobalt steel has a curie point greater than 1700 F, and copper wire has a melting point beyond that. Therefore, practical limitations associated with the maximum magnetic field strength in the cobalt steel and the stress in the rotating components limit the temperature to about 1200 F. The objective of this effort is to determine the limits in temperature and speed of a magnetic bearing operating in an engine. Our approach is to use our in-house experience in magnets, mechanical components, high-temperature materials, and surface lubrication to build and test a magnetic bearing in both a rig and an engine. Testing will be done at Lewis or through cooperative programs in industrial facilities.

Source record↗

NASA NTRS1998

Signal Analysis of Helicopter Blade-Vortex-Interaction Acoustic Noise Data

Blade-Vortex-Interaction (BVI) produces annoying high-intensity impulsive noise. NASA Ames collected several sets of BVI noise data during in-flight and wind tunnel tests. The goal of this work is to extract the essential features of the BVI signals from the in-flight data and examine the feasibility of extracting those features from BVI noise recorded inside a large wind tunnel. BVI noise generating mechanisms and BVI radiation patterns an are considered and a simple mathematical-physical model is presented. It allows the construction of simple synthetic BVI events that are comparable to free flight data. The boundary effects of the wind tunnel floor and ceiling are identified and more complex synthetic BVI events are constructed to account for features observed in the wind tunnel data. It is demonstrated that improved recording of BVI events can be attained by changing the geometry of the rotor hub, floor, ceiling and microphone. The Euclidean distance measure is used to align BVI events from each blade and improved BVI signals are obtained by time-domain averaging the aligned data. The differences between BVI events for individual blades are then apparent. Removal of wind tunnel background noise by optimal Wiener-filtering is shown to be effective provided representative noise-only data have been recorded. Elimination of wind tunnel reflections by cepstral and optimal filtering deconvolution is examined. It is seen that the cepstral method is not applicable but that a pragmatic optimal filtering approach gives encouraging results. Recommendations for further work include: altering measurement geometry, real-time data observation and evaluation, examining reflection signals (particularly those from the ceiling) and performing further analysis of expected BVI signals for flight conditions of interest so that microphone placement can be optimized for each condition.

Rogers, James C.↗

NASA NTRS2004

Conical Magnetic Bearings Developed for Active Stall Control in Gas Turbine Engines

Active stall control is a current research area at the NASA Glenn Research Center that offers a great benefit in specific fuel consumption by allowing the gas turbine to operate beyond the onset of stall. Magnetic bearings are being investigated as a new method to perform active stall control. This enabling global aviation safety technology would result in improved fuel efficiency and decreased carbon dioxide emissions, as well as improve safety and reliability by eliminating oil-related delays and failures of engine components, which account for 40 percent of the commercial aircraft departure delays. Active stall control works by perturbing the flow in front of the compressor stage such that it cancels the pressure wave, which causes the compressor to go into stall. Radial magnetic bearings are able to whirl the shaft so that variations in blade tip leakage would flow upstream causing a perturbation wave that could cancel the rotating stall cell. Axial or thrust magnetic bearings cannot be used to cancel the surge mode in the compressor because they have a very low bandwidth and thus cannot modulate at a high enough frequency. Frequency response is limited because the thrust runner cannot be laminated. To improve the bandwidth of magnetic thrust bearings, researchers must use laminations to suppress the eddy currents. A conical magnetic bearing can be laminated, resulting in increased bandwidth in the axial direction. In addition, this design can produce both radial and thrust force in a single bearing, simplifying the installation. The proposed solution combines the radial and thrust bearing into one design that can be laminated--a conical magnetic bearing. The new conical magnetic bearing test rig, funded by a Glenn fiscal year 2002 Director's Discretionary Fund, was needed because none of the existing rigs has an axial degree of freedom. The rotor bearing configuration will simulate that of the main shaft on a gas turbine engine. One conical magnetic bearing replaces the ball bearing in front of the compressor, and the second replaces the roller bearing behind the burner. The rig was made operational to 10,000 rpm under Smart Efficient Components funding, and both position and current adaptive vibration control have been demonstrated. Upon program completion, recommendations will be made as to the efficacy of the conical magnetic bearing for active stall control.

Trudell, Jeffrey J.↗

NASA NTRS2022

AST Critical Propulsion and Noise Reduction Technologies for Future Commercial Subsonic Engines Aeroacoustic Prediction Codes - Supplement: Code Descriptions and Users Guides

This report describes work performed on Contract NAS3–27720 AoI 13 as part of the NASA Advanced Subsonic Transport (AST) Noise Reduction Technology effort. Computer codes were developed to provide quantitative prediction, design, and analysis capability for several aircraft engine noise sources. The objective was to provide improved, physics-based tools for the exploration of noise-reduction concepts and the understanding of experimental results. Methods and codes focused on fan broadband and “buzz saw” noise and on low-emissions combustor noise and complement work done by other contractors under the NASA AST program to develop methods and codes for fan harmonic tone noise and jet noise. The methods and codes developed and reported herein employ a wide range of approaches, from the strictly empirical to the completely computational, with some being semiempirical, analytical, and/or analytical/computational. Emphasis was on capturing the essential physics while still considering method or code utility as a practical design and analysis tool for everyday engineering use. Codes and prediction models were developed for: (1) an improved empirical correlation model for fan rotor exit flow mean and turbulence properties, for use in predicting broadband noise generated by rotor exit flow turbulence interaction with downstream stator vanes; (2) fan broadband noise models for rotor and stator/turbulence interaction sources including 3D effects, noncompact-source effects, directivity modeling, and extensions to the rotor supersonic tip-speed regime; (3) fan multiple-pure-tone in-duct sound pressure prediction methodology based on CFD analysis; and (4) low-emissions combustor prediction methodology and computer code based on CFD and actuator disk theory. In addition, the relative importance of dipole and quadrupole source mechanisms was studied using direct CFD source computation for a simple cascade/gust interaction problem, and an empirical combustor-noise correlation model was developed from engine acoustic test results. This work provided several insights on potential approaches to reducing aircraft engine noise. Code development is described in Volume I, and those insights are discussed. Volume II documents the computer codes developed and gives instructions on how to use them.

Philip Gliebe↗

NASA NTRS2000

Aeroacoustic Prediction Codes

This report describes work performed on Contract NAS3-27720AoI 13 as part of the NASA Advanced Subsonic Transport (AST) Noise Reduction Technology effort. Computer codes were developed to provide quantitative prediction, design, and analysis capability for several aircraft engine noise sources. The objective was to provide improved, physics-based tools for exploration of noise-reduction concepts and understanding of experimental results. Methods and codes focused on fan broadband and 'buzz saw' noise and on low-emissions combustor noise and compliment work done by other contractors under the NASA AST program to develop methods and codes for fan harmonic tone noise and jet noise. The methods and codes developed and reported herein employ a wide range of approaches, from the strictly empirical to the completely computational, with some being semiempirical analytical, and/or analytical/computational. Emphasis was on capturing the essential physics while still considering method or code utility as a practical design and analysis tool for everyday engineering use. Codes and prediction models were developed for: (1) an improved empirical correlation model for fan rotor exit flow mean and turbulence properties, for use in predicting broadband noise generated by rotor exit flow turbulence interaction with downstream stator vanes: (2) fan broadband noise models for rotor and stator/turbulence interaction sources including 3D effects, noncompact-source effects. directivity modeling, and extensions to the rotor supersonic tip-speed regime; (3) fan multiple-pure-tone in-duct sound pressure prediction methodology based on computational fluid dynamics (CFD) analysis; and (4) low-emissions combustor prediction methodology and computer code based on CFD and actuator disk theory. In addition. the relative importance of dipole and quadrupole source mechanisms was studied using direct CFD source computation for a simple cascadeigust interaction problem, and an empirical combustor-noise correlation model was developed from engine acoustic test results. This work provided several insights on potential approaches to reducing aircraft engine noise. Code development is described in this report, and those insights are discussed.

Gliebe, P↗