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DOE OSTI2023

Direct Numerical Simulation of Transitional and Turbulent Flows Over Multi-Scale Surface Roughness—Part I: Methodology and Challenges

Abstract High-fidelity simulation of transitional and turbulent flows over multi-scale surface roughness presents several challenges. For instance, the complex and irregular geometrical nature of surface roughness makes it impractical to employ conforming structured grids, commonly adopted in large-scale numerical simulations due to their high computational efficiency. One possible solution to overcome this problem is offered by immersed boundary methods, which allow wall boundary conditions to be enforced on grids that do not conform to the geometry of the solid boundary. To this end, a three-dimensional, second-order accurate boundary data immersion method (BDIM) is adopted. A novel mapping algorithm that can be applied to general three-dimensional surfaces is presented, together with a newly developed data-capturing methodology to extract and analyze on-surface flow quantities of interest. A rigorous procedure to compute gradient quantities such as the wall shear stress and the heat flux on complex non-conforming geometries is also introduced. The new framework is validated by performing a direct numerical simulation (DNS) of fully developed turbulent channel flow over sinusoidal egg-carton roughness in a minimal-span domain. For this canonical case, the averaged streamwise velocity profiles are compared against results from the literature obtained with a body-fitted grid. General guidelines on the BDIM resolution requirements for multi-scale roughness simulation are given. Momentum and energy balance methods are used to validate the calculation of the overall skin friction and heat transfer at the wall. The BDIM is then employed to investigate the effect of irregular homogeneous surface roughness on the performance of an LS-89 high-pressure turbine blade at engine-relevant conditions using DNS. This is the first application of the BDIM to realize multi-scale roughness for transitional flow in transonic conditions in the context of high-pressure turbines. The methodology adopted to generate the desired roughness distribution and to apply it to the reference blade geometry is introduced. The results are compared to the case of an equivalent smooth blade.

Engineering↗

DOE OSTI2025

Wafer-scale waveguide sidewall roughness scattering loss characterization by image processing

Photonic integrated circuits (PICs) are vital for developing affordable, high-performance optoelectronic devices that can be manufactured at an industrial scale, driving innovation and efficiency in various applications. Optical loss of modes in thin film waveguides and devices is a critical measure of their performance. Thin film growth, lithography, masking, and etching processes are imperfect processes that introduce significant sidewall and top-surface roughness and cause dominating optical losses in waveguides and photonic structures. This roughness, as perturbations couple light from guided to far-field radiation modes, leads to scattering losses that can be estimated from theoretical models. Typically, with UV-based lithography, sidewall roughness is significantly larger than wafer-top surface roughness. Atomic force microscopy (AFM) imaging measurement gives a 3D and high-resolution roughness profile, but the measurement is inconvenient, costly, and unscalable for large-scale PICs and at wafer-scale. Here, we evaluate the sidewall roughness profile based on 2D high-resolution scanning electron microscope (SEM) imaging. We characterized the loss on two homemade nitride and oxide films on 3-inch silicon wafers with 12 waveguide devices on each and correlated the scattering loss estimated from a 2D image-based sidewall profile and theoretical Payne model. The lowest loss of guided fundamental transverse electric (TE 0 ) mode is found at 0.075 dB/cm at 633 nm across 24 devices, a record at visible wavelength. Our work shows 100% success (edge continuity span exceeding 95% of image width/height) in edge detection in image processing of all images to estimate autocorrelation function and optical mode loss. These demonstrations offer valuable insights into waveguide sidewall roughness and a comparison of experimental and 2D SEM image processing based loss estimations with applications in loss characterization at wafer-scale PICs.

Khurana, Mohit (ORCID:0000000207898672)↗

NASA NTRS1976

The effect of surface roughness on the average film thickness between lubricated rollers

The Christensen theory of stochastic models for hydrodynamic lubrication of rough surfaces is extended to elastohydrodynamic lubrication between two rollers. The Grubin-type equation including asperity effects in the inlet region is derived. Solutions for the reduced pressure at the entrance as a function of the ratio of the average nominal film thickness to the rms surface roughness (in terms of standard deviation), have been obtained numerically. Results were obtained for purely transverse and purely longitudinal surface roughness for cases with or without slip. The reduced pressure is shown to decrease slightly by considering longitudinal surface roughness. Transverse surface roughness has a slight beneficial effect on the average film thickness at the inlet. The same approach was used to study the effect of surface roughness on lubrication between rigid rollers and lubrication of an infinitely-wide slider bearing. The effects of surface roughness are shown to be similar to those found in elastohydrodynamic contacts.

Chow, L. S. H.↗

NASA NTRS1985

The performance of smooth-wall drag reducing outer-layer devices in rough-wall boundary layers

The boundary layer drag on a 0.28 m x 0.91 m flat-plate was measured to evaluate the performance of smooth-wall drag reducing outer-layer devices in rough-wall boundary layers up to a chord Reynolds number, Re(c) of 17,000. The devices were a pair of thin flat ribbons placed in tandem. The wall conditions examined were smooth, transverse-groove roughnesses having cavity width/depth ratios of 0.7 (d-type) and 3 (k-type), and sandpaper roughness (k-type) of grit sizes 180, 50 and 36. The area-averaged wall-drag was reduced compared to the respective normal levels for all wall conditions. All k-type rough walls exhibited a comparable level of drag reduction (about 7 percent) which was lower than that in the smooth-wall. The d-type rough-wall exhibited a transitional behavior in that the drag reduction dropped from the smooth-wall level to that of the k-type roughnesses with increase in the flow speed. In further experiments on a 6 meter long sandpaper roughened wall and with a pair of symmetric airfoil devices in tandem at an Re(c) of 77,500, it was possible to recover the device drag penalty fully, but no net drag reduction was achieved. The apparent loss of performance of the devices in a rough-wall is explained in terms of their inability to alter the pressure component of the drag in a significant way.

Bandyopadhyay, P. R.↗

NASA NTRS1988

A relationship between radar backscatter and aerodynamic roughness - Preliminary results

The ability of the wind to move particles and the flux of windblown sand are both dependent on the topographic roughness of the surface, as measured by the aerodynamic roughness, z(0). For most surfaces, topographic roughness controls many of the characteristics of the radar return, and the magnitude of the radar backscatter can be regarded as a measure of the surface roughness at or near the wavelength scale. Radar backscatter data may therefore be useful in obtaining a value of aerodynamic roughness which can be used to assess aeolian sediment transport via remote sensing. In this study, calibrated L(HH), C(HH) and Ku(VV) radar data were used to derive characteristic backscatter coefficients sigma(0) for three lava flow units, an alluvial fan, and a playa surface. Preliminary analyses show that values of sigma(0) and z(0) both increase with topographic roughness and that there is a good correlation between the two coefficients. This correlation suggests that it may be possible to assess aerodynamic roughness directly from radar data.

Greeley, Ronald↗

NASA NTRS1991

Investigation of the influence of a step change in surface roughness on turbulent heat transfer

The use is studied of smooth heat flux gages on the otherwise very rough SSME fuel pump turbine blades. To gain insights into behavior of such installations, fluid mechanics and heat transfer data were collected and are reported for a turbulent boundary layer over a surface with a step change from a rough surface to a smooth surface. The first 0.9 m length of the flat plate test surface was roughened with 1.27 mm hemispheres in a staggered, uniform array spaced 2 base diameters apart. The remaining 1.5 m length was smooth. The effect of the alignment of the smooth surface with respect to the rough surface was also studied by conducting experiments with the smooth surface aligned with the bases or alternatively with the crests of the roughness elements. Stanton number distributions, skin friction distributions, and boundary layer profiles of temperature and velocity are reported and are compared to previous data for both all rough and all smooth wall cases. The experiments show that the step change from rough to smooth has a dramatic effect on the convective heat transfer. It is concluded that use of smooth heat flux gages on otherwise rough surfaces could cause large errors.

Taylor, Robert P.↗

NASA NTRS1993

Roughness-induced generation of crossflow vortices in three-dimensional boundary layers

The receptivity theory of Goldstein and Ruban is extended within the nonasymptotic (quasi-parallel) framework of Zavol'skii et al to predict the roughness-induced generation of stationary and nonstationary instability waves in three-dimensional, incompressible boundary layers. The influence of acoustic-wave orientation, as well as that of different types of roughness geometries, including isolated roughness elements, periodic arrays, and two-dimensional lattices of compact roughness shapes, as well as random, but spatially homogeneous roughness distributions, is examined. The parametric study for the Falkner-Skan-Cooke family of boundary layers supports our earlier conjecture that the initial amplitudes of roughness-induced stationary vortices are likely to be significantly larger than the amplitudes of similarly induced nonstationary vortices in the presence of acoustic disturbances in the free stream. Maximum unsteady receptivity occurs when the acoustic velocity fluctuation is aligned with the wavenumber vector of the unsteady vortex mode. On the other hand, roughness arrays that are oriented somewhere close to the group velocity direction are likely to produce higher instability amplitudes. Limitations of the nonasymptotic theory are discussed, and future work is suggested.

Choudhari, Meelan↗

NASA NTRS1955

Effect of surface roughness on characteristics of spherical shock waves

An investigation has been conducted on a small-scale test layout in which direct observation of the shock wave movement with time could be made in order to determine the effects of surface roughness on the characteristics of spherical shock waves. Data were obtained with 15-gram pentolite charges at four heights of burst, both for a smooth surface and for a surface completely covered with pyramid-shaped roughness elements. The observations resulted in determinations of shock peak overpressure and Mach stem height as a function of distance for each test. Comparison of the smooth-surface data with those obtained for the extremely rough condition showed a small net effort of roughness on the shock peak overpressures at the surface for all burst heights, the effect being to lower the overpressures. The effect of surface roughness on the Mach stem formation and growth was to delay the formation at the greatest charge height and to lower the height of the Mach stem for all heights.Comparison of the free-air shock peak overpressures with larger scale data showed good similarity of the overpressure-distance relationships. The data did not fit a geometrical similarity parameter for the path of the triple point at different heights of burst suggested by other investigators. A simple similarity parameter (relating the horizontal distance to the theoretical point of Mach formation) was found which showed only a small influence of burst height on the path of the triple point. While the data presented provide knowledge of the effect of many surface-roughness elements on the overall shock characteristics, the data do not provide insight into the details of the air-flow characteristics along the surface, nor the relative contribution of individual roughness elements to the results obtained.

Huber, Paul W↗

NASA NTRS1937

Experimental Investigation of the Problem of Surface Roughness

Based on the universal laws of turbulent velocity distribution at rough and smooth walls, there is in the present work presented a method that allows surface roughness tests and in particular, measurements on the roughness of ship surfaces to be carried out in a much simpler manner. The types of roughness investigated were in the form of flat, rough plates installed in a square-section rectangular channel, the other three walls always being smooth. Twenty-one plates of various roughness were investigated, the roughness elements being the following: spheres of diameter 0.41 and 0.21, respectively, spherical segments, cones, and "short" and "long" angles.

Schlichting, H↗

NASA NTRS1995

The effect of adding roughness and thickness to a transonic axial compressor rotor

The performance deterioration of a high speed axial compressor rotor due to surface roughness and airfoil thickness variations is reported. A 0.025 mm (0.001 in.) thick rough coating with a surface finish of 2.54-3.18 RMS microns (100-125 RMS microinches) is applied to the pressure and suction surface of the rotor blades. Coating both surfaces increases the leading edge thickness by 10% at the hub and 20% at the tip. Application of this coating results in a loss in efficiency of 6 points and a 9% reduction in the pressure ratio across the rotor at an operating condition near the design point. To separate the effect of thickness and roughness, a smooth coating of equal thickness is also applied to the blade. The smooth coating surface finish is 0.254-0.508 RMS microns (10-20 RMS microinches), compared to the bare metal blade surface finish of 0.508 RMS microns (20 RMS microinches). The smooth coating results in approximately half of the performance deterioration found from the rough coating. Both coatings are then applied to different portions of the blade surface to determine which portions of the airfoil are most sensitive to thickness/roughness variations. Aerodynamic performance measurements are presented for a number of coating configurations at 60%, 80%, and 100% of design speed. The results indicate that thickness/roughness over the first 10% of blade chord accounts for virtually all of the observed performance degradation for the smooth coating, compared to about 70% of the observed performance degradation for the rough coating. The performance deterioration is investigated in more detail at design speed using laser anemometer measurements as well as predictions generated by a quasi-3D Navier-Stokes flow solver which includes a surface roughness model. Measurements and analysis are performed on the baseline blade and the full-coverage smooth and rough coatings. The results indicate that coating the blade causes a thickening of the blade boundary layers. The interaction between the rotor passage shock and the thickened suction surface boundary layer then results in an increase in blockage which reduces the diffusion level in the rear half of the blade passage, thus reducing the aerodynamic performance of the rotor.

Suder, Kenneth L.↗

NASA NTRS1995

Bleed Roughness Mechanism

Suction applied through wall bleed is expected to reduce boundary-layer thickness and lead to a profile that can resist separation. However, experiments with rows of suction holes or slots have shown that the benefits of suction are not realized under certain circumstances. Lee, Sloan and Paynter attributed this to a 'bleed roughness', and modeled the phenomena using a modified inner-length scale with convective lag for the eddy viscosity. Test information was required to determine the roughness values at each Mach number and bleed rate. The present work used numerical calculation, subsonic and supersonic experimentation, and physical modeling were used to explore bleed roughness. It was found that the phenomena can exist in the absence of bleed, that it is a function of geometry and Mach number, and that it does not appear in low subsonic flow. The inner-length scale/convective lag approach was found to be inconsistent with recent physical observation. Alternate steady models for the roughness effect disagreed with mass flux trends and the choked flow limit, and suggested that non-steady mechanisms are present. While new supersonic experiments did exhibit low-frequency plenum oscillations, high-frequency unsteadiness associated with the orifice flow scale appears to be the cause of bleed roughness. In fact, boundary-layer calculations with an oscillatory orifice flow produced the same effect in the time-averaged downstream profile for incompressibile flow. A new empirical turbulence-model was proposed which increased the eddy viscosity throughout the entire boundary-layer by a constant which was calibrated using the zero-bleed profile. Preliminary calculations agreed with the experimental data. The model significantly reduced the test information required to determine roughness values for turbulence modeling, and provided prediction capability for supersonic bleed flows. An abstract of a thesis entitled 'Boundary-Layer Bleed Roughness' is included.

Russell, David A.↗

NASA NTRS1997

Intelligent System Development Using a Rough Sets Methodology

The purpose of this research was to examine the potential of the rough sets technique for developing intelligent models of complex systems from limited information. Rough sets a simple but promising technology to extract easily understood rules from data. The rough set methodology has been shown to perform well when used with a large set of exemplars, but its performance with sparse data sets is less certain. The difficulty is that rules will be developed based on just a few examples, each of which might have a large amount of noise associated with them. The question then becomes, what is the probability of a useful rule being developed from such limited information? One nice feature of rough sets is that in unusual situations, the technique can give an answer of 'I don't know'. That is, if a case arises that is different from the cases the rough set rules were developed on, the methodology can recognize this and alert human operators of it. It can also be trained to do this when the desired action is unknown because conflicting examples apply to the same set of inputs. This summer's project was to look at combining rough set theory with statistical theory to develop confidence limits in rules developed by rough sets. Often it is important not to make a certain type of mistake (e.g., false positives or false negatives), so the rules must be biased toward preventing a catastrophic error, rather than giving the most likely course of action. A method to determine the best course of action in the light of such constraints was examined. The resulting technique was tested with files containing electrical power line 'signatures' from the space shuttle and with decompression sickness data.

Anderson, Gray T.↗

NASA NTRS1959

An Experimental Study at a Mach Number of 3 of the Effect of Turbulence Level and Sandpaper Type Roughness on Transition on a Flat Plate

An investigation has been conducted at a Mach number of 3 of the effect of turbulence level and sandpaper-type roughness on transition for a flat plate. The Reynolds number varied from 0.8 x 10(exp 6) to 1.8 x 10(exp 6) per inch; the settling-chamber turbulence level varied from 0.7 percent to 35 percent; and the heat transfer between the plate and the stream was negligible. Transition locations were determined by an optical method. This method was indicative of a permanent change in the boundary-layer density distribution rather than the onset of turbulent bursts. Results showed that, when transition was influenced by roughness, it moved in a way similar to its movement on a smooth plate. That is, it gradually approached the roughness location with either an increase in unit Reynolds number or an increase in turbulence level. For roughness submerged in the linear portion of the boundary-layer velocity profile, the square root of the roughness Reynolds number and the ratio of roughness height to boundary-layer displacement thickness gave similar results as parameters for predicting the effects of roughness. A range of each of these parameters which moved transition less than 10 percent was found and this range was a function of turbulence level.

Jones, Robert A.↗

NASA NTRS2000

Comparison of Predicted and Measured Turbine Vane Rough Surface Heat Transfer

The proposed paper compares predicted turbine vane heat transfer for a rough surface over a wide range of test conditions with experimental data. Predictions were made for the entire vane surface. However, measurements were made only over the suction surface of the vane, and the leading edge region of the pressure surface. Comparisons are shown for a wide range of test conditions. Inlet pressures varied between 3 and 15 psia, and exit Mach numbers ranged between 0.3 and 0.9. Thus, while a single roughened vane was used for the tests, the effective rougness,(k(sup +)), varied by more than a factor of ten. Results were obtained for freestream turbulence levels of 1 and 10%. Heat transfer predictions were obtained using the Navier-Stokes computer code RVCQ3D. Two turbulence models, suitable for rough surface analysis, are incorporated in this code. The Cebeci-Chang roughness model is part of the algebraic turbulence model. The k-omega turbulence model accounts for the effect of roughness in the application of the boundary condition. Roughness causes turbulent flow over the vane surface. Even after accounting for transition, surface roughness significantly increased heat transfer compared to a smooth surface. The k-omega results agreed better with the data than the Cebeci-Chang model. However, the low Reynolds number k-omega model did not accurately account for roughness when the freestream turbulence level was low. The high Reynolds number version of this model was more suitable when the freestream turbulence was low.

Boyle, R. J.↗

NASA NTRS1961

Pressure Distributions and Wave Drag Due to Two-Dimensional Fabrication-Type Surface Roughness on an Ogive Cylinder at Mach Numbers of 1.61 and 2.01

An investigation has been made at Mach numbers of 1.61 and 2.01 and over a range of free-stream Reynolds number per foot from about 1.2 x 10(exp 6) to 8.3 x 10(exp 6) to determine the pressure distributions and wave drags due to two-dimensional fabrication-type surface roughness. Ten types of surface roughness, including step, wave, crease, and swept configurations were investigated. The tests were made on an ogive cylinder of fineness ratio 12.2, the roughness elements covering the cylindrical portion of the model. The results indicate that wave drag is the major component of the drag due to roughness at supersonic speeds. The pressure distributions over the roughness elements were generally found to be in good agreement with linearized two-dimensional theory except for regions of the elements affected by boundary-layer separation and shock detachment. There was little or no effect of Reynolds number except on the pressures within the regions influenced by separation or shock detachment. Inasmuch as most of the roughness configurations were affected by flow separation and shock detachment, there was generally an effect of Reynolds number on the roughness wave drag. This wave drag decreased as the free-stream Reynolds number was decreased.

Czarnecki, K. R.↗

NASA NTRS2004

Examination of Surface Roughness on Light Scattering by Long Ice Columns by Use of a Two-Dimensional Finite-Difference Time-Domain Algorithm

Natural particles such as ice crystals in cirrus clouds generally are not pristine but have additional micro-roughness on their surfaces. A two-dimensional finite-difference time-domain (FDTD) program with a perfectly matched layer absorbing boundary condition is developed to calculate the effect of surface roughness on light scattering by long ice columns. When we use a spatial cell size of 1/120 incident wavelength for ice circular cylinders with size parameters of 6 and 24 at wavelengths of 0.55 and 10.8 mum, respectively, the errors in the FDTD results in the extinction, scattering, and absorption efficiencies are smaller than similar to 0.5%. The errors in the FDTD results in the asymmetry factor are smaller than similar to 0.05%. The errors in the FDTD results in the phase-matrix elements are smaller than similar to 5%. By adding a pseudorandom change as great as 10% of the radius of a cylinder, we calculate the scattering properties of randomly oriented rough-surfaced ice columns. We conclude that, although the effect of small surface roughness on light scattering is negligible, the scattering phase-matrix elements change significantly for particles with large surface roughness. The roughness on the particle surface can make the conventional phase function smooth. The most significant effect of the surface roughness is the decay of polarization of the scattered light.

Sun, W.↗

NASA NTRS2010

Transition Experiments on Blunt Bodies with Isolated Roughness Elements in Hypersonic Free Flight

Smooth titanium hemispheres with isolated three-dimensional (3D) surface roughness elements were flown in the NASA Ames hypersonic ballistic range through quiescent CO2 and air environments. Global surface intensity (temperature) distributions were optically measured and thermal wakes behind individual roughness elements were analyzed to define tripping effectiveness. Real-gas Navier-Stokes calculations of model flowfields, including laminar boundary layer development in these flowfields, were conducted predict key dimensionless parameters used to correlate transition on blunt bodies in hypersonic flow. For isolated roughness elements totally immersed within the laminar boundary layer, critical roughness Reynolds numbers for flights in air were found to be higher than those measured for flights in CO2, i.e., it was easier to trip the CO2 boundary layer to turbulence. Tripping effectiveness was found to be dependent on trip location within the subsonic region of the blunt body flowfield, with effective tripping being most difficult to achieve for elements positioned closest to the stagnation point. Direct comparisons of critical roughness Reynolds numbers for 3D isolated versus 3D distributed roughness elements for flights in air showed that distributed roughness patterns were significantly more effective at tripping the blunt body laminar boundary layer to turbulence.

Reda, Daniel C.↗

NASA NTRS2011

Numerical Model Sensitivity to Heterogeneous Satellite Derived Vegetation Roughness

The sensitivity of a mesoscale weather prediction model to a 1 km satellite-based vegetation roughness initialization is investigated for a domain within the south central United States. Three different roughness databases are employed: i) a control or standard lookup table roughness that is a function only of land cover type, ii) a spatially heterogeneous roughness database, specific to the domain, that was previously derived using a physically based procedure and Moderate Resolution Imaging Spectroradiometer (MODIS) imagery, and iii) a MODIS climatologic roughness database that like (i) is a function only of land cover type, but possesses domain specific mean values from (ii). The model used is the Weather Research and Forecast Model (WRF) coupled to the Community Land Model within the Land Information System (LIS). For each simulation, a statistical comparison is made between modeled results and ground observations within a domain including Oklahoma, Eastern Arkansas, and Northwest Louisiana during a 4-day period within IHOP 2002. Sensitivity analysis compares the impact the three roughness initializations on time-series temperature, precipitation probability of detection (POD), average wind speed, boundary layer height, and turbulent kinetic energy (TKE). Overall, the results indicate that, for the current investigation, replacement of the standard look-up table values with the satellite-derived values statistically improves model performance for most observed variables. Such natural roughness heterogeneity enhances the surface wind speed, PBL height and TKE production up to 10 percent, with a lesser effect over grassland, and greater effect over mixed land cover domains.

Jasinski, Michael↗