Navier-Stokes flow simulation of the Space Shuttle Main Engine hot gas manifold
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This document contains presentations from the joint UVA/NASA Workshop on Computational Tools and Facilities for the Next-Generation Analysis and Design Environment held at the Virginia Consortium of Engineering and Science Universities in Hampton, Virginia on September 17-18, 1996. The presentations focused on the computational tools and facilities for analysis and design of engineering systems, including, real-time simulations, immersive systems, collaborative engineering environment, Web-based tools and interactive media for technical training. Workshop attendees represented NASA, commercial software developers, the aerospace industry, government labs, and academia. The workshop objectives were to assess the level of maturity of a number of computational tools and facilities and their potential for application to the next-generation integrated design environment.
This paper discusses the development and performance of the X-33 Aerospike Engine RealTime Model. This model was developed for the purposes of control law development, six degree-of-freedom trajectory analysis, vehicle system integration testing, and hardware-in-the loop controller verification. The Real-Time Model uses time-step marching solution of non-linear differential equations representing the physical processes involved in the operation of a liquid propellant rocket engine, albeit in a simplified form. These processes include heat transfer, fluid dynamics, combustion, and turbomachine performance. Two engine models are typically employed in order to accurately model maneuvering and the powerpack-out condition where the power section of one engine is used to supply propellants to both engines if one engine malfunctions. The X-33 Real-Time Model is compared to actual hot fire test data and is been found to be in good agreement.
Contents include the following: General Background and Introduction of Capability Roadmaps. Agency Objective. Strategic Planning Transformation. Advanced Planning Organizational Roles. Public Involvement in Strategic Planning. Strategic Roadmaps and Schedule. Capability Roadmaps and Schedule. Purpose of NRC Review. Capability Roadmap Development (Progress to Date).
The Jet Propulsion Laboratory (JPL) is developing a high-fidelity, real-time spacecraft simulator for Entry, Descent and Landing (EDL) on planetary and small bodies. This simulator, DSENDS (Dynamics Simulator for Entry, Descent and Surface landing), is an EDL-specific extension of the JPL Darts/Dshell multi-mission spacecraft dynamics and devices simulation toolkit which is in use by missions such as Cassini, Galileo, SIM, and Starlight.
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The development of Nuclear Thermal Propulsion engines depends heavily on modeling and simulation of a number of disciplines—neutronic / fluid / thermal / structural are only a start. Further, rockets involve extreme conditions, particularly high material temperatures in the nuclear fuel. This paper considers validation of the underling physical models and codes and how their accuracy influences several design challenges. Several issues are identified, where models, material data, could enable design solutions. In particular, thermal and CTE mismatch stresses are a concern, and stress predictions would benefit from improved mechanical property data at high temperatures. Nuclear inter-element heating causes propellant flow maldistribution and performance risks, but a simple model provides insights. High temperature chemical diffusion should be modeled to understand fuel element mass loss.
The development of Nuclear Thermal Propulsion engines depends heavily on modeling and simulation of a number of disciplines—neutronic / fluid / thermal / structural are only a start. Further, rockets involve extreme conditions, particularly high material temperatures in the nuclear fuel. This paper considers validation of the underling physical models and codes and how their accuracy influences several design challenges. Several issues are identified, where models, material data, could enable design solutions. In particular, thermal and CTE mismatch stresses are a concern, and stress predictions would benefit from improved mechanical property data at high temperatures. Nuclear inter-element heating causes propellant flow maldistribution and performance risks, but a simple model provides insights. High temperature chemical diffusion should be modeled to understand fuel element mass loss.
Abstract not provided.
A large scale model representative of a low-noise, high bypass ratio turbofan engine was tested for acoustics and performance in the NASA Lewis 9- by 15-Foot Low-Speed Wind Tunnel. This test was part of NASA's continuing Advanced Subsonic Technology Noise Reduction Program. The low tip speed fan, nacelle, and an un-powered core passage (with core inlet guide vanes) were simulated. The fan blades and hub are mounted on a rotating thrust and torque balance. The nacelle, bypass duct stators, and core passage are attached to a six component force balance. The two balance forces, when corrected for internal pressure tares, measure the total thrust-minus-drag of the engine simulator. Corrected for scaling and other effects, it is basically the same force that the engine supports would feel, operating at similar conditions. A control volume is shown and discussed, identifying the various force components of the engine simulator thrust and definitions of net thrust. Several wind tunnel runs with nearly the same hardware installed are compared, to identify the repeatability of the measured thrust-minus-drag. Other wind tunnel runs, with hardware changes that affected fan performance, are compared to the baseline configuration, and the thrust and torque effects are shown. Finally, a thrust comparison between the force balance and nozzle gross thrust methods is shown, and both yield very similar results.
The objective of this project is to improve the prediction of engine knock by developing a new combustion modeling framework. Engine knock is a limiting factor to constrain the increase of fuel efficiency for spark ignition (SI) engines in most passenger cars. Efforts to increase fuel efficiency, increasing the compression ratio or downsizing, lead to the increase in the tendency of the knock occurrence. The knock is an undesired ignition of the end-gas, unburned fuel/air mixture ahead of the spark-ignited premixed flame, resulting in rapid in-cylinder pressure rises and engine damages. The combustion modeling framework developed in this project can consider turbulence-chemistry interactions during end-gas ignition, while using a reasonably detailed chemical mechanism developed for ignition and combustion reactions under engine relevant conditions, and the subtle characteristics of spark-ignited flame propagation. It is developed in the context of large eddy simulation (LES), which can capture stochastic in-cylinder processes. The developed model is incorporated into a commercial software for engine simulation, CONVERGE CFD, as a user defined function, and validated. Engine knock and knock-free experiments as well as direct numerical simulation (DNS) of end-gas ignition in homogeneous turbulence are performed to help model development and provide data sets for model validation. With further validation, the developed model is expected to advance the predictive capability for engine knock simulations and thus contribute to improving the fuel efficiency.
The objective of this project is to improve the prediction of engine knock by developing a new combustion modeling framework. Engine knock is a limiting factor to constrain the increase of fuel efficiency for spark ignition (SI) engines in most passenger cars. Efforts to increase fuel efficiency, increasing the compression ratio or downsizing, lead to the increase in the tendency of the knock occurrence. The knock is an undesired ignition of the end-gas, unburned fuel/air mixture ahead of the spark-ignited premixed flame, resulting in rapid in-cylinder pressure rises and engine damages. The combustion modeling framework developed in this project can consider turbulence-chemistry interactions during end-gas ignition, while using a reasonably detailed chemical mechanism developed for ignition and combustion reactions under engine relevant conditions, and the subtle characteristics of spark-ignited flame propagation. It is developed in the context of large eddy simulation (LES), which can capture stochastic in-cylinder processes. The developed model is incorporated into a commercial software for engine simulation, CONVERGE CFD, as a user defined function, and validated. Engine knock and knock-free experiments as well as direct numerical simulation (DNS) of end-gas ignition in homogeneous turbulence are performed to help model development and provide data sets for model validation. With further validation, the developed model is expected to advance the predictive capability for engine knock simulations and thus contribute to improving the fuel efficiency.
The occurrence of ice accretion within commercial high bypass aircraft turbine engines has been reported under certain atmospheric conditions. Engine anomalies have taken place at high altitudes that have been attributed to ice crystal ingestion, partially melting, and ice accretion on the compression system components. The result was degraded engine performance, and one or more of the following: loss of thrust control (roll back), compressor surge or stall, and flameout of the combustor. As ice crystals are ingested into the fan and low pressure compression system, the increase in air temperature causes a portion of the ice crystals to melt. It is hypothesized that this allows the ice-water mixture to cover the metal surfaces of the compressor stationary components which leads to ice accretion through evaporative cooling. Ice accretion causes a blockage which subsequently results in the deterioration in performance of the compressor and engine. The focus of this research is to apply an engine icing computational tool to simulate the flow through a turbofan engine and assess the risk of ice accretion. The tool is comprised of an engine system thermodynamic cycle code, a compressor flow analysis code, and an ice particle melt code that has the capability of determining the rate of sublimation, melting, and evaporation through the compressor flow path, without modeling the actual ice accretion. A commercial turbofan engine which has previously experienced icing events during operation in a high altitude ice crystal environment has been tested in the Propulsion Systems Laboratory (PSL) altitude test facility at NASA Glenn Research Center. The PSL has the capability to produce a continuous ice cloud which are ingested by the engine during operation over a range of altitude conditions. The PSL test results confirmed that there was ice accretion in the engine due to ice crystal ingestion, at the same simulated altitude operating conditions as experienced previously in flight. The computational tool was utilized to help guide a portion of the PSL testing, and was used to predict ice accretion could also occur at significantly lower altitudes. The predictions were qualitatively verified by subsequent testing of the engine in the PSL. The PSL test has helped to calibrate the engine icing computational tool to assess the risk of ice accretion. The results from the computer simulation identified prevalent trends in wet bulb temperature, ice particle melt ratio, and engine inlet temperature as a function of altitude for predicting engine icing risk due to ice crystal ingestion.
An additional data base for improving and verifying a computer simulation developed by an engine manufacturer was obtained. The multisegment parallel compressor simulation was designed to predict the effects of steady-state circumferential inlet total-pressure and total-temperature distortions on the flows into and through a turbofan compression system. It also predicts the degree of distortion that will result in surge of the compressor. The effect of combined 180 deg square-wave distortion patterns of total pressure and total temperature in various relative positions is reported. The observed effects of the combined distortion on a unitary bypass ratio turbofan engine are presented in terms of total and static pressure profiles and total temperature profiles at stations ahead of the inlet guide vanes as well as through the fan-compressor system. These observed profiles are compared with those predicted by the complex multisegment model. The effects of relative position of the two components comprising the combined distortion on the degree resulting in surge are discussed. Certain relative positions required less combined distortion than either a temperature or pressure distortion by itself.
The objective of this paper is to utilize the design methods of modern control theory to realize a dual-adaptive feedback control unit for a highly nonlinear single spool airbreathing turbojet engine. Using a very detailed and accurate simulation of the nonlinear engine as the data source, linear operating point models of unspecified dimension are identified. Feedback control laws are designed at each operating point for a prespecified set of sampling rates using sampled-data output regulator theory. The control system sampling rate is determined by an adaptive sampling algorithm in correspondence with turbojet engine performance. The result is a dual-adaptive control law that is functionally dependent upon the sampling rate selected and environmental operating conditions. Simulation transients demonstrate the utility of the dual-adaptive design to improve on-board computer utilization while maintaining acceptable levels of engine performance.
Two Galileo dynamic models were developed to simulate the spinup/400-N main engine burn/spindown maneuvers for the critical events of Jupiter Orbit Insertion (JOI) and Perijove Raise Maneuver (PRM). The dynamic interaction among the spin thruster pulsing frequency science/magnetometer (SCI/MAG) boom flexible modes, and the propellant slosh modes were studied.
The durability of CATCOM catalysts and catalyst supports was experimentally demonstrated in a combustion environment under simulated gas turbine engine combustor operating conditions. A test of 1000 hours duration was completed with one catalyst using no. 2 diesel fuel and operating at catalytically-supported thermal combustion conditions. The performance of the catalyst was determined by monitoring emissions throughout the test, and by examining the physical condition of the catalyst core at the conclusion of the test. Tests were performed periodically to determine changes in catalytic activity of the catalyst core. Detailed parametric studies were also run at the beginning and end of the durability test, using no. 2 fuel oil. Initial and final emissions for the 1000 hours test respectively were: unburned hydrocarbons (C3 vppm):0, 146, carbon monoxide (vppm):30, 2420; nitrogen oxides (vppm):5.7, 5.6.
The “curse of dimensionality” has limited the applicability and expansion of tabulated combustion models. While the tabulated flamelet model and other multi-dimensional manifold approaches have shown predictive capability, the associated tabulation involves the storage of large lookup tables, requiring large memory as well as multi-dimensional interpolation subroutines, all implemented during runtime. As such, this work investigates the use of deep artificial neural networks to replace lookup tables in order to reduce the memory footprint and increase the computational speed of tabulated flamelets and related approaches. Specifically, different strategic approaches to training the artificial neural network models are explored and a grouped multi-target artificial neural network is introduced, which takes advantage of the ability of artificial neural networks to map an input space to multiple targets by classifying the species based on their correlation to one another. The grouped multi-target artificial neural network approach is validated by applying it to an n-dodecane spray flame using conditions of the Spray A flame from the Engine Combustion Network and comparing global flame characteristics for different ambient conditions using a well-established large-eddy simulation framework. The same framework is then extended to the simulations of methyl decanoate combustion in a compression ignition engine. The validation studies show that the grouped multi-target artificial neural networks are able to accurately capture flame liftoff, autoignition, two-stage heat release and other quantitative trends over a range of conditions. The use of neural networks in conjunction with the grouping mechanism as performed in the grouped multi-target artificial neural network produces a significant reduction in the memory footprint and computational costs for the code and, thus, widens the operating envelope for higher fidelity engine simulations with detailed mechanisms.