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At least 163 records · Page 9

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated temperatures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple)trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A Baseline CFD model is defined and its accuracy established to be comparable to(and which usually exceeds) the accuracy of existing HTC (heat-transfer coefficient) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled),generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.1

99 GENERAL AND MISCELLANEOUS↗

TEAMER: Crossflow Turbine Fairing Geometry Optimization - Report and CFD Modeling Files

The dataset includes computational fluid dynamics (CFD) models and simulation files for crossflow turbines as well as a detailed project report. The report documents the project undertaken by the Ocean Renewable Power Company (ORPC) to design and optimize a modular fairing for the Modular RivGen Marine Hydrokinetic (MHK) turbine, which enhances the efficient deployment and operation of turbine arrays. The project focused on optimizing the hydrodynamic performance of the fairing using CFD, with an emphasis on two key geometric parameters: the fairing's cross-sectional shape and the spacing between the rotor and the fairing. The analysis aimed to maximize net power output while also assessing discretized loading to evaluate ultimate and fatigue loads on the turbine components. The numerical modeling was conducted using both the commercial CFD software Star-CCM+ and the open-source code openFOAM, with the latter utilizing the actuator line library, turbinesFOAM. This dual-code approach was intended to increase confidence in the results and demonstrate the viability of using open-source tools for high-fidelity marine energy modeling. This dataset includes all necessary files for actuator line simulations in openFOAM, as well as 2D blade-resolved CFD results, along with Python and Java scripts for setting up and post-processing simulations.

16 TIDAL AND WAVE POWER↗

Validation Framework for Post-Combustion Carbon Capture CFD Simulations

First-principles based computational fluid dynamics (CFD) simulations are proposed as a fundamental tool for investigating solvent-based CO2 absorption in packed columns, due to the ability to accurately represent the underlying non-linear multiscale dynamics. In this work, we employ such models to investigate hydrodynamics of columns with structured by assessing the key hydrodynamic metrics, such as pressure drop and liquid holdup. Our models are validated with experimental data from a specifically designed column for this line of work. The test cases of gas and liquid flowrates and operating conditions were selected through a comprehensive sequential design of experiments approach offered by the CCSI2 toolset.

Panagakos, Grigorios↗

CFD validation experiments for internal flows

Computational Fluid Dynamics (CFD) validation experiments at NASA Lewis Research Center are described. The material presented summarizes the research in three areas: Inlets, Ducts and Nozzles; Turbomachinery; and Chemically Reacting Flows. The specific validation activities are concerned with shock-boundary layer interactions, vortex generator effects, large low speed centrifugal compressor measurements, transonic fan shock structure, rotor/stator kinetic energy distributions, stator wake shedding characteristics, boundary layer transition, multiphase flow and reacting shear layers. These experiments are intended to provide CFD validation data for the internal flow fields within aerospace propulsion system components.

Povinelli, Louis A.↗

CFD validation experiments for internal flows

Computational Fluid Dynamics (CFD) validation experiments at NASA Lewis are described. The material presented summarized the research in 3 areas: Inlets, ducts and nozzles; Turbomachinery; and Chemically reacting flows. The specific validation activities are concerned with shock boundary layer interactions, vortex generator effects, large low speed centrifugal compressor measurements, transonic fan shock structure, rotor/stator kinetic energy distributions, stator wake shedding characteristics, boundary layer transition, multiphase flow and reacting shear layers. These experiments are intended to provide CFD validation data for the internal flow fields within aerospace propulsion system components.

Povinelli, Louis A.↗

An Approach to Improved Credibility of CFD Simulations for Rocket Injector Design

Computational fluid dynamics (CFD) has the potential to improve the historical rocket injector design process by simulating the sensitivity of performance and injector-driven thermal environments to. the details of the injector geometry and key operational parameters. Methodical verification and validation efforts on a range of coaxial injector elements have shown the current production CFD capability must be improved in order to quantitatively impact the injector design process.. This paper documents the status of an effort to understand and compare the predictive capabilities and resource requirements of a range of CFD methodologies on a set of model problem injectors. Preliminary results from a steady Reynolds-Average Navier-Stokes (RANS), an unsteady Reynolds-Average Navier Stokes (URANS) and three different Large Eddy Simulation (LES) techniques used to model a single element coaxial injector using gaseous oxygen and gaseous hydrogen propellants are presented. Initial observations are made comparing instantaneous results, corresponding time-averaged and steady-state solutions in the near -injector flow field. Significant differences in the flow fields exist, as expected, and are discussed. An important preliminary result is the identification of a fundamental mixing mechanism, accounted for by URANS and LES, but missing in the steady BANS methodology. Since propellant mixing is the core injector function, this mixing process may prove to have a profound effect on the ability to more correctly simulate injector performance and resulting thermal environments. Issues important to unifying the basis for future comparison such as solution initialization, required run time and grid resolution are addressed.

Tucker, Paul K.↗

High Accuracy Liquid Propellant Slosh Predictions Using an Integrated CFD and Controls Analysis Interface

Coupling computational fluid dynamics (CFD) with a controls analysis tool elegantly allows for high accuracy predictions of the interaction between sloshing liquid propellants and th e control system of a launch vehicle. Instead of relying on mechanical analogs which are not valid during aU stages of flight, this method allows for a direct link between the vehicle dynamic environments calculated by the solver in the controls analysis tool to the fluid flow equations solved by the CFD code. This paper describes such a coupling methodology, presents the results of a series of test cases, and compares said results against equivalent results from extensively validated tools. The coupling methodology, described herein, has proven to be highly accurate in a variety of different cases.

Marsell, Brandon↗

Improving Fidelity of Launch Vehicle Liftoff Acoustic Simulations

Launch vehicles experience high acoustic loads during ignition and liftoff affected by the interaction of rocket plume generated acoustic waves with launch pad structures. Application of highly parallelized Computational Fluid Dynamics (CFD) analysis tools optimized for application on the NAS computer systems such as the Loci/CHEM program now enable simulation of time-accurate, turbulent, multi-species plume formation and interaction with launch pad geometry and capture the generation of acoustic noise at the source regions in the plume shear layers and impingement regions. These CFD solvers are robust in capturing the acoustic fluctuations, but they are too dissipative to accurately resolve the propagation of the acoustic waves throughout the launch environment domain along the vehicle. A hybrid Computational Fluid Dynamics and Computational Aero-Acoustics (CFD/CAA) modeling framework has been developed to improve such liftoff acoustic environment predictions. The framework combines the existing highly-scalable NASA production CFD code, Loci/CHEM, with a high-order accurate discontinuous Galerkin (DG) solver, Loci/THRUST, developed in the same computational framework. Loci/THRUST employs a low dissipation, high-order, unstructured DG method to accurately propagate acoustic waves away from the source regions across large distances. The DG solver is currently capable of solving up to 4th order solutions for non-linear, conservative acoustic field propagation. Higher order boundary conditions are implemented to accurately model the reflection and refraction of acoustic waves on launch pad components. The DG solver accepts generalized unstructured meshes, enabling efficient application of common mesh generation tools for CHEM and THRUST simulations. The DG solution is coupled with the CFD solution at interface boundaries placed near the CFD acoustic source regions. Both simulations are executed simultaneously with coordinated boundary condition data exchange.

Liever, Peter↗

Accuracy requirements and benchmark experiments for CFD validation

The role of experiment in the development of Computation Fluid Dynamics (CFD) for aerodynamic flow prediction is discussed. The CFD verification is a concept that depends on closely coordinated planning between computational and experimental disciplines. Because code applications are becoming more complex and their potential for design more feasible, it no longer suffices to use experimental data from surface or integral measurements alone to provide the required verification. Flow physics and modeling, flow field, and boundary condition measurements are emerging as critical data. Four types of experiments are introduced and examples given that meet the challenge of validation: flow physics experiments; flow modeling experiments; calibration experiments; and verification experiments. Measurement and accuracy requirements for each of these differ and are discussed. A comprehensive program of validation is described, some examples given, and it is concluded that the future prospects are encouraging.

Marvin, Joseph G.↗

Accuracy requirements and benchmark experiments for CFD validation

The role of experiment in the development of Computational Fluid Dynamics (CFD) for aerodynamic flow prediction is discussed. The CFD verification is a concept that depends on closely coordinated planning between computational and experimental disciplines. Because code applications are becoming more complex and their potential for design more feasible, it no longer suffices to use experimental data from surface or integral measurements alone to provide the required verification. Flow physics and modeling, flow field, and boundary condition measurements are emerging as critical data. Four types of experiments are introduced and examples are given that meet the challenge of validation: flow physics experiments; flow modeling experiments; calibration experiments; and verification experiments. Measurement and accuracy requirements for each of these differ and are discussed. A comprehensive program of validation is described, some examples given, and it is concluded that the future prospects are encouraging.

Marvin, Joseph G.↗

Three-dimensional computations of transverse hydrogen jet combustion in a supersonic airstream

A computational fluid dynamics (CFD) code is being developed to compute the mixing and combustion of hydrogen fuel in the turbulent flow fields of supersonic combustion ramjets (scramjet). The code solves the three-dimensional Reynolds time-averaged complete Navier-Stokes equations including transport equations for a four species, two reaction, global finite rate chemistry model. The code was applied to the case of transverse injection of hydrogen from a sonic circular orifice into a supersonic airstream. The equations were numerically integrated using MacCormack's explicit method, and the algebraic eddy viscosity model of Baldwin-Lomax was used to model the turbulence. In the species transport and energy equations, diffusion coefficients based on Fick's Law and an assumption of unit Lewis number were applied. Computed features of the three-dimensional flow field are depicted by static pressure, static temperature, mass fraction of species, and velocity vectors. For engineering interest, mixing and combustion parameters were examined to assess the effect of injector diameter, injected fuel pressure, fuel-air ratio, and spacing of fuel injectors. The objective of the present paper is to demonstrate the capability of the present three-dimensional spatially elliptic, CFD code for turbulent, reacting flow. Application of the code to specific supersonic combustion configurations is planned.

Uenishi, K.↗

Enhancing aeropropulsion research with high-speed interactive computing

NASA-Lewis has committed to a long range goal of creating a numerical test cell for aeropropulsion research and development. Efforts are underway to develop a first generation Numerical Propulsion System Simulation (NPSS). The NPSS will provide a unique capability to numerically simulate advanced propulsion systems from nose to tail. Two essential ingredients to the NPSS are: (1) experimentally validated Computational Fluid Dynamics (CFD) codes; and (2) high performing computing systems (hardware and software) that will permit those codes to be used efficiently. To this end, NASA-Lewis is using high speed, interactive computing as a means for achieving Integrated CFD and Experiments (ICE). The development is described of a prototype ICE system for multistage compressor flow physics research.

Szuch, John R.↗

Enhancing aeropropulsion research with high-speed interactive computing

NASA-Lewis has committed to a long range goal of creating a numerical test cell for aeropropulsion research and development. Efforts are underway to develop a first generation Numerical Propulsion System Simulation (NPSS). The NPSS will provide a unique capability to numerically simulate advanced propulsion systems from nose to tail. Two essential ingredients to the NPSS are: (1) experimentally validated Computational Fluid Dynamics (CFD) codes; and (2) high performing computing systems (hardware and software) that will permit those codes to be used efficiently. To this end, NASA-Lewis is using high speed, interactive computing as a means for achieving Integrated CFD and Experiments (ICE). The development is described of a prototype ICE system for multistage compressor flow physics research.

Szuch, John R.↗

Analysis of film cooling in rocket nozzles

Computational Fluid Dynamics (CFD) programs are customarily used to compute details of a flow field, such as velocity fields or species concentrations. Generally they are not used to determine the resulting conditions at a solid boundary such as wall shear stress or heat flux. However, determination of this information should be within the capability of a CFD code, as the code supposedly contains appropriate models for these wall conditions. Before such predictions from CFD analyses can be accepted, the credibility of the CFD codes upon which they are based must be established. This report details the progress made in constructing a CFD model to predict the heat transfer to the wall in a film cooled rocket nozzle. Specifically, the objective of this work is to use the NASA code FDNS to predict the heat transfer which will occur during the upcoming hot-firing of the Pratt & Whitney 40K subscale nozzle (1Q93). Toward this end, an M = 3 wall jet is considered, and the resulting heat transfer to the wall is computed. The values are compared against experimental data available in Reference 1. Also, FDNS's ability to compute heat flux in a reacting flow will be determined by comparing the code's predictions against calorimeter data from the hot firing of a 40K combustor. The process of modeling the flow of combusting gases through the Pratt & Whitney 40K subscale combustor and nozzle is outlined. What follows in this report is a brief description of the FDNS code, with special emphasis on how it handles solid wall boundary conditions. The test cases and some FDNS solution are presented next, along with comparison to experimental data. The process of modeling the flow through a chamber and a nozzle using the FDNS code will also be outlined.

Woodbury, Keith A.↗

Sensitivity calculations for a 2D, inviscid, supersonic forebody problem

The use of a sensitivity equation method to computer derivatives for optimization based design algorithms are discussed. The problem of designing an optimal forebody simulator is used to motivate the algorithm and to illustrate the basic ideas. Finally, how an existing computational fluid dynamics (CFD) code can be modified to compute sensitivities and a numerical example is presented.

Borggaard, Jeff↗

Visualization of unsteady computational fluid dynamics

The current computing environment that most researchers are using for the calculation of 3D unsteady Computational Fluid Dynamic (CFD) results is a super-computer class machine. The Massively Parallel Processors (MPP's) such as the 160 node IBM SP2 at NAS and clusters of workstations acting as a single MPP (like NAS's SGI Power-Challenge array) provide the required computation bandwidth for CFD calculations of transient problems. Work is in progress on a set of software tools designed specifically to address visualizing 3D unsteady CFD results in these super-computer-like environments. The visualization is concurrently executed with the CFD solver. The parallel version of Visual3, pV3 required splitting up the unsteady visualization task to allow execution across a network of workstation(s) and compute servers. In this computing model, the network is almost always the bottleneck so much of the effort involved techniques to reduce the size of the data transferred between machines.

Haimes, Robert↗

Visualization of Unsteady Computational Fluid Dynamics

The current compute environment that most researchers are using for the calculation of 3D unsteady Computational Fluid Dynamic (CFD) results is a super-computer class machine. The Massively Parallel Processors (MPP's) such as the 160 node IBM SP2 at NAS and clusters of workstations acting as a single MPP (like NAS's SGI Power-Challenge array and the J90 cluster) provide the required computation bandwidth for CFD calculations of transient problems. If we follow the traditional computational analysis steps for CFD (and we wish to construct an interactive visualizer) we need to be aware of the following: (1) Disk space requirements. A single snap-shot must contain at least the values (primitive variables) stored at the appropriate locations within the mesh. For most simple 3D Euler solvers that means 5 floating point words. Navier-Stokes solutions with turbulence models may contain 7 state-variables. (2) Disk speed vs. Computational speeds. The time required to read the complete solution of a saved time frame from disk is now longer than the compute time for a set number of iterations from an explicit solver. Depending, on the hardware and solver an iteration of an implicit code may also take less time than reading the solution from disk. If one examines the performance improvements in the last decade or two, it is easy to see that depending on disk performance (vs. CPU improvement) may not be the best method for enhancing interactivity. (3) Cluster and Parallel Machine I/O problems. Disk access time is much worse within current parallel machines and cluster of workstations that are acting in concert to solve a single problem. In this case we are not trying to read the volume of data, but are running the solver and the solver outputs the solution. These traditional network interfaces must be used for the file system. (4) Numerics of particle traces. Most visualization tools can work upon a single snap shot of the data but some visualization tools for transient problems require dealing with time.

Haimes, Robert↗

Aeroelastic Analysis of Modern Complex Wings

A process is presented by which aeroelastic analysis is performed by using an advanced computational fluid dynamics (CFD) code coupled with an advanced computational structural dynamics (CSD) code. The process is demonstrated on an F/A-18 Stabilator using NASTD (an in-house McDonnell Douglas Aerospace East CFD code) coupled with NASTRAN. The process is also demonstrated on an aeroelastic research wing (ARW-2) using ENSAERO (an in-house NASA Ames Research Center CFD code) coupled with a finite element wing-box structures code. Good results have been obtained for the F/A-18 Stabilator while results for the ARW-2 supercritical wing are still being obtained.

Kapania, Rakesh K.↗