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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Coupled Aeropropulsive Design Optimization of a Podded Electric Propulsor

New aircraft concepts are increasingly relying on non-traditional propulsion systems to achieve lower energy consumption. These non-traditional technologies, such as boundary layer ingestion or distributed electric propulsion, require a tight integration of the propulsion sys- tem to the airframe, and therefore, a traditional design approach where the aerodynamics and propulsion disciplines are considered separately is likely to result in sub-optimal designs. As a result, we have to rely on coupled aeropropulsive design optimization, in which fully coupled aeropropulsive models are optimized to maximize the advantages of these tightly integrated propulsion systems. Despite its advantages, aeropropulsive design optimization is a relatively new field, and significant advancements are required for wide adoption of this approach, especially in the context of robustness. In this work, we introduce two fully coupled aeropropulsive design optimization approaches that are compatible with CFD models with body-force terms and boundary conditions to model the effects of the propulsion system in the flow field. To test these new approaches, we developed a podded electric fan model based on the aft-propulsor of NASA’s STARC-ABL concept. This simple design problem enables us to rapidly develop and test different aeropropulsive coupling approaches, while including the challenging physical interactions that arise from coupling CFD and propulsion models. The coupled aeropropulsive model is implemented using the MPhys library, which is built with NASA’s OpenMDAO frame- work. Using this benchmark design problem, we demonstrate the robustness of the approaches and our aeropropulsive design optimization framework by performing a sweep of optimizations for a total of 50 CFD-based aeropropulsive design optimizations. Furthermore, the new aero- propulsive coupling approaches enable multi-point design optimizations. We demonstrate this capability in a multi-point design optimization problem where we optimize cruise performance subject to a fan-face distortion constraint at rolling take-off conditions. The aeropropulsive modeling approaches we present in this work represent a significant milestone in the field of aeropropulsive design optimization. The framework we developed is extremely robust and flexible, and these developments will be crucial for future aeropropulsive design optimizations of complete turbofan engines.

Optimization propulsion aerodynamics↗
NASA NTRS2018

Aeropropulsive Design Optimization of a Turboelectric Boundary Layer Ingestion Propulsion System

Boundary Layer Ingestion (BLI) for aircraft applications was first proposed by Apollo Smith and Howard Roberts in a 1947 paper that studied the use of jet intakes embedded in the boundary layer as a means to maintain laminar flow and reduce aircraft drag. While the use of BLI in aviation didn't catch on it was heavily studied and utilized for marine applications. In 1993 interest in BLI applications to aircraft design was renewed when Leyroy Smith published novel work using a boundary layer analysis combined with basic propulsion modeling to show the potential for significant fuel burn reduction. Smith identified the tightly coupled aero-propulsive nature of BLI as a key challenge in the analysis and design of the concept.

Gray, Justin S.↗
NASA NTRS2004

Multidisciplinary Design Optimization for Aeropropulsion Engines and Solid Modeling/Animation via the Integrated Forced Methods

The grant closure report is organized in the following four chapters: Chapter describes the two research areas Design optimization and Solid mechanics. Ten journal publications are listed in the second chapter. Five highlights is the subject matter of chapter three. CHAPTER 1. The Design Optimization Test Bed CometBoards. CHAPTER 2. Solid Mechanics: Integrated Force Method of Analysis. CHAPTER 3. Five Highlights: Neural Network and Regression Methods Demonstrated in the Design Optimization of a Subsonic Aircraft. Neural Network and Regression Soft Model Extended for PX-300 Aircraft Engine. Engine with Regression and Neural Network Approximators Designed. Cascade Optimization Strategy with Neural network and Regression Approximations Demonstrated on a Preliminary Aircraft Engine Design. Neural Network and Regression Approximations Used in Aircraft Design.

Source record↗
NASA NTRSDate not supplied

A Nonlinear Schur Complement Solver for CFD-Based Multidisciplinary Models

CFD-based multidisciplinary models are the fundamental building blocks of multidis- ciplinary design optimization frameworks. Linear and nonlinear solutions of these coupled models are difficult, especially when the Jacobian matrices represent a saddle point problem, where a block-diagonal corresponding to a discipline is non-invertible. These scenarios necessitate the use of a coupled solver algorithm such as the Newton’s method instead of the popular block Gauss– Seidel-based methods because of this non-invertible block. To address this challenge, we introduce a nonlinear Schur complement solver suitable for CFD-based multidisciplinary models. The solver leverages the specialized linear and nonlinear solvers of the CFD code, and therefore, does not require the solution of a large coupled linear system as the coupled Newton’s method. Further- more, because the solver primarily uses the specialized linear and nonlinear solvers of the CFD code, it does not suffer from the same robustness limitations as the coupled Newton’s method. In this work, we will implement this solver in NASA’s OpenMDAO framework and demonstrate its effectiveness using a CFD-based aeropropulsive model. The solver will contribute to the develop- ment of aeropropulsive design optimization and CFD-based design optimization methods with the ultimate goal of accelerating the design and integration of advanced propulsion systems.

Nonlinear Solvers↗
NASA NTRS1994

Portable parallel stochastic optimization for the design of aeropropulsion components

This report presents the results of Phase 1 research to develop a methodology for performing large-scale Multi-disciplinary Stochastic Optimization (MSO) for the design of aerospace systems ranging from aeropropulsion components to complete aircraft configurations. The current research recognizes that such design optimization problems are computationally expensive, and require the use of either massively parallel or multiple-processor computers. The methodology also recognizes that many operational and performance parameters are uncertain, and that uncertainty must be considered explicitly to achieve optimum performance and cost. The objective of this Phase 1 research was to initialize the development of an MSO methodology that is portable to a wide variety of hardware platforms, while achieving efficient, large-scale parallelism when multiple processors are available. The first effort in the project was a literature review of available computer hardware, as well as review of portable, parallel programming environments. The first effort was to implement the MSO methodology for a problem using the portable parallel programming language, Parallel Virtual Machine (PVM). The third and final effort was to demonstrate the example on a variety of computers, including a distributed-memory multiprocessor, a distributed-memory network of workstations, and a single-processor workstation. Results indicate the MSO methodology can be well-applied towards large-scale aerospace design problems. Nearly perfect linear speedup was demonstrated for computation of optimization sensitivity coefficients on both a 128-node distributed-memory multiprocessor (the Intel iPSC/860) and a network of workstations (speedups of almost 19 times achieved for 20 workstations). Very high parallel efficiencies (75 percent for 31 processors and 60 percent for 50 processors) were also achieved for computation of aerodynamic influence coefficients on the Intel. Finally, the multi-level parallelization strategy that will be needed for large-scale MSO problems was demonstrated to be highly efficient. The same parallel code instructions were used on both platforms, demonstrating portability. There are many applications for which MSO can be applied, including NASA's High-Speed-Civil Transport, and advanced propulsion systems. The use of MSO will reduce design and development time and testing costs dramatically.

Sues, Robert H.↗
NASA NTRS1994

Effect of Aeropropulsive Interactions and Design Sensitivities on Optimal Hypersonic Ascent Trajectories

In this paper, trajectory optimization is used as a tool to better understand the performance characteristics of hypersonic Single-Stage-To-Orbit(SSTO) vehicle exhibiting significant aeropropulsive interactions. The energy state approximation is used to determine a straightforward method of determining the scramjet-powered phase of the mission. The energy state method is then used to generate fuel-optimal trajectory results over this portion of the mission for a vehicle configuration of this class. The fuel-optimal unconstrained trajectory is marked by low-altitude acceleration, while a dynamic pressure-constrained trajectory is seen to ride the dynamic pressure constraint for the entire scramjet mission phase. The significance of aeropropulsive interactions in affecting vehicle performance is also investigated.

Lovell, T. Alan↗
NASA NTRSDate not supplied

Performance Analysis of Optimized STARC-ABL Designs Across the Entire Mission Profile

Boundary layer ingestion (BLI) offers the potential for significant fuel burn reduction by exploiting strong aeropropulsive interactions. NASA’s STARC–ABL concept uses an electri- cally powered BLI tail cone thruster on what is otherwise a traditional airframe. Despite the traditional airframe of this configuration, aeropropulsive integration is critical to the perfor- mance of the BLI propulsor. Furthermore, due to being electrically powered, the fan pressure ratio and efficiency of the BLI tail cone thruster vary widely across the flight envelope, and this variation in fan performance must be accounted for with the aeropropulsive integration of the BLI system. Thus, accurate performance prediction for this novel propulsion configu- ration requires the use of a coupled aeropropulsive model across the flight envelope. In this work, we analyze the off-design performance of 18 optimized designs using an aeropropulsive model that is built with the OpenMDAO framework to couple 3-D RANS CFD simulations to 1-D thermodynamic cycle analyses. The designs are created via high-fidelity aeropropulsive design optimizations that span a range of fan pressure ratio and thrust values at the cruise conditions for the STARC-ABL concept, which was chosen as the aerodynamic design point for the propulsor. Performance analyses we present herein are then performed at a range of off-design flight conditions that span the flight envelope, including low-speed and low-altitude flight conditions. This study provides the first set of high-fidelity data for the STARC–ABL configuration at off-design conditions, and the results quantify the power savings through BLI compared to a traditional propulsion system across the entire mission profile.

optimization↗
NASA NTRS2023

Propulsion-Airframe Integration for Conceptual Redesign of a Low-Boom Supersonic Transport

A low-boom supersonic transport was generated in a previous low-boom multidisciplinary optimization (MDO) study that used computational fluid dynamics (CFD) off-body pressure to compute the undertrack sonic boom ground signature and calibrated low-fidelity aerodynamics analyses to compute the mission performance metrics. This low-boom aircraft, referred to as the Mach 1.7 40-PAX concept, can carry 40 passengers for a low-boom overland mission with cruise Mach 1.7 for the airport pairs over the continental US and has the potential to achieve an undertrack sonic boom ground noise level below 70 perceived level of decibels at the start of overland cruise (SOC). The engine for the Mach 1.7 40-PAX concept was designed using the Numerical Propulsion System Simulation (NPSS) for the mission analysis and modeled as a flow-through nacelle for CFD-based sonic boom analysis. To understand how the engine plume affects the undertrack ground signature, the Mach 1.7 40-PAX concept is redesigned in this paper after replacing the flow-through nacelles by CFD engines for sonic boom analysis using aeropropulsive CFD simulation. A process is developed for approximation of the NPSS engine at SOC by a CFD engine for aeropropulsive CFD simulation. The generated CFD engine has the identical nozzle boundary conditions and approximately the same mass flow and thrust as those of the NPSS engine at SOC. Then, the outer mold line of the configuration with the CFD engines is redesigned to approximately restore the low-boom characteristics of the Mach 1.7 40-PAX concept at SOC. Finally, the CFD simulation data for the redesigned concept with the CFD engines is used to calibrate the low-fidelity aerodynamic analyses for mission analysis of this concept. The cyclic dependency of the involved disciplinary analyses is resolved using an iteration method for a consistent coupling of the mission analysis, NPSS engine analysis, and low-boom redesign using the aeropropulsive CFD simulation. This low-boom redesign study is used as an example to demonstrate how the propulsion-airframe integration could be implemented for conceptual design of supersonic transports that satisfy both the low-boom and mission performance requirements.

Low-boom supersonic transport↗
NASA NTRSDate not supplied

Propulsion-Airframe Integration for Conceptual Redesign of a Low-Boom Supersonic Transport

A low-boom supersonic transport was designed for a cruise Mach of 1.7 and 40 passengers. This low-boom aircraft, referred to as the Mach 1.7 40-PAX concept, was generated using computational fluid dynamics (CFD) based sonic boom analysis at the start of overland cruise (SOC). The engine for the Mach 1.7 40-PAX concept was designed using the Numerical Propulsion System Simulation (NPSS) and modeled as a flow-through nacelle for CFD analysis. To understand how the engine plume affects the undertrack ground signature, the Mach 1.7 40-PAX concept is redesigned using an aeropropulsive CFD simulation. A process for approximation of the NPSS engine at SOC by a CFD engine is developed. The generated CFD engine has the identical nozzle boundary conditions and approximately the same mass flow and thrust as those of the NPSS engine at SOC. Then, the configuration with the CFD engines is optimized to approximately restore the low-boom characteristics of the Mach 1.7 40-PAX concept. Finally, the CFD simulation data for the optimized concept with the CFD engines is used to calibrate the low-fidelity aerodynamic analyses for mission analysis of this concept. The cyclic dependency of the involved disciplinary analyses is resolved using an iteration method for a consistent coupling of the mission analysis, NPSS engine analysis, and low-boom redesign using the aeropropulsive CFD simulation. This low-boom redesign study is used as an example to demonstrate how the propulsion-airframe integration could be implemented for conceptual design of low-boom supersonic transports.

Low-boom supersonic transport↗
NASA NTRSDate not supplied

Propulsion-Airframe Integration for Conceptual Redesign of a Low-Boom Supersonic Transport

A low-boom supersonic transport was designed for a cruise Mach of 1.7 and 40 passengers. This low-boom aircraft, referred to as the Mach 1.7 40-PAX concept, was generated using computational fluid dynamics (CFD) based sonic boom analysis at the start of overland cruise (SOC). The engine for the Mach 1.7 40-PAX concept was designed using the Numerical Propulsion System Simulation (NPSS) and modeled as a flow-through nacelle for CFD analysis. To understand how the engine plume affects the undertrack ground signature, the Mach 1.7 40-PAX concept is redesigned using an aeropropulsive CFD simulation. A process is developed for approximation of the NPSS engine at SOC by a CFD engine for aeropropulsive CFD simulation. The generated CFD engine has the identical nozzle boundary conditions and approximately the same mass flow and thrust as those of the NPSS engine at SOC. Then, the configuration with the CFD engines is optimized to approximately restore the low-boom characteristics of the Mach 1.7 40-PAX concept. Finally, the CFD simulation data for the optimized concept with the CFD engines is used to calibrate the low-fidelity aerodynamic analyses for mission analysis of this concept. The cyclic dependency of the involved disciplinary analyses is resolved using an iteration method for a consistent coupling of the mission analysis, NPSS engine analysis, and low-boom redesign using the aeropropulsive CFD simulation. This low-boom redesign study is used as an example to demonstrate how the propulsion-airframe integration could be implemented for conceptual design of low-boom supersonic transports.

Low-boom supersonic transport↗
NASA NTRS2002

Turbopump Performance Improved by Evolutionary Algorithms

The development of design optimization technology for turbomachinery has been initiated using the multiobjective evolutionary algorithm under NASA's Intelligent Synthesis Environment and Revolutionary Aeropropulsion Concepts programs. As an alternative to the traditional gradient-based methods, evolutionary algorithms (EA's) are emergent design-optimization algorithms modeled after the mechanisms found in natural evolution. EA's search from multiple points, instead of moving from a single point. In addition, they require no derivatives or gradients of the objective function, leading to robustness and simplicity in coupling any evaluation codes. Parallel efficiency also becomes very high by using a simple master-slave concept for function evaluations, since such evaluations often consume the most CPU time, such as computational fluid dynamics. Application of EA's to multiobjective design problems is also straightforward because EA's maintain a population of design candidates in parallel. Because of these advantages, EA's are a unique and attractive approach to real-world design optimization problems.

Oyama, Akira↗
NASA NTRSDate not supplied

High-Fidelity Aeropropulsive Optimization of a Mail-Slot Distributed Electric Propulsion System for the SUSAN Electrofan

Hybrid- and all-electric aircraft concepts use electric motors for power rather than a conventional jet engine. Electric propulsors open the door to new ways to synergistically integrate the propulsion system with the airframe. For example, many small electric propulsors can be distributed along the wing to increase the effective bypass ratio for better overall efficiency. Furthermore, these propulsors can be attached to the wing surface for boundary layer ingestion(BLI) to further the efficiency gains. However, these novel methods of aeropropulsive integration also create challenges such as nonuniform inflow and complex nacelle geometries. Here we use gradient-based aerodynamic shape optimization to address the design challenges of the wing-mounted distributed electric propulsion system of the Subsonic Single Aft Engine (SUSAN)concept. In doing so, we aim to more accurately benchmark the flow power of SUSAN’s mail slot propulsors relative to a conventional propulsion system in both an isolated and BLI configuration. Our preliminary results found relative to an optimized podded propulsor the optimized mailslot and BLI mailslot design required 8% and 17% more flow power respectively.The methods and key design insights also apply to other aircraft concepts that utilize distributed electric propulsion and boundary layer ingestion.

CAS↗
NASA NTRS1995

Structural Optimization Methodology for Rotating Disks of Aircraft Engines

In support of the preliminary evaluation of various engine technologies, a methodology has been developed for structurally designing the rotating disks of an aircraft engine. The structural design methodology, along with a previously derived methodology for predicting low-cycle fatigue life, was implemented in a computer program. An interface computer program was also developed that gathers the required data from a flowpath analysis program (WATE) being used at NASA Lewis. The computer program developed for this study requires minimum interaction with the user, thus allowing engineers with varying backgrounds in aeropropulsion to successfully execute it. The stress analysis portion of the methodology and the computer program were verified by employing the finite element analysis method. The 10th- stage, high-pressure-compressor disk of the Energy Efficient Engine Program (E3) engine was used to verify the stress analysis; the differences between the stresses and displacements obtained from the computer program developed for this study and from the finite element analysis were all below 3 percent for the problem solved. The computer program developed for this study was employed to structurally optimize the rotating disks of the E3 high-pressure compressor. The rotating disks designed by the computer program in this study were approximately 26 percent lighter than calculated from the E3 drawings. The methodology is presented herein.

Armand, Sasan C.↗
NASA NTRSDate not supplied

High-Fidelity Aeropropulsive Assessment of Distributed Electric Propulsion and Boundary Layer Ingestion for the SUSAN Electrofan

This paper presents a high-fidelity aeropropulsive assessment of the SUSAN Electrofan’s distributed electric propulsion (DEP) and boundary layer ingestion (BLI) aft fuselage turbofan technologies. This is achieved through the application of computational tools for aerodynamic and aeropropulsive design and analysis based on the Reynolds-averaged Navier-Stokes (RANS) equations. Representative aircraft models are first developed in 3D for the SUSAN Electrofan concept, a non-DEP variant, and a year 2020 technology level reference aircraft based on the Boeing 737-8. These include airframes developed through the application of RANS-based aerodynamic shape optimization, with the objective of drag minimization at cruise while subject to constant lift and zero pitching moment constraints. Wing propulsors are also included and modeled as free-flying ducted fans. These are developed through RANS-based aeropropulsive shape optimization, with the objective of shaft power minimization while subject to constant net thrust and maximum fan face Mach number constraints. An iterative power balance method is then used to trim each of the decoupled aircraft configurations, providing estimates of relative aerodynamic performance, shaft power, and range efficiency. Results also include power on and off analyses, which indicate reduced thrust-induced drag for the SUSAN Electrofan’s DEP and BLI aft fuselage turbofan propulsors when compared to those of the Boeing 737-8-like reference aircraft.

CAS↗
NASA NTRS1995

Surface modeling and grid generation for aeropropulsion CFD

The efforts in geometry modeling and grid generation at the NASA Lewis Research Center, as applied to the computational fluid dynamic (CFD) analysis of aeropropulsion systems, are presented. The efforts are mainly characterized by a focus on the analysis of components of an aeropropulsion system, which involve turbulent viscous flow with heat transfer and chemistry. Thus, this discussion will follow that characterization and will sequence through the components of typical propulsion systems consisting of inlets, compressors, combustors, turbines, and nozzles. For each component, some applications of CFD analysis will be presented to show how CFD is used to compute the desired performance information, how geometry modeling and grid generation are performed, and what issues have developed related to geometry modeling and grid generation. The discussion will illustrate the following needs related to geometry modeling and grid generation as observed in aeropropulsion analysis: (1) accurate and efficient resolution of turbulent viscous and chemically-reacting flowfields; (2) easy-to-use interfaces with CAD data for automated grid generation about complex geometries; and (3) automated batch grid generation software for use with design and optimization software.

Choo, Yung K.↗
NASA NTRS2002

Mystery of Foil Air Bearings for Oil-free Turbomachinery Unlocked: Load Capacity Rule-of-thumb Allows Simple Estimation of Performance

The Oil-Free Turbomachinery team at the NASA Glenn Research Center has unlocked one of the mysteries surrounding foil air bearing performance. Foil air bearings are self-acting hydrodynamic bearings that use ambient air, or any fluid, as their lubricant. In operation, the motion of the shaft's surface drags fluid into the bearing by viscous action, creating a pressurized lubricant film. This lubricating film separates the stationary foil bearing surface from the moving shaft and supports load. Foil bearings have been around for decades and are widely employed in the air cycle machines used for cabin pressurization and cooling aboard commercial jetliners. The Oil-Free Turbomachinery team is fostering the maturation of this technology for integration into advanced Oil-Free aircraft engines. Elimination of the engine oil system can significantly reduce weight and cost and could enable revolutionary new engine designs. Foil bearings, however, have complex elastic support structures (spring packs) that make the prediction of bearing performance, such as load capacity, difficult if not impossible. Researchers at Glenn recently found a link between foil bearing design and load capacity performance. The results have led to a simple rule-of-thumb that relates a bearing's size, speed, and design to its load capacity. Early simple designs (Generation I) had simple elastic (spring) support elements, and performance was limited. More advanced bearings (Generation III) with elastic supports, in which the stiffness is varied locally to optimize gas film pressures, exhibit load capacities that are more than double those of the best previous designs. This is shown graphically in the figure. These more advanced bearings have enabled industry to introduce commercial Oil-Free gas-turbine-based electrical generators and are allowing the aeropropulsion industry to incorporate the technology into aircraft engines. The rule-of-thumb enables engine and bearing designers to easily size and select bearing technology for a new application and determine the level of complexity required in the bearings. This new understanding enables industry to assess the feasibility of new engine designs and provides critical guidance toward the future development of Oil-Free turbomachinery propulsion systems.

DellaCorte, Christopher↗
NASA NTRS2019

How Certain Physical Considerations Impact Aerostructural Wing Optimization

Wing design optimization has been studied extensively and is of continued interest as optimization tools are developed and become more accessible. In each of these studies, certain assumptions and simplifications are made to make the design problem tractable. However, it is difficult to find systematic studies in which several considerations are added or removed one at a time to study how much impact they have. In this work, we examine how certain physical considerations (viscous drag, wave drag, thrust loads, and inertial relief from structural, fuel, and engine masses), impact the aerostructural optimization results for three distinct aircraft wings. The goal is to help develop a rough idea of how important these physical considerations are. We do this using gradient-based optimization and a multidisciplinary design optimization framework, OpenMDAO. We use the open-source tool OpenAeroStruct that couples a vortex lattice method to a finite element method. We establish a baseline aerostructural design optimization problem then perform a series of optimizations, each with one physical consideration removed from the baseline case. We find that depending on the size of the aircraft and flight conditions, the importance of some of these physical considerations varies considerably whereas the importance of others do not. Specifically, the optimal designs change radically without proper viscous and wave drag considerations and smaller aircraft with more distributed propulsion are more affected by the inclusion of engine loads.

Aeropropulsion↗