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CFD Applications in Support of the Space Shuttle Risk Assessment

The paper describes a numerical study of a potential accident scenario of the space shuttle, operating at the same flight conditions as flight 51L, the Challenger accident. The interest in performing this simulation is derived by evidence that indicates that the event itself did not exert large enough blast loading on the shuttle to break it apart. Rather, the quasi-steady aerodynamic loading on the damaged, unbalance vehicle caused the break-up. Despite the enormous explosive potential of the shuttle total fuel load (both liquid and solid), the post accident explosives working group estimated the maximum energy involvement to be equivalent to about five hundreds of pounds of TNT. This understanding motivated the simulation described here. To err on the conservative side, we modeled the event as an explosion, and used the maximum energy estimate. We modeled the transient detonation of a 500 lbs spherical charge of TNT, placed at the main engine, and the resulting blast wave propagation about the complete stack. Tracking of peak pressures and impulses at hundreds of locations on the vehicle surface indicate that the blast load was insufficient to break the vehicle, hence demonstrating likely crew survivability through such an event.

Baum, Joseph D.

Effects of Wing Leading Edge Penetration with Venting and Exhaust Flow from Wheel Well at Mach 24 in Flight

A baseline solution for CFD Point 1 (Mach 24) in the STS-107 accident investigation was modified to include effects of: (1) holes through the leading edge into a vented cavity; and (2) a scarfed, conical nozzle directed toward the centerline of the vehicle from the forward, inboard corner of the landing gear door. The simulations were generated relatively quickly and early in the investigation because simplifications were made to the leading edge cavity geometry and an existing utility to merge scarfed nozzle grid domains with structured baseline external domains was implemented. These simplifications in the breach simulations enabled: (1) a very quick grid generation procedure; and (2) high fidelity corroboration of jet physics with internal surface impingements ensuing from a breach through the leading edge, fully coupled to the external shock layer flow at flight conditions. These simulations provided early evidence that the flow through a two-inch diameter (or larger) breach enters the cavity with significant retention of external flow directionality. A normal jet directed into the cavity was not an appropriate model for these conditions at CFD Point 1 (Mach 24). The breach diameters were of the same order or larger than the local, external boundary-layer thickness. High impingement heating and pressures on the downstream lip of the breach were computed. It is likely that hole shape would evolve as a slot cut in the direction of the external streamlines. In the case of the six-inch diameter breach the boundary layer is fully ingested. The intent of externally directed jet simulations in the second scenario was to approximately model aerodynamic effects of a relatively large internal wing pressure, fueled by combusting aluminum, which deforms the corner of the landing gear door and directs a jet across the windside surface. These jet interactions, in and of themselves, were not sufficiently large to explain observed aerodynamic behavior.

Gnoffo, Peter A.