Measuring Side Loads On Bolts
Side loads on clevis bolt measured quickly and easily. Such loads introduced during assembly of bolt and affect operation. Now, unwanted loads determined quantitatively and corrected.
Kilgrove, T. O.↗
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Transient Three-Dimensional Startup Side Load Analysis of a Regeneratively Cooled Nozzle
The objective of this effort is to develop a computational methodology to capture the startup side load physics and to anchor the computed aerodynamic side loads with the available data from a regeneratively cooled, high-aspect-ratio nozzle, hot-fired at sea level. The computational methodology is based on an unstructured-grid, pressure-based, reacting flow computational fluid dynamics and heat transfer formulation, a transient 5 s inlet history based on an engine system simulation, and a wall temperature distribution to reflect the effect of regenerative cooling. To understand the effect of regenerative wall cooling, two transient computations were performed using the boundary conditions of adiabatic and cooled walls, respectively. The results show that three types of shock evolution are responsible for side loads: generation of combustion wave; transitions among free-shock separation, restricted-shock separation, and simultaneous free-shock and restricted shock separations; along with the pulsation of shocks across the lip, although the combustion wave is commonly eliminated with the sparklers during actual test. The test measured two side load events: a secondary and lower side load, followed by a primary and peak side load. Results from both wall boundary conditions captured the free-shock separation to restricted-shock separation transition with computed side loads matching the measured secondary side load. For the primary side load, the cooled wall transient produced restricted-shock pulsation across the nozzle lip with peak side load matching that of the test, while the adiabatic wall transient captured shock transitions and free-shock pulsation across the lip with computed peak side load 50% lower than that of the measurement. The computed dominant pulsation frequency of the cooled wall nozzle agrees with that of a separate test, while that of the adiabatic wall nozzle is more than 50% lower than that of the measurement. The computed teepee-like formation and the tangential motion of the shocks during lip pulsation also qualitatively agree with those of test observations. Moreover, a third transient computation was performed with a proportionately shortened 1 s sequence, and lower side loads were obtained with the higher ramp rate.
Wang, Ten-See↗
Transient Three-Dimensional Analysis of Nozzle Side Load in Regeneratively Cooled Engines
Nozzle side loads are potentially detrimental to the integrity and life of almost all launch vehicles. the lack of a detailed prediction capability results in reducing life and increased weight for reusable nozzle systems. A clear understanding of the mechanism that contribute to side loads during engine startup, shutdown, and steady-state operations must be established. A CFD based predictive tool must be developed to aid the understanding of side load physics and development of future reusable engine.
ng, Ten-See↗
Transient Three-Dimensional Side Load Analysis of a Film Cooled Nozzle
Transient three-dimensional numerical investigations on the side load physics for an engine encompassing a film cooled nozzle extension and a regeneratively cooled thrust chamber, were performed. The objectives of this study are to identify the three-dimensional side load physics and to compute the associated aerodynamic side load using an anchored computational methodology. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Ultimately, the computational results will be provided to the nozzle designers for estimating of effect of the peak side load on the nozzle structure. Computations simulating engine startup at ambient pressures corresponding to sea level and three high altitudes were performed. In addition, computations for both engine startup and shutdown transients were also performed for a stub nozzle, operating at sea level. For engine with the full nozzle extension, computational result shows starting up at sea level, the peak side load occurs when the lambda shock steps into the turbine exhaust flow, while the side load caused by the transition from free-shock separation to restricted-shock separation comes at second; and the side loads decreasing rapidly and progressively as the ambient pressure decreases. For the stub nozzle operating at sea level, the computed side loads during both startup and shutdown becomes very small due to the much reduced flow area.
Wang, Ten-See↗
Transient Three-Dimensional Analysis of Side Load in Liquid Rocket Engine Nozzles
Three-dimensional numerical investigations on the nozzle start-up side load physics were performed. The objective of this study is to identify the three-dimensional side load physics and to compute the associated aerodynamic side load using an anchored computational methodology. The computational methodology is based on an unstructured-grid, and pressure-based computational fluid dynamics formulation, and a simulated inlet condition based on a system calculation. Finite-rate chemistry was used throughout the study so that combustion effect is always included, and the effect of wall cooling on side load physics is studied. The side load physics captured include the afterburning wave, transition from free- shock to restricted-shock separation, and lip Lambda shock oscillation. With the adiabatic nozzle, free-shock separation reappears after the transition from free-shock separation to restricted-shock separation, and the subsequent flow pattern of the simultaneous free-shock and restricted-shock separations creates a very asymmetric Mach disk flow. With the cooled nozzle, the more symmetric restricted-shock separation persisted throughout the start-up transient after the transition, leading to an overall lower side load than that of the adiabatic nozzle. The tepee structures corresponding to the maximum side load were addressed.
Wang, Ten-See↗
Transient Three-Dimensional Analysis of Nozzle Side Load in Regeneratively Cooled Engines
Three-dimensional numerical investigations on the start-up side load physics for a regeneratively cooled, high-aspect-ratio nozzle were performed. The objectives of this study are to identify the three-dimensional side load physics and to compute the associated aerodynamic side load using an anchored computational methodology. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet condition based on an engine system simulation. Computations were performed for both the adiabatic and cooled walls in order to understand the effect of boundary conditions. Finite-rate chemistry was used throughout the study so that combustion effect is always included. The results show that three types of shock evolution are responsible for side loads: generation of combustion wave; transitions among free-shock separation, restricted-shock separation, and simultaneous free-shock and restricted shock separations; along with oscillation of shocks across the lip. Wall boundary conditions drastically affect the computed side load physics: the adiabatic nozzle prefers free-shock separation while the cooled nozzle favors restricted-shock separation, resulting in higher peak side load for the cooled nozzle than that of the adiabatic nozzle. By comparing the computed physics with those of test observations, it is concluded that cooled wall is a more realistic boundary condition, and the oscillation of the restricted-shock separation flow pattern across the lip along with its associated tangential shock motion are the dominant side load physics for a regeneratively cooled, high aspect-ratio rocket engine.
Wang, Ten-See↗
Nozzle Side Load Testing and Analysis at Marshall Space Flight Center
Realistic estimates of nozzle side loads, the off-axis forces that develop during engine start and shutdown, are important in the design cycle of a rocket engine. The estimated magnitude of the nozzle side loads has a large impact on the design of the nozzle shell and the engine s thrust vector control system. In 2004 Marshall Space Flight Center (MSFC) began developing a capability to quantify the relative magnitude of side loads caused by different types of nozzle contours. The MSFC Nozzle Test Facility was modified to measure nozzle side loads during simulated nozzle start. Side load results from cold flow tests on two nozzle test articles, one with a truncated ideal contour and one with a parabolic contour are provided. The experimental approach, nozzle contour designs and wall static pressures are also discussed
Ruf, Joseph H.↗
Transient Two-Dimensional Analysis of Side Load in Liquid Rocket Engine Nozzles
Two-dimensional planar and axisymmetric numerical investigations on the nozzle start-up side load physics were performed. The objective of this study is to develop a computational methodology to identify nozzle side load physics using simplified two-dimensional geometries, in order to come up with a computational strategy to eventually predict the three-dimensional side loads. The computational methodology is based on a multidimensional, finite-volume, viscous, chemically reacting, unstructured-grid, and pressure-based computational fluid dynamics formulation, and a transient inlet condition based on an engine system modeling. The side load physics captured in the low aspect-ratio, two-dimensional planar nozzle include the Coanda effect, afterburning wave, and the associated lip free-shock oscillation. Results of parametric studies indicate that equivalence ratio, combustion and ramp rate affect the side load physics. The side load physics inferred in the high aspect-ratio, axisymmetric nozzle study include the afterburning wave; transition from free-shock to restricted-shock separation, reverting back to free-shock separation, and transforming to restricted-shock separation again; and lip restricted-shock oscillation. The Mach disk loci and wall pressure history studies reconfirm that combustion and the associated thermodynamic properties affect the formation and duration of the asymmetric flow.
Wang, Ten-See↗
Details of Side Load Test Data and Analysis for a Truncated Ideal Contour Nozzle and a Parabolic Contour Nozzle
Two cold flow subscale nozzles were tested for side load characteristics during simulated nozzle start transients. The two test article contours were a truncated ideal and a parabolic. The current paper is an extension of a 2009 AIAA JPC paper on the test results for the same two nozzle test articles. The side load moments were measured with the strain tube approach in MSFC s Nozzle Test Facility. The processing techniques implemented to convert the strain gage signals into side load moment data are explained. Nozzle wall pressure profiles for separated nozzle flow at many NPRs are presented and discussed in detail. The effect of the test cell diffuser inlet on the parabolic nozzle s wall pressure profiles for separated flow is shown. The maximum measured side load moments for the two contours are compared. The truncated ideal contour s peak side load moment was 45% of that of the parabolic contour. The calculated side load moments, via mean-plus-three-standard-deviations at each nozzle pressure ratio, reproduced the characteristics and absolute values of measured maximums for both contours. The effect of facility vibration on the measured side load moments is quantified and the effect on uncertainty is calculated. The nozzle contour designs are discussed and the impact of a minor fabrication flaw in the nozzle contours is explained.
Ruf, Joseph H.↗
Calculating Nozzle Side Loads using Acceleration Measurements of Test-Based Models
As part of a NASA/MSFC research program to evaluate the effect of different nozzle contours on the well-known but poorly characterized "side load" phenomena, we attempt to back out the net force on a sub-scale nozzle during cold-flow testing using acceleration measurements. Because modeling the test facility dynamics is problematic, new techniques for creating a "pseudo-model" of the facility and nozzle directly from modal test results are applied. Extensive verification procedures were undertaken, resulting in a loading scale factor necessary for agreement between test and model based frequency response functions. Side loads are then obtained by applying a wide-band random load onto the system model, obtaining nozzle response PSD's, and iterating both the amplitude and frequency of the input until a good comparison of the response with the measured response PSD for a specific time point is obtained. The final calculated loading can be used to compare different nozzle profiles for assessment during rocket engine nozzle development and as a basis for accurate design of the nozzle and engine structure to withstand these loads. The techniques applied within this procedure have extensive applicability to timely and accurate characterization of all test fixtures used for modal test.A viewgraph presentation on a model-test based pseudo-model used to calculate side loads on rocket engine nozzles is included. The topics include: 1) Side Loads in Rocket Nozzles; 2) Present Side Loads Research at NASA/MSFC; 3) Structural Dynamic Model Generation; 4) Pseudo-Model Generation; 5) Implementation; 6) Calibration of Pseudo-Model Response; 7) Pseudo-Model Response Verification; 8) Inverse Force Determination; 9) Results; and 10) Recent Work.
Brown, Andrew M.↗
Transient Side Load Analysis of Out-of-Round Film-Cooled Nozzle Extensions
There was interest in understanding the impact of out-of-round nozzle extension on the nozzle side load during transient startup operations. The out-of-round nozzle extension could be the result of asymmetric internal stresses, deformation induced by previous tests, and asymmetric loads induced by hardware attached to the nozzle. The objective of this study was therefore to computationally investigate the effect of out-of-round nozzle extension on the nozzle side loads during an engine startup transient. The rocket engine studied encompasses a regeneratively cooled chamber and nozzle, along with a film cooled nozzle extension. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and transient inlet boundary flow properties derived from an engine system simulation. Six three-dimensional cases were performed with the out-of-roundness achieved by three different degrees of ovalization, elongated on lateral y and z axes: one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The results show that the separation line jump was the primary source of the peak side loads. Comparing to the peak side load of the perfectly round nozzle, the peak side loads increased for the slightly and more ovalized nozzle extensions, and either increased or decreased for the two significantly ovalized nozzle extensions. A theory based on the counteraction of the flow destabilizing effect of an exacerbated asymmetrical flow caused by a lower degree of ovalization, and the flow stabilizing effect of a more symmetrical flow, created also by ovalization, is presented to explain the observations obtained in this effort.
Wang, Ten-See↗
Sea level side loads in high-area-ratio rocket engines
An empirical separation and side load model to obtain applied aerodynamic loads has been developed based on data obtained from full-scale J-2S (265K-pound-thrust engine with an area ratio of 40:1) engine and model testing. Experimental data include visual observations of the separation patterns that show the dynamic nature of the separation phenomenon. Comparisons between measured and applied side loads are made. Correlations relating the separation location to the applied side loads and the methods used to determine the separation location are given.
Nave, L. H.↗
Flow processes in overexpanded chemical rocket nozzles. Part 2: Side loads due to asymmetric separation
Methods for measuring the lateral forces, occurring as a result of asymmetric nozzle flow separation, are discussed. The effect of some parameters on the side load is explained. A new method was developed for calculation of the side load. The values calculated are compared with side load data of the J-2 engine. Results are used for predicting side loads of the space shuttle main engine.
Schmucker, R. H.↗
Transient Three-Dimensional Side Load Analysis of Out-of-Round Film Cooled Nozzles
The objective of this study is to investigate the effect of nozzle out-of-roundness on the transient startup side loads at a high altitude, with an anchored computational methodology. The out-of-roundness could be the result of asymmetric loads induced by hardware attached to the nozzle, asymmetric internal stresses induced by previous tests, and deformation, such as creep, from previous tests. The rocket engine studied encompasses a regeneratively cooled thrust chamber and a film cooled nozzle extension with film coolant distributed from a turbine exhaust manifold. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Transient startup computations were performed with the out-of-roundness achieved by four different degrees of ovalization: one perfectly round, one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The results show that the separation-line-jump is the peak side load physics for the round, slightly our-of-round, and more out-of-round cases, and the peak side load increases as the degree of out-of-roundness increases. For the significantly out-of-round nozzle, however, the peak side load reduces to comparable to that of the round nozzle and the separation line jump is not the peak side load physics. The counter-intuitive result of the significantly out-of-round case is found to be related to a side force reduction mechanism that splits the effect of the separation-line-jump into two parts, not only in the circumferential direction and most importantly in time.
Wang, Ten-See↗
Flow Separation Side Loads Excitation of Rocket Nozzle FEM
Modern rocket nozzles are designed to operate over a wide range of altitudes, and are also built with large aspect ratios to enable high efficiencies. Nozzles designed to operate over specific regions of a trajectory are being replaced in modern launch vehicles by those that are designed to operate from earth to orbit. This is happening in parallel with modern manufacturing and wall cooling techniques allowing for larger aspect ratio nozzles to be produced. Such nozzles, though operating over a large range of altitudes and ambient pressures, are typically designed for one specific altitude. Above that altitude the nozzle flow is 'underexpanded' and below that altitude, the nozzle flow is 'overexpanded'. In both conditions the nozzle produces less than the maximum possible thrust at that altitude. Usually the nozzle design altitude is well above sea level, leaving the nozzle flow in an overexpanded state for its start up as well as for its ground testing where, if it is a reusable nozzle such as the Space Shuttle Main Engine (SSME), the nozzle will operate for the majority of its life. Overexpansion in a rocket nozzle presents the critical, and sometimes design driving, problem of flow separation induced side loads. To increase their understanding of nozzle side loads, engineers at MSFC began an investigation in 2000 into the phenomenon through a task entitled "Characterization and Accurate Modeling of Rocket Engine Nozzle Side Loads", led by A. Brown. The stated objective of this study was to develop a methodology to accurately predict the character and magnitude of nozzle side loads. The study included further hot-fire testing of the MC-l engine, cold flow testing of subscale nozzles, CFD analyses of both hot-fire and cold flow nozzle testing, and finite element (fe.) analysis of the MC-1 engine and cold flow tested nozzles. A follow on task included an effort to formulate a simplified methodology for modeling a side load during a two nodal diameter fluid/structure interaction for a single moment in time.
Smalley, Kurt B.↗
Flow processes in overexpanded chemical rocket nozzles. Part 3: Methods for the aimed flow separation and side load reduction
Methods aimed at reduction of overexpansion and side load resulting from asymmetric flow separation for rocket nozzles with a high opening ratio are described. The methods employ additional measures for nozzles with a fixed opening ratio. The flow separation can be controlled by several types of nozzle inserts, the properties of which are discussed. Side loads and overexpansion can be reduced by adapting the shape of the nozzle and taking other additional measures for controlled separation of the boundary layer, such as trip wires.
Schmucker, R. H.↗
Transient Three-Dimensional Side Load Analysis of Out-of-Round Film Cooled Nozzles
The objective of this study is to investigate the effect of nozzle out-of-roundness on the transient startup side loads. The out-of-roundness could be the result of asymmetric loads induced by hardware attached to the nozzle, asymmetric internal stresses induced by previous tests and/or deformation, such as creep, from previous tests. The rocket engine studied encompasses a regeneratively cooled thrust chamber and a film cooled nozzle extension with film coolant distributed from a turbine exhaust manifold. The computational methodology is based on an unstructured-grid, pressure-based computational fluid dynamics formulation, and a transient inlet history based on an engine system simulation. Transient startup computations were performed with the out-of-roundness achieved by four degrees of ovalization of the nozzle: one perfectly round, one slightly out-of-round, one more out-of-round, and one significantly out-of-round. The computed side load physics caused by the nozzle out-of-roundness and its effect on nozzle side load are reported and discussed.
Wang, Ten-See↗
Characterization of Side Load Phenomena Using Measurement of Fluid/Structure Interaction
During ground-tests of most production rocket engines over the last 30 years, large asymmetric transient side loads coming from the nozzle and related steady-state vibrational loads within the nozzle have been measured. The widely varying magnitude of these loads has been large enough to fail interfacing components as well as nozzles in these engines. This paper will discuss a comprehensive test and analysis program that has been undertaken to develop a methodology to accurately predict the character and magnitude of this loading. The project to-date has incorporated analytical modeling of both the fluid flow and the nozzle structure and testing of both full-scale and sub-scale rocket nodes. Examination of the test data indicates that one of the two-nodal diameter structural modes may be interacting with flow separation from the nozzle inside-wall in a self-excited or aeroelastic vibration phenomenon. If verified, this observation will be used to develop a methodology for design and analysis. A fuller understanding of the characteristics of this vibration will provide an increase in the accuracy and confidence of side load predictions, which will be critical for the successful construction of the next generation of low-cost, reliable rocket engines.
Brown, Andrew M.↗