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Computer program called TRACK was developed by combining a transient fluid flow computer code and the existing modified TOSS heat conduction code to perform the computation.
The SHABERTH program is capable of simulating the thermomechanical performance of a load support system consisting of a flexible shaft supported by up to five rolling element bearings. Any combination of ball, cylindrical, and tapered roller bearings can be used to support the shaft. The user can select models in calculating lubricant film thickness and traction forces. The formulation of the cage pocket/rolling element interaction model was revised to improve solution numerical convergence characteristics.
The material presented is structured to guide the user in the practical and correct implementation of PLANETSYS which is capable of simulating the thermomechanical performance of a multistage planetary power transmission. In this version of PLANETSYS, the user can select either SKF or NASA models in calculating lubricant film thickness and traction forces.
A three-dimensional (3-D) numerical model has been developed to study the fluid flow and heat transfer through a manifold-microchannel (MMC) heat sink, a microfluidic cooling system designed as a heat dissipation solution for compact, high-powered electronic systems. An MMC consists of a 3-D manifold structure that distributes working fluid through alternating inlet and outlet manifold channels that guide the fluid to and from the microchannels, shortening the flow length and thereby, reducing the pressure drop across the system. Wide bandgap semiconductors such as silicon carbide (SiC) are increasingly utilized due to their ability to enable smaller electronic devices and components to operate more efficiently at higher frequencies. These semiconductors can greatly benefit from the MMC, which can extract all the heat produced by compact, high-powered electronics, enabling them to achieve optimal performance. The MMC also utilizes an embedded cooling approach which allows for fabrication directly within SiC-based electronics, resulting in significant mass and weight savings and lower thermal resistance than conventional heat sink designs. This paper outlines the methods used to conduct fluid and thermal analysis of different MMC configurations for flow parameters such as flow rate and inlet flow conditions. This study involves both steady state and transient thermal analysis as a gradually increasing heat flux is applied to the system over time, which is representative of the heat dissipation from the electronics over a given period. Results from the analysis show that the MMC is capable of effectively dissipating heat flux of ~100 W/cm2 while maintaining considerably low pressure drop (< 1 kPa) and thermal resistance (< 1 K/W) for certain single-phase working fluids.
A three-dimensional (3-D) numerical model has been developed to study the fluid flow and heat transfer through a manifold-microchannel (MMC) heat sink, a microfluidic cooling system designed as a heat dissipation solution for compact, high-powered electronic systems. An MMC consists of a 3-D manifold structure that distributes working fluid through alternating inlet and outlet manifold channels that guide the fluid to and from the microchannels, shortening the flow length and thereby, reducing the pressure drop across the system. Wide bandgap semiconductors such as silicon carbide (SiC) are increasingly utilized due to their ability to enable smaller electronic devices and components to operate more efficiently at higher frequencies. These semiconductors can greatly benefit from the MMC, which can extract all the heat produced by compact, high-powered electronics, enabling them to achieve optimal performance. The MMC also utilizes an embedded cooling approach which allows for fabrication directly within SiC-based electronics, resulting in significant mass and weight savings and lower thermal resistance than conventional heat sink designs. This paper outlines the methods used to conduct fluid and thermal analysis of different MMC configurations for flow parameters such as flow rate and inlet flow conditions. This study involves both steady state and transient thermal analysis as a gradually increasing heat flux is applied to the system over time, which is representative of the heat dissipation from the electronics over a given period. Results from the analysis show that the MMC is capable of effectively dissipating heat flux of ~100 W/cm2 while maintaining considerably low pressure drop (< 1 kPa) and thermal resistance (< 1 K/W) for certain single-phase working fluids.
This report discusses the design, development, fabrication and testing of IR transparent solar array modules. Three modules, consisting of a baseline design using back surface reflector cells, and two modules using gridded back contact, IR transparent cells, were subjected to vacuum thermal balance testing to verify analytical predictions of lower operating emperature and increased efficiency. As a result of this test program, LMSC has verified that a significant degree of IR transparency can be designed into a flexible solar array. Test data correlates with both steady state and transient thermal analysis.
Planetsys and Spherbean, two computer programs developed for the analysis of rolling element bearings, were used to simulate the thermal performance of an OH-58 helicopter main rotor transmission. A steady state and a transient thermal analysis were made and temperatures thus calculated were compared with experimental data obtained from a transmission that was operated to destruction, which occurred about 30 min after all the oil was drained from the transmission. Temperatures predicted by Spherbean were within 3% of the corresponding measured values at 15 min elapsed time and within 9% at 25 min. Spherbean also indicates a potential for high bearing cage temperatures with misalignment and outer ring rotation.
Finite element methodology for steady state thermal analysis of convectively cooled structures has been extended for transient analysis. The finite elements are based on representing the fluid passages by fluid bulk-temperature nodes and fluid-solid interface nodes. The formulation of the finite element equations for a typical flow passage is based on the weighted residual method with upwind weighting functions. Computer implementation of the convective finite element methodology using explicit and implicit time integration algorithms is described. Accuracy and efficiency of the methodology is evaluated by comparisons with analytical solutions and finite-difference lumped-parameter analyses. The comparative analyses demonstrate that finite element conduction/conduction methodology may be used to predict transient temperatures with an accuracy equal or superior to the lumped-parameter finite-difference method.
Cryogenic Fluid Management (CFM) is a critical capability for a hydrogen NTP vehicle for a crewed mission to Mars. AMA has investigated the concept of operations for zero boiloff CFM systems and provided feasibility assessment for a zero-boiloff CFM system based on gravity-independent technologies. This includes identification of CFM-critical mission stages, modelling of CFM operational modes in steady state and transient conditions, thermal analysis of the NTP vehicle and CFM systems, hydrogen leakage analysis, and system margins and fault tolerance. This work illustrates the feasibility of a zero boiloff mission with a set of technology performance assumptions.
The efficient simulation of multidisciplinary thermo-opto-mechanical effects in precision deployable systems has for years been limited by numerical toolsets that do not necessarily share the same finite element basis, level of mesh discretization, data formats, or compute platforms. Cielo, a general purpose integrated modeling tool funded by the Jet Propulsion Laboratory and the Exoplanet Exploration Program, addresses shortcomings in the current state of the art via features that enable the use of a single, common model for thermal, structural and optical aberration analysis, producing results of greater accuracy, without the need for results interpolation or mapping. This paper will highlight some of these advances, and will demonstrate them within the context of detailed external occulter analyses, focusing on in-plane deformations of the petal edges for both steady-state and transient conditions, with subsequent optical performance metrics including intensity distributions at the pupil and image plane.
User instructions are given for performing linear and nonlinear steady state and transient thermal analyses with SPAR thermal analysis processors TGEO, SSTA, and TRTA. It is assumed that the user is familiar with basic SPAR operations and basic heat transfer theory.
Small radius leading edges and nosetips were used to minimize wave drag in early hypervelocity vehicle concepts until further analysis demonstrated that extreme aerothermodynamic heating blunted the available thermal protection system materials. Recent studies indicate that ultra-high temperature composite (UHTC) materials are shape stable at temperatures approaching 3033 K and will be available for use as sharp leading edge components in the near future. Steady-state aerothermal performance constraints for UHTC components are presented in this paper to identify their non-ablating operational capability at altitudes from sea level to 90 km. An integrated design tool was developed to estimate these constraints. The tool couples aerothermodynamic heating with material response using commercial finite element analysis software and is capable of both steady-state and transient analysis. Performance during entry is analyzed by transient thermal analysis along the trajectory. The thermal load condition from the transient thermal analysis is used to estimate thermal stress. Applying the tool to UHTC materials shows that steady-state, non-ablating operation of a HfB2/SiC(A-7) (A-7) component is possible at velocities approaching Earth's circular orbital velocity of 7.9 km/s at altitudes approaching 70 km.
The computer program SASHBEAN (Sikorsky Aircraft Spherical Roller High Speed Bearing Analysis) analyzes and predicts the operating characteristics of a Single Row, Angular Contact, Spherical Roller Bearing (SRACSRB). The program runs on an IBM or IBM compatible personal computer, and for a given set of input data analyzes the bearing design for it's ring deflections (axial and radial), roller deflections, contact areas and stresses, induced axial thrust, rolling element and cage rotation speeds, lubrication parameters, fatigue lives, and amount of heat generated in the bearing. The dynamic loading of rollers due to centrifugal forces and gyroscopic moments, which becomes quite significant at high speeds, is fully considered in this analysis. For a known application and it's parameters, the program is also capable of performing steady-state and time-transient thermal analyses of the bearing system. The steady-state analysis capability allows the user to estimate the expected steady-state temperature map in and around the bearing under normal operating conditions. On the other hand, the transient analysis feature provides the user a means to simulate the 'lost lubricant' condition and predict a time-temperature history of various critical points in the system. The bearing's 'time-to-failure' estimate may also be made from this (transient) analysis by considering the bearing as failed when a certain temperature limit is reached in the bearing components. The program is fully interactive and allows the user to get started and access most of its features with a minimal of training. For the most part, the program is menu driven, and adequate help messages were provided to guide a new user through various menu options and data input screens. All input data, both for mechanical and thermal analyses, are read through graphical input screens, thereby eliminating any need of a separate text editor/word processor to edit/create data files. Provision is also available to select and view the contents of output files on the monitor screen if no paper printouts are required. A separate volume (Volume-2) of this documentation describes, in detail, the underlying mathematical formulations, assumptions, and solution algorithms of this program.
Very flexible computer-assisted numerical analysis is used to solve dynamic fluid-flow equations characterizing computer-controlled heat dissipation system developed for Space lab. Losses caused by bends, ties, fittings, valves, and like are easily included, and analysis can solve both steady-state and transient cases. It can also interact with parallel thermal analysis.
A finite element computer program (TAP 2) for steady-state and transient thermal analyses of convectively cooled structures is presented. The program has a finite element library of six elements: two conduction/convection elements to model heat transfer in a solid, two convection elements to model heat transfer in a fluid, and two integrated conduction/convection elements to represent combined heat transfer in tubular and plate/fin fluid passages. Nonlinear thermal analysis due to temperature-dependent thermal parameters is performed using the Newton-Raphson iteration method. Transient analyses are performed using an implicit Crank-Nicolson time integration scheme with consistent or lumped capacitance matrices as an option. Program output includes nodal temperatures and element heat fluxes. Pressure drops in fluid passages may be computed as an option. User instructions and sample problems are presented in appendixes.
A method has been developed which integrates a fluid flow analyzer and a thermal analyzer to produce both steady state and transient results of 1-D, 2-D, and 3-D analysis models. The Generalized Fluid System Simulation Program (GFSSP) is a one dimensional, general purpose fluid analysis code which computes pressures and flow distributions in complex fluid networks. The MSC Systems Improved Numerical Differencing Analyzer (MSC.SINDA) is a one dimensional general purpose thermal analyzer that solves network representations of thermal systems. Both GFSSP and MSC.SINDA have graphical user interfaces which are used to build the respective model and prepare it for analysis. The SINDA/GFSSP Conjugate Integrator (SGCI) is a formbase graphical integration program used to set input parameters for the conjugate analyses and run the models. The contents of this paper describes SGCI and its thermo-fluids conjugate analysis techniques and capabilities by presenting results from some example models including the cryogenic chill down of a copper pipe, a bar between two walls in a fluid stream, and a solid plate creating a phase change in a flowing fluid.
Ceramic parts and coatings are needed to withstand high temperatures in advanced aircraft engines. In hot environments, such as in the combustion chambers of these engines, infrared and visible radiation can penetrate into some ceramics and heat them internally. The internal temperatures depend on radiative effects combined with heat conduction, and on convection and radiation at the material boundaries. Since engine temperatures are high, radiant emission can be large from within translucent parts and coatings, and this must be included in the analysis. Transient and steady-state behavior are both important. During a transient, radiant penetration provides more rapid internal heating than conduction alone, and the temperature distributions are usually considerably different than for steady-state conditions; this can produce transient thermal stresses. Analytical and numerical methods are being used at the NASA Lewis Research Center to predict transient temperatures and heat flows in translucent materials. A transient analysis was done for a composite of two translucent layers. The layer refractive indices were larger than 1, producing internal reflections at the boundaries and at the internal interface. In addition, steady-state results were computed for a two-layer composite with one layer opaque. The results were used to assess the importance of internal radiation in a zirconia thermal barrier coating on a cooled metal wall. Since the radiative transfer equations are rather complex, especially when internal scattering is included, approximate methods are being investigated that might be convenient for computer design programs. An approximate two-flux method was used and verified by comparisons with solutions that used exact radiative transfer relations. The two-flux equations include scattering without increasing solution difficulty.
Integrated modeling of spacecraft systems is a rapidly evolving area in which multidisciplinary models are developed to design and analyze spacecraft configurations. These models are especially important in the early design stages where rapid trades between subsystems can substantially impact design decisions. Integrated modeling is one of the cornerstones of two of NASA's planned missions in the Origins Program -- the Next Generation Space Telescope (NGST) and the Space Interferometry Mission (SIM). Common modeling tools for control design and opto-mechanical analysis have recently emerged and are becoming increasingly widely used. A discipline that has been somewhat less integrated, but is nevertheless of critical concern for high precision optical instruments, is thermal analysis and design. A major factor contributing to this mild estrangement is that the modeling philosophies and objectives for structural and thermal systems typically do not coincide. Consequently the tools that are used in these discplines suffer a degree of incompatibility, each having developed along their own evolutionary path. Although standard thermal tools have worked relatively well in the past. integration with other disciplines requires revisiting modeling assumptions and solution methods. Over the past several years we have been developing a MATLAB based integrated modeling tool called IMOS (Integrated Modeling of Optical Systems) which integrates many aspects of structural, optical, control and dynamical analysis disciplines. Recent efforts have included developing a thermal modeling and analysis capability, which is the subject of this article. Currently, the IMOS thermal suite contains steady state and transient heat equation solvers, and the ability to set up the linear conduction network from an IMOS finite element model. The IMOS code generates linear conduction elements associated with plates and beams/rods of the thermal network directly from the finite element structural model. Conductances for temperature varying materials are accommodated. This capability both streamlines the process of developing the thermal model from the finite element model, and also makes the structural and thermal models compatible in the sense that each structural node is associated with a thermal node. This is particularly useful when the purpose of the analysis is to predict structural deformations due to thermal loads. The steady state solver uses a restricted step size Newton method, and the transient solver is an adaptive step size implicit method applicable to general differential algebraic systems. Temperature dependent conductances and capacitances are accommodated by the solvers. In addition to discussing the modeling and solution methods. applications where the thermal modeling is "in the loop" with sensitivity analysis, optimization and optical performance drawn from our experiences with the Space Interferometry Mission (SIM), and the Next Generation Space Telescope (NGST) are presented.