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During the past year, various computational fluid dynamic (CFD) analyses were performed at Marshall Space Flight Center to support the Reusable Solid Rocket Motor program. The successful completion of these analyses involved application of the CFD codes FDNS and CELMINT. The topics addressed by the analyses were: (1) the design and prediction of slag pool accumulation within the five inch test motor, (2) prediction of slag pool behavior and its response to lateral accelerations, (3) the clogging of potential insulation debonds within the nozzle by slag accumulation, (4) the behavior of jets within small voids inside nozzle joint gaps, (5) The effect of increased inhibitor stiffness on motor acoustics, and (6) the effect of a nozzle defect on particle impingement enhanced erosion. The emphasis of this presentation will be to further discuss the work in topics 3, 4, and 5.

It is known that the flow field of the redesigned solid rocket motor (RSRM) is very complicated due to the complex characteristics of turbulent multi-phase flow, chemical reaction, particle combustion, evaporation, breakup and agglomeration etc. It requires multi-phase calculations, chemical reaction simulation, and particle combustion, evaporation, and breakup models to obtain a better understanding of thermophysics for the RSRM design using numerical methods. Also, the slag buildup due to the molten particles is another factor affecting the performance of the RSRM. To achieve this goal, the volume of fluid (VOF) method is used to capture the free surface motion so as to simulate the accumulation of the molten particles (slag) of the RSRM. A finite rate chemistry model is used to simulate the chemical reaction effects. For multi-phase calculations, the Hermsen combustion model is used for the aluminum particle combustion analysis and the Taylor Analogy Breakup (TAB) model is used for the particle breakup analysis. An interphase mas-exchange model introduced by Spalding is used for the evaporation calculation. The particle trajectories are calculated using a one-step implicit method for several groups of particle sizes by which the drag forces and heat fluxes are then coupled with the gas phase equations. The preliminary results predicted a reasonable physical simulation of the particle effects using a simple two dimensional solid rocket motor configuration. It shows that the AL/AL2O3 particle sizes are reduced due to the combustion, evaporation, and breakup. The flow field is disturbed by the particles. Mach number distributions in the nozzle are deformed due to the effect of particle concentrations away from the center line.

Collector scrolls on high performance centrifugal pumps are currently designed with methods which are based on very approximate flowfield models. Such design practices result in some volute configurations causing excessive side loads even at design flowrates. The purpose of this study was to develop and verify computational design tools which may be used to optimize volute configurations with respect to avoiding excessive loads on the bearings. The new design methodology consisted of a volute grid generation module and a computational fluid dynamics (CFD) module to describe the volute geometry and predict the radial forces for a given flow condition, respectively. Initially, the CFD module was used to predict the impeller and the volute flowfields simultaneously; however, the required computation time was found to be excessive for parametric design studies. A second computational procedure was developed which utilized an analytical impeller flowfield model and an ordinary differential equation to describe the impeller/volute coupling obtained from the literature, Adkins & Brennen (1988). The second procedure resulted in 20 to 30 fold increase in computational speed for an analysis. The volute design analysis was validated by postulating a volute geometry, constructing a volute to this configuration, and measuring the steady radial forces over a range of flow coefficients. Excellent agreement between model predictions and observed pump operation prove the computational impeller/volute pump model to be a valuable design tool. Further applications are recommended to fully establish the benefits of this new methodology.

Time-accurate computational fluid dynamics (CFD) algorithms are among the basic requirements as an engineering or research tool for realistic simulations of transient combustion phenomena, such as combustion instability, transient start-up, etc., inside the rocket engine combustion chamber. A time-accurate pressure based method is employed in the FDNS code for combustion model development. This is in connection with other program development activities such as spray combustion model development and efficient finite-rate chemistry solution method implementation. In the present study, a second-order time-accurate time-marching scheme is employed. For better spatial resolutions near discontinuities (e.g., shocks, contact discontinuities), a 3rd-order accurate TVD scheme for modeling the convection terms is implemented in the FDNS code. Necessary modification to the predictor/multi-corrector solution algorithm in order to maintain time-accurate wave propagation is also investigated. Benchmark 1-D and multidimensional test cases, which include the classical shock tube wave propagation problems, resonant pipe test case, unsteady flow development of a blast tube test case, and H2/O2 rocket engine chamber combustion start-up transient simulation, etc., are investigated to validate and demonstrate the accuracy and robustness of the present numerical scheme and solution algorithm.

Combustion processes in rocket propulsion systems are characterized by the existence of multiple, vastly differing time and length scales, as well as flow-speeds at wide variation of Mach numbers. The chemical kinetics processes in the highly active reaction zone are characterized by much smaller scales compared to fluid convective and diffusive time scales. An operator splitting procedure for transient finite rate chemistry problems has been developed using a pressure based method, which can be applied to all speed flows without difficulties. The splitting of chemical kinetics terms formed the fluid-mechanical terms of the species equation ameliorated the difficulties associated with the disparate time scales and stiffness in the set of equations which describes highly exothermic combustion. A combined efficient ordinary differential equations (ODE) solver was used to integrate the effective chemical source terms over the residence time at each grid cell. One and two dimensional reacting flow situations were carried out to demonstrate and verify the current procedure. Different chemical kinetics with different degrees of nonlinearity have also been incorporated to test the robustness and generality of the proposed method.

It is known that the simulations of solid rocket motor internal flow field with AL-based propellants require complex multi-phase turbulent flow model. The objective of this study is to develop an advanced particulate multi-phase flow model which includes the effects of particle dynamics, chemical reaction and hot gas flow turbulence. The inclusion of particle agglomeration, particle/gas reaction and mass transfer, particle collision, coalescence and breakup mechanisms in modeling the particle dynamics will allow the proposed model to realistically simulate the flowfield inside a solid rocket motor. The Finite Difference Navier-Stokes numerical code FDNS is used to simulate the steady-state multi-phase particulate flow field for a 3-zone 2-D axisymmetric ASRM model and a 6-zone 3-D ASRM model at launch conditions. The 2-D model includes aft-end cavity and submerged nozzle. The 3-D model represents the whole ASRM geometry, including additional grain port area in the gas cavity and two inhibitors. FDNS is a pressure based finite difference Navier-Stokes flow solver with time-accurate adaptive second-order upwind schemes, standard and extended k-epsilon models with compressibility corrections, multi zone body-fitted formulations, and turbulence particle interaction model. Eulerian/Lagrangian multi-phase solution method is applied for multi-zone mesh. To simulate the chemical reaction, penalty function corrected efficient finite-rate chemistry integration method is used in FDNS. For the AL particle combustion rate, the Hermsen correlation is employed. To simulate the turbulent dispersion of particles, the Gaussian probability distribution with standard deviation equal to (2k/3)(exp 1/2) is used for the random turbulent velocity components. The computational results reveal that the flow field near the juncture of aft-end cavity and the submerged nozzle is very complex. The effects of the turbulent particles affect the flow field significantly and provide better prediction of the ASRM performance. The multi-phase flow analysis using the FDNS code in the present research can be used as a design tool for solid rocket motor applications.

Current design of high performance turbopumps for rocket engines requires effective and robust analytical tools to provide design impact in a productive manner. The main goal of this study is to develop a robust and effective computational fluid dynamics (CFD) pump model for general turbopump design and analysis applications. A Finite Difference Navier-Stokes flow solver, FDNS, which includes the extended k-epsilon turbulence model and appropriate moving interface boundary conditions, was developed to analyze turbulent flows in turbomachinery devices. A second-order central difference scheme plus adaptive dissipation terms was employed in the FDNS code, along with a predictor plus multi-corrector pressure-based solution procedure. The multi-zone, multi-block capability allows the FDNS code to efficiently solve flow fields with complicated geometry. The FDNS code has been benchmarked by analyzing the pump consortium inducer, and it provided satisfactory results. In the present study, a CFD parametric study of the pump consortium impeller was conducted using the FDNS code. The pump consortium impeller, with partial blades, is a new design concept of the advanced rocket engines. The parametric study was to analyze the baseline design of the consortium impeller and its modification which utilizes TANDEM blades. In the present study, the TANDEM blade configuration of the consortium impeller considers cut full blades for about one quarter chord length from the leading edge and clocks the leading edge portion with an angle of 7.5 or 22.5 degrees. The purpose of the present study is to investigate the effect and trend of the TANDEM blade modification and provide the result as a design guideline. A 3-D flow analysis, with a 103 x 23 x 30 mesh grid system and with the inlet flow conditions measured by Rocketdyne, was performed for the baseline consortium impeller. The numerical result shows that the mass flow rate splits through various blade passages are relatively uniform. Due to the complexity of blade geometries, the TANDEM blade configurations were analyzed with the multi-zone grid structure. Both the 7.5 deg- and the 22.5 deg-clocking TANDEM blade cases utilized a 80K mesh system. The numerical result of two TANDEM blade modifications indicates the efficiency and the head are worse than those of the baseline case due to larger flow distortion. The gap between the TANDEM blade and the full blade allows the flow passes through and heavily loads the pressure side of the partial blade such that flow reversal occurs near the suction side of the splitter. The flow split at the exit of impeller blades is very non-uniform for TANDEM blade cases, and this will greatly induce the side load on the diffuser. Therefore, the TANDEM blade modification in the present CFD analysis does not improve the performance of the consortium impeller.

Hot gas turbulent flow distribution around the main injector assembly of the Space Shuttle Main Engine (SSME) and liquid oxygen (LOX) flow distributions through the LOX posts have great effect on the combustion phenomenon inside the main combustion chamber. An advanced computational fluid dynamics (CFD) analysis will help to provide more accurate and efficient characterization of this type of flow field. In order to design a CFD model to be an effective engineering analysis tool with good computational turn-around time and still maintain good accuracy in describing the flow features, the concept of porosity is employed to describe the effects of blockage and drag force due to the presence of the LOX posts in the turbulent flow field around the main injector assembly of the SSME. A validated non-isotropic porosity model is developed and incorporated into an existing Navier-Stokes flow solver (FDNS). Volume and surface porosity parameters, which are based on the configurations of local LOX post clustering, are introduced into the governing equations.

Current design of high performance turbopumps for rocket engines requires effective and robust analytical tools to provide design impact in a productive manner. The main goal of this study is to develop a robust and effective computational fluid dynamics (CFD) pump model for general turbopump design and analysis applications. A Navier-Stokes flow solver, FDNS, embedded with the extended k-epsilon turbulence model and with appropriate moving interface boundary conditions, is developed to analyze turbulent flows in the turbomachinery devices. The FDNS code was benchmarked with its numerical predictions of the pump consortium inducer, and provides satisfactory results. In the present study, a CFD analysis of the pump consortium impeller will be conducted with the application of the FDNS code. The pump consortium impeller, with partial blades, is the new design concept of the advanced rocket engine.

The complexities of liquid rocket engine heat transfer which involve the injector faceplate and regeneratively and film cooled walls are being investigated by computational analysis. A conjugate heat transfer analysis will be used to describe localized heating phenomena associated with particular injector configurations and coolant channels and film coolant dumps. These components are being analyzed, and the analysis verified with appropriate test data. Finally, the component analysis will be synthesized into an overall flowfield/heat transfer model. The FDNS code is being used to make the component analyses. Particular attention is being given to the representation of the thermodynamic properties of the fluid streams and to the method of combining the detailed models to represent overall heating. Unit flow models of specific coaxial injector elements have been developed and will be described. Film cooling simulations of film coolant flows typical of the subscale Space Transportation Main Engine (STME) being experimentally studied by Pratt and Whitney have been made, and these results will be presented. Other film coolant experiments have also been simulated to verify the CFD heat transfer model being developed. The status of the study and its relevance as a new design tool are covered. Information is given in viewgraph form.

The present use of a numerical model developed for the prediction of high-frequency combustion stabilities in liquid propellant rocket engines focuses on (1) the overall behavior of nonlinear combustion instabilities (2) the effects of acoustic oscillations on the fuel-droplet vaporization and combustion process in stable and unstable engine operating conditions, oscillating flowfields, and liquid-fuel trajectories during combustion instability, and (3) the effects of such design parameters as inlet boundary conditions, initial spray conditions, and baffle length. The numerical model has yielded predictions of the tangential-mode combustion instability; baffle length and droplet size variations are noted to have significant effects on engine stability.

Hot gas turbulent flow distribution around the main injector assembly of the Space Shuttle Main Engine (SSME) and LOX flow distribution through the LOX posts have a great effect on the combustion phenomena inside the main combustion chamber. In order to design a CFD model to be an effective engineering analysis tool with good computational turn-around time (especially for 3-D flow problems) and still maintain good accuracy in describing the flow features, the concept of porosity was employed to describe the effects of blockage and drag force due to the presence of the LOX posts in the turbulent flow field around the main injector assembly of the SSME. Two-dimensional numerical studies were conducted to identify the drag coefficients of the flows, both through tube banks and round the shielded posts, over a wide range of Reynolds numbers. Empirical, analytical expressions of the drag coefficients as a function of local flow Reynolds number were then deduced. The porosity model was applied to the turbulent flow around the main injector assembly of the SSME, and analyses were performed. The 3-D CFD analysis was divided into three parts: LOX dome, hot gas injector assembly, and hydrogen cavity. The numerical results indicate that the mixture ratio at the downstream of injector face was close to stoichiometric around baffle elements.

As a building block, numerical capabilities for predicting heat flux and turbulent flowfields of hypersonic vehicles require extensive model validations. Computational procedures for calculating turbulent flows and heat fluxes for supersonic film cooling with parallel slot injections are described in this study. Two injectant mass flow rates with matched and unmatched pressure conditions using the database of Holden et al. (1990) are considered. To avoid uncertainties associated with the boundary conditions in testing turbulence models, detailed three-dimensional flowfields of the injection nozzle were calculated. Two computational fluid dynamics codes, GASP and FDNS, with the algebraic Baldwin-Lomax and k-epsilon models with compressibility corrections were used. It was found that the B-L model which resolves near-wall viscous sublayer is very sensitive to the inlet boundary conditions at the nozzle exit face. The k-epsilon models with improved wall functions are less sensitive to the inlet boundary conditions. The testings show that compressibility corrections are necessary for the k-epsilon model to realistically predict the heat fluxes of the hypersonic film cooling problems.

A particulate two-phase flow CFD model was developed based on the FDNS code which is a pressure based predictor plus multi-corrector Navier-Stokes flow solver. Turbulence models with compressibility correction and the wall function models were employed as submodels. A finite-rate chemistry model was used for reacting flow simulation. For particulate two-phase flow simulations, a Eulerian-Lagrangian solution method using an efficient implicit particle trajectory integration scheme was developed in this study. Effects of particle-gas reaction and particle size change to agglomeration or fragmentation were not considered in this investigation. At the onset of the present study, a two-dimensional version of FDNS which had been modified to treat Lagrangian tracking of particles (FDNS-2DEL) had already been written and was operational. The FDNS-2DEL code was too slow for practical use, mainly because it had not been written in a form amenable to vectorization on the Cray, nor was the full three-dimensional form of FDNS utilized. The specific objective of this study was to reorder to calculations into long single arrays for automatic vectorization on the Cray and to implement the full three-dimensional version of FDNS to produce the FDNS-3DEL code. Since the FDNS-2DEL code was slow, a very limited number of test cases had been run with it. This study was also intended to increase the number of cases simulated to verify and improve, as necessary, the particle tracking methodology coded in FDNS.

In the present computations of a wide range of fluid flow problems by means of the primitive variables-incorporating Navier-Stokes equations, a mixed second-order upwinding scheme approximates the convective terms of the transport equations and the scheme's accuracy is verified for convection-dominated high Re number flow problems. An adaptive dissipation scheme is used as a monotonic supersonic shock flow capture mechanism. Many benchmark fluid flow problems, including the compressible and incompressible, laminar and turbulent, over a wide range of M and Re numbers, are presently studied to verify the accuracy and robustness of this numerical method.

An extended kappa-epsilon turbulence model is proposed and tested with successful results. An improved transport equation for the rate of dissipation of the turbulent kinetic energy, epsilon, is proposed. The proposed model gives more effective response to the energy production rate than does the standard kappa-epsilon turbulence model. An extra time scale of the production range is included in the dissipation rate equation. This enables the present model to perform equally well for several turbulent flows with different characteristics, e.g., plane and axisymmetric jets, turbulent boundary layer flow, turbulent flow over a backward-facing step, and a confined turbulent swirling flow. A second-order accurate finite difference boundary layer code and a nearly second-order accurate finite difference elliptic flow solver are used for the present numerical computations.

A theoretical and experimental investigation of turbulent flows inside a 180-deg strongly curved channel is included in the present study. A 10 by 100 centimeter water channel with a 10 centimeter radius turn was employed for the experimental study. Data measured are velocity profiles and distributions of longitudinal turbulence intensity. Numerical investigations are performed by solving the incompressible Navier-Stokes equations and turbulence models using a finite difference flow solver in generalized curvilinear coordinate systems. A widely used two-equation turbulence model and its modified version, which includes the effect of strong curvature on the turbulence length scale through a relation of algebraic Reynolds stress model, are employed to predict the turbulence quantities inside the flow field. Improvements on the predictions are obtained using the present approach.

In the present paper, a numerical method for solving the equations of motion of three-dimensional incompressible flows in nonorthogonal body-fitted coordinate (BEC) systems has been developed and evaluated. The equations of motion are transformed to a generalized curvilinear coordinate system from which the transformed equations are discretized using finite difference approximations in the transformed domain. The hybrid scheme and a central differencing plus artificial dissipation scheme are used to approximate the convection terms in the governing equations. Effects of these two schemes on the accuracy of numerical predictions are studied. Solutions of the finite difference equations are obtained iteratively by using a pressure-velocity correction algorithm, SIMPLE-C. Numerical examples of two- and three-dimensional, laminar and turbulent flow problems are employed to evaluate the accuracy and efficiency of the present numerical method.

The Melick method of inlet flow dynamic distortion prediction by statistical means is outlined. A hypothetic vortex model is used as the basis for the mathematical formulations. The main variables are identified by matching the theoretical total pressure rms ratio with the measured total pressure rms ratio. Data comparisons, using the HiMAT inlet test data set, indicate satisfactory prediction of the dynamic peak distortion for cases with boundary layer control device vortex generators. A method for the dynamic probe selection was developed. Validity of the probe selection criteria is demonstrated by comparing the reduced-probe predictions with the 40-probe predictions. It is indicated that the the number of dynamic probes can be reduced to as few as two and still retain good accuracy.

In this report, a numerical method for solving the equations of motion of three-dimensional incompressible flows in nonorthogonal body-fitted coordinate (BFC) systems has been developed. The equations of motion are transformed to a generalized curvilinear coordinate system from which the transformed equations are discretized using finite difference approximations in the transformed domain. The hybrid scheme is used to approximate the convection terms in the governing equations. Solutions of the finite difference equations are obtained iteratively by using a pressure-velocity correction algorithm (SIMPLE-C). Numerical examples of two- and three-dimensional, laminar and turbulent flow problems are employed to evaluate the accuracy and efficiency of the present computer code. The user's guide and computer program listing of the present code are also included.

A new wall function approach is developed based on a wall law suitable for incompressible turbulent boundary layers under strong adverse pressure gradients. This wall law was derived from a one-dimensional analysis of the turbulent kinetic energy equation with gradient diffusion concept employed in modeling the near-wall shear stress gradient. Numerical testing cases for the present wall functions include turbulent separating flows around an airfoil and turbulent recirculating flows in several confined regions. Improvements on the predictions using the present wall functions are illustrated. For cases of internal recirculating flows, one modification factor for improving the performance of the k-epsilon turbulence model in the flow recirculation regions is also included.

A transport equation for the root-mean-square pressure fluctuations of turbulent flow is derived from the time-dependent momentum equation for incompressible flow. Approximate modeling of this transport equation is included to relate terms with higher order correlations to the mean quantities of turbulent flow. Three empirical constants are introduced in the model. Two of the empirical constants are estimated from homogeneous turbulence data and wall pressure fluctuations measurements. The third constant is determined by comparing the results of large eddy simulations for a plane channel flow and an annulus flow.