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Overview of
Pratt & Whitney Rocketdyne
Modeling & Simulation Practices
for Liquid Propellant Rocket Engines
Agenda
• Extreme Environment
SSME operates at greater temperature extremes
than any mechanical system known to man
(from 6000o F in the combustion chamber to fuel at
-423o F just a few inches away)
Rotating Machinery
Turbopump Physics
Rotating machinery flows are among the most complex internal flowpaths
• 3D, large regions of separation, strong flow non-uniformities
• May contain incompressible, subsonic, transonic and even supersonic
flows within the same turbopump
• High speeds of rotation (e.g. 38,000 RPM for the SSME HPFTP) create
a highly turbulent, and strongly anisotropic flow dominated by vortical
motions, separated boundary layers and vortex shedding
• Multiphase flows (cavitation in inducers and liquid-gas mixtures around
some types of bearings) are also observed
• Extremely high dynamic loads and thermal gradients (e.g. temperatures
change by ~ 2000o R within a few inches)
0.4
0.3 4400
0.2 4200
0.1 4000
0 3800
-0.7 -0.6 -0.5 -0.4 -0.3 -0.2 -0.1 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
-0.1 3600
TIP
MEAN
-0.2 HUB
3400
TANGENTIAL LENGTH, INCH
-0.3
3200
-0.4
3000
-0.5
2800
-0.6
2600
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00
AXIAL LENGTH RATIO
• Ability to rapidly predict the flow and thermal environment in the entire
turbopump (a CFD challenge – dynamic grid adaptation; highly efficient
solvers for 3D transient mixed flows; workable turbulence models; PC-based
parallel computing capability (~ 1000 PCs); and large database management &
postprocessing technologies)
• Interfacing CFD predicted flow and thermal environments and loads with
stress and structural dynamics codes and material databases to determine
part thickness, yield and failure limits, and margins of safety (dual
challenge – CFD has to provide what stress needs, stress has to understand
CFD’s limitations and areas of uncertainty)
• Understanding turbine disk instability mechanisms including acoustic
excitation
• Developing a user-friendly methodology to include secondary (thermal)
stresses in fracture mechanics analysis
• Acquiring quality test data and experiments to validate models and predictions
Thrust Chamber
Nozzle
Combustion
Chamber
6.00
5.00
4.00
3.00
2.00
1.00
Gas Film Cooling
Nozzle Start-up Transient Load Analyses
0.00
0 2000 4000 6000 8000 10000 12000 14000 16000
Frequency (Hz)
Contour 1
Expansion
Field Diamond Shock
Contour 2
-
1.2
Generation 1 Generation 7
• Ability to rapidly predict the flow and thermal environment in the combustion
chamber (another CFD challenge – dynamic grid adaptation; highly efficient
solvers for 3D transient mixed flows; workable turbulence models; mechanistic
combustion models & correlations; PC-based parallel computing capability (~ 1000 PCs);
and large database management & postprocessing technologies)
• Interfacing CFD predicted flow and thermal environments and loads with
stress and structural dynamics codes and material databases to select
materials and coatings, yield and failure limits, active cooling requirements,
and margins of safety (triple challenge – CFD has to provide what material scientists
and stress engineers need, and they have to understand CFD’s limitations
and areas of uncertainty)
• Chamber durability and injector performance
• Combustion stability especially with hydrocarbon based fuels
• Acquiring quality test data and experiments to validate models and predictions
Propellant Feed System is an assembly of ducts, valves, pipes, and manifolds that
deliver the propellants to the turbopumps from the fuel and oxidizer tanks and
then from the turbopumps to the combustion chamber.
• SINDA/FLUINT enhancements
• Process dynamics & control system
algorithms
• Advanced accumulator transient
simulation methodology
• Extended fluid property databases
including cryogenic propellants
• Ability to rapidly predict the flow environment (a CFD challenge – dynamic grid
adaptation; highly efficient solvers for 3D transient mixed flows; workable turbulence
models; PC-based parallel computing capability (~ 1000 PCs); and large database
management & postprocessing technologies)
• Interfacing CFD predicted flow environments and loads with stress and
structural dynamics codes and material databases to determine
part thickness, yield and failure limits, and margins of safety (dual
challenge – CFD has to provide what stress needs, stress has to understand
CFD’s limitations and areas of uncertainty)
• Acquiring quality test data and experiments to validate models and predictions
• The design process is still a mix of engineering, science, experience, & art
• Since the SSMEs there has been no new flight engine development in the
USA for a quarter of a century until the RS-68 engine (first flown in 2003)
Concurrent
Engineering &
Robust Design
Practices
RDCS System
4
CODE 2 CODE 6
Parametric Analysis of a Set of
5
CODE 1
Multidisciplinary Codes
Closely Coupled Connected Together
CODE 7
CODE 3
Thermal
Analyzer
orientation • Orbital |
|T7770
|T777
T77
T7
T777
T7770
____
777001n
77
7
|T777001n
___
___
77 01
_
01n
1n
1 n
angles
_
7 | -15.0 | 15.0 | -15.0 | 220.0 | -75.0 | 180.639 | 182.95 | 169.572 | 172.586 |
INTERFACING 89.633
10 | -15.0 | -20.0 | 0.0
107.68
| 220.0 | -75.0 | 194.19 | 195.067 | 187.64 | 187.992 |
• Hundreds of • Environmental 22
123.789
19
| -15.0 | -2.5 | 15.0 | 220.0 | -75.0 | 198.351 | 199.303 | 189.414 | 191.119 |
THERMAL MODEL
|T777001n
86.2578
____
5 | 0.0 | -2.5 | -15.0 | 220.0 | -75.0 | 160.799 | 166.289 | 155.931 | 160.635 |
_|_______|_______|_______|_______|_______|_________|_________|_________|_________|________
single submittal
71.1556
interchange
10 | -15.0 | -20.0 | 0.0 | 220.0 | -75.0 | 194.19 | 195.067 | 187.64 | 187.992 |
103.477
107.68
6 | 15.0 | -2.5 | -15.0 | 220.0 | -75.0 | 134.112 | 139.303 | 131.704 | 135.329 |
• Massively
22 | -15.0 | -2.5 | 15.0 | 220.0 | -75.0 | 198.351 | 199.303 | 189.414 | 191.119 |
47.7254
123.789
11 | 0.0 | -20.0 | 0.0 | 220.0 | -75.0 | 163.546 | 171.222 | 158.41 | 164.865 |
19 | -15.0 | -20.0 | 15.0 | 220.0 | -75.0 | 201.932 | 203.249 | 191.554 | 193.307 |
parallel
23
Seq | 0.0
#| YAW | | -2.5 | 15.0 | 220.0 | -75.0 |
| 181.027 |
| 186.322 || 177.267 | | 181.89 |
4 | -15.0 | PITCH
-2.5 || ROLL
-15.0 || ALTIT
220.0 || BETA
-75.0 | T92540n
178.722 | T92540x
180.719 | T92640n
164.061 | T92640x
168.369 |
103.423
|T777001n
86.2578
(SINDA/FLUINT) ____
temperature
5 | 0.0 | -2.5 | -15.0 | 220.0 | -75.0 | 160.799 | 166.289 | 155.931 | 160.635 |
processing
_|_______|_______|_______|_______|_______|_________|_________|_________|_________|________
71.1556
_
14 | 0.0 | -2.5 | 0.0 | 220.0 | -75.0 | 164.833 | 171.696 | 158.185 | 164.306 |
7 | -15.0 | 15.0 | -15.0 | 220.0 | -75.0 | 180.639 | 182.95 | 169.572 | 172.586 |
response
75.0061
89.633
16 | -15.0 | 15.0 | 0.0 | 220.0 | -75.0 | 190.766 | 191.509 | 185.373 | 185.839 |
10 | -15.0 | -20.0 | 0.0
103.477 | 220.0 | -75.0 | 194.19 | 195.067 | 187.64 | 187.992 |
107.68
6 | 15.0 | -2.5 | -15.0 | 220.0 | -75.0 | 134.112 | 139.303 | 131.704 | 135.329 |
22
47.7254 | -15.0 | -2.5 | 15.0 | 220.0 | -75.0 | 198.351 | 199.303 | 189.414 | 191.119 |
123.789
11 | 0.0 | -20.0 | 0.0 | 220.0 | -75.0 | 163.546 | 171.222 | 158.41 | 164.865 |
19
73.0811 | -15.0 | -20.0 | 15.0 | 220.0 | -75.0 | 201.932 | 203.249 | 191.554 | 193.307 |
128.376
23 | 0.0 | -2.5 | 15.0 | 220.0 | -75.0 | 181.027 | 186.322 | 177.267 | 181.89 |
4
103.423 | -15.0 | -2.5 | -15.0 | 220.0 | -75.0 | 178.722 | 180.719 | 164.061 | 168.369 |
86.2578
5 | 0.0 | -2.5 | -15.0 | 220.0 | -75.0 | 160.799 | 166.289 | 155.931 | 160.635 |