Development of the Orion Crew Module Static Aerodynamic Database

The Orion aerodynamic database provides force and moment coefficients given the velocity, attitude, configuration, etc. of the Crew Exploration Vehicle (CEV). The database is developed and maintained by the NASA CEV Aerosciences Project team from computational and experimental aerodynamic simulations. The database is used primarily by the Guidance, Navigation, and Control (GNC) team to design vehicle trajectories and assess flight performance. The initial hypersonic re-entry portion of the Crew Module (CM) database was developed in 2006. Updates incorporating additional data and improvements to the database formulation and uncertainty methodologies have been made since then. This paper details the process used to develop the CM database, including nominal values and uncertainties, for Mach numbers greater than 8 and angles of attack between 140deg and 180deg. The primary available data are more than 1000 viscous, reacting gas chemistry computational simulations using both the Laura and Dplr codes, over a range of Mach numbers from 2 to 37 and a range of angles of attack from 147deg to 172deg. Uncertainties were based on grid convergence, laminar-turbulent solution variations, combined altitude and code-to-code variations, and expected heatshield asymmetry. A radial basis function response surface tool, NEAR-RS, was used to fit the coefficient data smoothly in a velocity-angle-of-attack space. The resulting database is presented and includes some data comparisons and a discussion of the predicted variation of trim angle of attack and lift-to-drag ratio. The database provides a variation in trim angle of attack on the order of +/-2deg, and a range in lift-to-drag ratio of +/-0.035 for typical vehicle flight conditions

Aerodynamic Analysis of Simulated Heat Shield Recession for the Orion Command Module

The aerodynamic effects of the recession of the ablative thermal protection system for the Orion Command Module of the Crew Exploration Vehicle are important for the vehicle guidance. At the present time, the aerodynamic effects of recession being handled within the Orion aerodynamic database indirectly with an additional safety factor placed on the uncertainty bounds. This study is an initial attempt to quantify the effects for a particular set of recessed geometry shapes, in order to provide more rigorous analysis for managing recession effects within the aerodynamic database. The aerodynamic forces and moments for the baseline and recessed geometries were computed at several trajectory points using multiple CFD codes, both viscous and inviscid. The resulting aerodynamics for the baseline and recessed geometries were compared. The forces (lift, drag) show negligible differences between baseline and recessed geometries. Generally, the moments show a difference between baseline and recessed geometries that correlates with the maximum amount of recession of the geometry. The difference between the pitching moments for the baseline and recessed geometries increases as Mach number decreases (and the recession is greater), and reach a value of -0.0026 for the lowest Mach number. The change in trim angle of attack increases from approx. 0.5deg at M = 28.7 to approx. 1.3deg at M = 6, and is consistent with a previous analysis with a lower fidelity engineering tool. This correlation of the present results with the engineering tool results supports the continued use of the engineering tool for future work. The present analysis suggests there does not need to be an uncertainty due to recession in the Orion aerodynamic database for the force quantities. The magnitude of the change in pitching moment due to recession is large enough to warrant inclusion in the aerodynamic database. An increment in the uncertainty for pitching moment could be calculated from these results and included in the development of the aerodynamic database uncertainty for pitching moment

Development of the Orion Crew Module Static Aerodynamic Database

This work describes the process of developing the nominal static aerodynamic coefficients and associated uncertainties for the Orion Crew Module for Mach 8 and below. The database was developed from wind tunnel test data and computational simulations of the smooth Crew Module geometry, with no asymmetries or protuberances. The database covers the full range of Reynolds numbers seen in both entry and ascent abort scenarios. The basic uncertainties were developed as functions of Mach number and total angle of attack from variations in the primary data as well as computations at lower Reynolds numbers, on the baseline geometry, and using different flow solvers. The resulting aerodynamic database represents the Crew Exploration Vehicle Aerosciences Project's best estimate of the nominal aerodynamics for the current Crew Module vehicle

Sketch-To-Solution: An Exploration of Viscous CFD with Automatic Grids

Numerical simulation of the Reynolds-averaged NavierStokes (RANS) equations has become a critical tool for the design of aerospace vehicles. However, the issues that affect the grid convergence of three dimensional RANS solutions are not completely understood, as documented in the AIAA Drag Prediction Workshop series. Grid adaption methods have the potential for increasing the automation and discretization error control of RANS solutions to impact the aerospace design and certification process. The realization of the CFD Vision 2030 Study includes automated management of errors and uncertainties of physics-based, predictive modeling that can set the stage for ensuring a vehicle is in compliance with a regulation or specification by using analysis without demonstration in flight test (i.e., certification or qualification by analysis). For example, the Cart3D inviscid analysis package has automated Cartesian cut-cell gridding with output-based error control. Fueled by recent advances in the fields of anisotropic grid adaptation, error estimation, and geometry modeling, a similar work flow is explored for viscous CFD simulations; where a CFD application engineer provides geometry, boundary conditions, and flow parameters, and the sketch-to-solution process yields a CFD simulation through automatic, error-based, grid adaptation

Parallel, Gradient-Based Anisotropic Mesh Adaptation for Re-entry Vehicle Configurations

Two gradient-based adaptation methodologies have been implemented into the Fun3d refine GridEx infrastructure. A spring-analogy adaptation which provides for nodal movement to cluster mesh nodes in the vicinity of strong shocks has been extended for general use within Fun3d, and is demonstrated for a 70 sphere cone at Mach 2. A more general feature-based adaptation metric has been developed for use with the adaptation mechanics available in Fun3d, and is applicable to any unstructured, tetrahedral, flow solver. The basic functionality of general adaptation is explored through a case of flow over the forebody of a 70 sphere cone at Mach 6. A practical application of Mach 10 flow over an Apollo capsule, computed with the Felisa flow solver, is given to compare the adaptive mesh refinement with uniform mesh refinement. The examples of the paper demonstrate that the gradient-based adaptation capability as implemented can give an improvement in solution quality

Constellation Program Lessons Learned in the Quantification and Use of Aerodynamic Uncertainty

The NASA Constellation Program has worked for the past five years to develop a re- placement for the current Space Transportation System. Of the elements that form the Constellation Program, only two require databases that define aerodynamic environments and their respective uncertainty: the Ares launch vehicles and the Orion crew and launch abort vehicles. Teams were established within the Ares and Orion projects to provide repre- sentative aerodynamic models including both baseline values and quantified uncertainties. A technical team was also formed within the Constellation Program to facilitate integra- tion among the project elements. This paper is a summary of the collective experience of the three teams working with the quantification and use of uncertainty in aerodynamic environments: the Ares and Orion project teams as well as the Constellation integration team. Not all of the lessons learned discussed in this paper could be applied during the course of the program, but they are included in the hope of benefiting future projects

Orion Crew Module Aerodynamic Testing

The Apollo-derived Orion Crew Exploration Vehicle (CEV), part of NASA s now-cancelled Constellation Program, has become the reference design for the new Multi-Purpose Crew Vehicle (MPCV). The MPCV will serve as the exploration vehicle for all near-term human space missions. A strategic wind-tunnel test program has been executed at numerous facilities throughout the country to support several phases of aerodynamic database development for the Orion spacecraft. This paper presents a summary of the experimental static aerodynamic data collected to-date for the Orion Crew Module (CM) capsule. The test program described herein involved personnel and resources from NASA Langley Research Center, NASA Ames Research Center, NASA Johnson Space Flight Center, Arnold Engineering and Development Center, Lockheed Martin Space Sciences, and Orbital Sciences. Data has been compiled from eight different wind tunnel tests in the CEV Aerosciences Program. Comparisons are made as appropriate to highlight effects of angle of attack, Mach number, Reynolds number, and model support system effects

Opportunities for Breakthroughs in Large-Scale Computational Simulation and Design

Opportunities for breakthroughs in the large-scale computational simulation and design of aerospace vehicles are presented. Computational fluid dynamics tools to be used within multidisciplinary analysis and design methods are emphasized. The opportunities stem from speedups and robustness improvements in the underlying unit operations associated with simulation (geometry modeling, grid generation, physical modeling, analysis, etc.). Further, an improved programming environment can synergistically integrate these unit operations to leverage the gains. The speedups result from reducing the problem setup time through geometry modeling and grid generation operations, and reducing the solution time through the operation counts associated with solving the discretized equations to a sufficient accuracy. The opportunities are addressed only at a general level here, but an extensive list of references containing further details is included. The opportunities discussed are being addressed through the Fast Adaptive Aerospace Tools (FAAST) element of the Advanced Systems Concept to Test (ASCoT) and the third Generation Reusable Launch Vehicles (RLV) projects at NASA Langley Research Center. The overall goal is to enable greater inroads into the design process with large-scale simulations