Application of CFD Analysis to Design Support and Problem Resolution for ASRM and RSRM

The use of Navier-Stokes CFD codes to predict the internal flow field environment in a solid rocket motor is a very important analysis element during the design phase of a motor development program. These computational flow field solutions uncover a variety of potential problems associated with motor performance as well as suggesting solutions to these problems. CFD codes have also proven to be of great benefit in explaining problems associated with operational motors such as in the case of the pressure spike problem with the STS-54B flight motor. This paper presents results from analyses involving both motor design support and problem resolution. The issues discussed include the fluid dynamic/mechanical stress coupling at field joints relative to significant propellant deformations, the prediction of axial and radial pressure gradients in the motor associated with motor performance and propellant mechanical loading, the prediction of transition of the internal flow in the motor associated with erosive burning, the accumulation of slag at the field joints and in the submerged nozzle region, impingement of flow on the nozzle nose, and pressure gradients in the nozzle region of the motor. The analyses presented in this paper have been performed using a two-dimensional axisymmetric model. Fluent/BFC, a three dimensional Navier-Stokes flow field code, has been used to make the numerical calculations. This code utilizes a staggered grid formulation along with the SIMPLER numerical pressure-velocity coupling algorithm. Wall functions are used to represent the character of the viscous sub-layer flow, and an adjusted k-epsilon turbulence model especially configured for mass injection internal flows, is used to model the growth of turbulence in the motor port. Conclusions discussed in this paper consider flow field effects on the forward, center, and aft propellant grains except for the head end star grain region of the forward propellant segment. The field joints and the submerged nozzle are discussed as well. Conclusions relative to both the design evaluation of the ASRM and the RSRM scenarios explaining the pressure spikes were based on the flow field solutions presented in this paper

RSRM 10 percent Scale Model Drilled Hole Plate Tests

The RSRM 10% Scaled Model under design will make use of drilled hole liners to provide mass addition along the axial length of the model. The model will have two sets of liners in use at a time. The outer most liner is a flow distribution tube, the purpose of which is to help distribute the flow evenly over each model segment. The inner most liner will simulate the propellant burning surface at a burn time of 80 seconds. This liner will replicate as closely as possible the actual geometry of the full scale RSRM at the 80 second burn time. In order to obtain the correct mass flow rate for the burn time selected, it is necessary to determine the porosity of the holes drilled in each liner and the performance of those holes. The pressure drop across the liners directly effects the uniformity of the flow in the axial direction for a given model section. It is desired to have a pressure drop across the liners which is greater than the axial pressure drop in a given section. However, the pressure drop across the liner also has a bearing on the structural soundness of the model. The performance of the model was determined analytically, but there was some uncertainty as to the value of the discharge coefficient used. This uncertainty was the impetus for these drilled hole plate tests. Experimentally obtaining the discharge coefficients for sample plates of the porosity to be used in the model would increase the fidelity of the model design. These tests were developed in order to provide the required information with the least amount of testing time and hardware

A Coupled CFD/FEM Structural Analysis to Determine Deformed Shapes of the RSRM Inhibitors

Recent trends towards an increase in the stiffness of the acrylonitrile butadiene rubber (NBR) insulation material used in the construction of the redesigned solid rocket motor (RSRM) propellant inhibitors prompted questions about possible effects on RSRM performance. The specific objectives of the computational fluid dynamics (CFD) task included: (1) the definition of pressure loads to calculate the deformed shape of stiffer inhibitors, (2) the calculation of higher port velocities over the inhibitors to determine shifts in the vortex shedding or edge tone frequencies, and (3) the quantification of higher slag impingement and collection rates on the inhibitors and in the submerged nose nozzle cavity

SRM Internal Flow Test and Computational Fluid Dynamic Analysis

During the four year period of performance for NASA contract, NASB-39095, ERC has performed a wide variety of tasks to support the design and continued development of new and existing solid rocket motors and the resolution of operational problems associated with existing solid rocket motor's at NASA MSFC. This report summarizes the support provided to NASA MSFC during the contractual period of performance. The report is divided into three main sections. The first section presents summaries for the major tasks performed. These tasks are grouped into three major categories: full scale motor analysis, subscale motor analysis and cold flow analysis. The second section includes summaries describing the computational fluid dynamics (CFD) tasks performed. The third section, the appendices of the report, presents detailed descriptions of the analysis efforts as well as published papers, memoranda and final reports associated with specific tasks. These appendices are referenced in the summaries. The subsection numbers for the three sections correspond to the same topics for direct cross referencing

Design of a Subscale Propellant Slag Evaluation Motor Using Two-Phase Fluid Dynamic Analysis

Small pressure perturbations in the Space Shuttle Reusable Solid Rocket Motor (RSRM) are caused by the periodic expulsion of molten aluminum oxide slag from a pool that collects in the aft end of the motor around the submerged nozzle nose during the last half of motor operation. It is suspected that some motors produce more slag than others due to differences in aluminum oxide agglomerate particle sizes that may relate to subtle differences in propellant ingredient characteristics such as particle size distributions or processing variations. A subscale motor experiment was designed to determine the effect of propellant ingredient characteristics on the propensity for slag production. An existing 5 inch ballistic test motor was selected as the basic test vehicle. The standard converging/diverging nozzle was replaced with a submerged nose nozzle design to provide a positive trap for the slag that would increase the measured slag weights. Two-phase fluid dynamic analyses were performed to develop a nozzle nose design that maintained similitude in major flow field features with the full scale RSRM. The 5 inch motor was spun about its longitudinal axis to further enhance slag collection and retention. Two-phase flow analysis was used to select an appropriate spin rate along with other considerations, such as avoiding bum rate increases due to radial acceleration effects. Aluminum oxide particle distributions used in the flow analyses were measured in a quench bomb for RSRM type propellants with minor variations in ingredient characteristics. Detailed predictions for slag accumulation weights during motor bum compared favorably with slag weight data taken from defined zones in the subscale motor and nozzle. The use of two-phase flow analysis proved successful in gauging the viability of the experimental program during the planning phase and in guiding the design of the critical submerged nose nozzle