Database Driven 6-DOF Trajectory Simulation for Debris Transport Analysis

Debris mitigation and risk assessment have been carried out by NASA and its contractors supporting Space Shuttle Return-To-Flight (RTF). As a part of this assessment, analysis of transport potential for debris that may be liberated from the vehicle or from pad facilities prior to tower clear (Lift-Off Debris) is being performed by MSFC. This class of debris includes plume driven and wind driven sources for which lift as well as drag are critical for the determination of the debris trajectory. As a result, NASA MSFC has a need for a debris transport or trajectory simulation that supports the computation of lift effect in addition to drag without the computational expense of fully coupled CFD with 6-DOF. A database driven 6-DOF simulation that uses aerodynamic force and moment coefficients for the debris shape that are interpolated from a database has been developed to meet this need. The design, implementation, and verification of the database driven six degree of freedom (6-DOF) simulation addition to the Lift-Off Debris Transport Analysis (LODTA) software are discussed in this paper

Characterization of the Ignition Over-Pressure/Sound Suppression Water in the Space Launch System Mobile Launcher Using Volume of Fluid Modeling

The Space Launch System (SLS) Vehicle consists of a Core Stage with four RS-25 engines and two Solid Rocket Boosters (SRBs). This vehicle is launched from the Launchpad using a Mobile Launcher (ML) which supports the SLS vehicle until its liftoff from the ML under its own power. The combination of the four RS-25 engines and two SRBs generate a significant Ignition Over-Pressure (IOP) and Acoustic Sound environment. One of the mitigations of these environments is the Ignition Over-Pressure/Sound Suppression (IOP/SS) subsystem installed on the ML. This system consists of six water nozzles located parallel to and 24 inches downstream of each SRB nozzle exit plane as well as 16 water nozzles located parallel to and 53 inches downstream of the RS-25 nozzle exit plane. During launch of the SLS vehicle, water is ejected through each water nozzle to reduce the intensity of the transient pressure environment imposed upon the SLS vehicle. While required for the mitigation of the transient pressure environment on the SLS vehicle, the IOP/SS subsystem interacts (possibly adversely) with other systems located on the Launch Pad. One of the other systems that the IOP/SS water is anticipated to interact with is the Hydrogen Burn-Off Igniter System (HBOI). The HBOI system's purpose is to ignite the unburned hydrogen/air mixture that develops in and around the nozzle of the RS-25 engines during engine start. Due to the close proximity of the water system to the HBOI system, the presence of the IOP/SS may degrade the effectiveness of the HBOI system. Another system that the IOP/SS water may interact with adversely is the RS-25 engine nozzles and the SRB nozzles. The adverse interaction anticipated is the wetting, to a significant degree, of the RS-25 nozzles resulting in substantial weight of ice forming and water present to a significant degree upstream of the SRB nozzle exit plane inside the nozzle itself, posing significant additional blockage of the effluent that exits the nozzle upon motor start leading to detrimental effects. The purpose of the CFD simulations were to i) characterize the location of the IOP/SS water after it is ejected from the IOP/SS nozzles, ii) characterize the interaction of the IOP/SS system with the HBOI system and iii) characterize the interaction of the IOP/SS water with the RS-25 nozzles and the SRB nozzles

Sloshing in the Liquid Hydrogen and Liquid Oxygen Propellant Tanks After Main Engine Cut Off

NASA Marshall Space Flight Center is designing and developing the Main Propulsion System (MPS) for Ares launch vehicles. Propellant sloshing in the liquid hydrogen (LH2) and liquid oxygen (LO2) propellant tanks after Main Engine Cut Off (MECO) was modeled using the Volume of Fluid (VOF) module of the computational fluid dynamics code, CFD-ACE+. The present simulation shows that there is substantial sloshing side forces acting on the LH2 tank during the deceleration of the vehicle after MECO. The LH2 tank features a side wall drain pipe. The side loads result from the residual propellant mass motion in the LH2 tank which is initiated by the stop of flow into the drain pipe at MECO. The simulations show that radial force on the LH2 tank wall is less than 50 lbf and the radial moment calculated based up through the center of gravity of the vehicle is predicted to be as high as 300 lbf-ft. The LO2 tank features a bottom dome drain system and is equipped with sloshing baffles. The remaining LO2 in the tank slowly forms a liquid column along the centerline of tank under the zero gravity environments. The radial force on the LO2 tank wall is predicted to be less than 100 lbf. The radial moment calculated based on the center of gravity of the vehicle is predicted as high as 4500 lbf-ft just before MECO and dropped down to near zero after propellant draining stopped completely

Scale Model Acoustic Test Validation of IOP-SS Water Prediction using Loci-STREAM-VoF

The Scale Model Acoustic Test (SMAT) is a 5% scale test of the Space Launch System (SLS), which is currently being designed at Marshall Space Flight Center (MSFC). SMAT consists of a 5% scale representation of the ignition overpressure sound-suppression system (IOP-SS) that is being tested to quantify the water flow and induced air entrainment in and around the mobile launcher exhaust hole. This data will be compared with computational fluid dynamics (CFD) simulations using the newly developed Loci-STREAM Volume of Fluid (VoF) methods. Compressible and incompressible VoF methods have been formulated, and are currently being used to simulate the water flow of SMAT IOP-SS. The test data will be used to qualitatively and quantitatively assess and validate the VoF methods

Accuracy Quantification of the Loci-CHEM Code for Chamber Wall Heat Fluxes in a G02/GH2 Single Element Injector Model Problem

A robust rocket engine combustor design and development process must include tools which can accurately predict the multi-dimensional thermal environments imposed on solid surfaces by the hot combustion products. Currently, empirical methods used in the design process are typically one dimensional and do not adequately account for the heat flux rise rate in the near-injector region of the chamber. Computational Fluid Dynamics holds promise to meet the design tool requirement, but requires accuracy quantification, or validation, before it can be confidently applied in the design process. This effort presents the beginning of such a validation process for the Loci- CHEM CPD code. The model problem examined here is a gaseous oxygen (GO2)/gaseous hydrogen (GH2) shear coaxial single element injector operating at a chamber pressure of 5.42 MPa. The GO2/GH2 propellant combination in this geometry represents one the simplest rocket model problems and is thus foundational to subsequent validation efforts for more complex injectors. Multiple steady state solutions have been produced with Loci-CHEM employing different hybrid grids and two-equation turbulence models. Iterative convergence for each solution is demonstrated via mass conservation, flow variable monitoring at discrete flow field locations as a function of solution iteration and overall residual performance. A baseline hybrid grid was used and then locally refined to demonstrate grid convergence. Solutions were also obtained with three variations of the k-omega turbulence model

Non-Linear Slosh Damping Model Development and Validation

Propellant tank slosh dynamics are typically represented by a mechanical model of spring mass damper. This mechanical model is then included in the equation of motion of the entire vehicle for Guidance, Navigation and Control (GN&C) analysis. For a partially-filled smooth wall propellant tank, the critical damping based on classical empirical correlation is as low as 0.05%. Due to this low value of damping, propellant slosh is potential sources of disturbance critical to the stability of launch and space vehicles. It is postulated that the commonly quoted slosh damping is valid only under the linear regime where the slosh amplitude is small. With the increase of slosh amplitude, the critical damping value should also increase. If this nonlinearity can be verified and validated, the slosh stability margin can be significantly improved, and the level of conservatism maintained in the GN&C analysis can be lessened. The purpose of this study is to explore and to quantify the dependence of slosh damping with slosh amplitude. Accurately predicting the extremely low damping value of a smooth wall tank is very challenging for any Computational Fluid Dynamics (CFD) tool. One must resolve thin boundary layers near the wall and limit numerical damping to minimum. This computational study demonstrates that with proper grid resolution, CFD can indeed accurately predict the low damping physics from smooth walls under the linear regime. Comparisons of extracted damping values with experimental data for different tank sizes show very good agreements. Numerical simulations confirm that slosh damping is indeed a function of slosh amplitude. When slosh amplitude is low, the damping ratio is essentially constant, which is consistent with the empirical correlation. Once the amplitude reaches a critical value, the damping ratio becomes a linearly increasing function of the slosh amplitude. A follow-on experiment validated the developed nonlinear damping relationship. This discovery can lead to significant savings by reducing the number and size of slosh baffles in liquid propellant tanks

CFD Extraction of Heat Transfer Coefficient in Cryogenic Propellant Tanks

Current reduced-order thermal model for cryogenic propellant tanks is based on correlations built for flat plates collected in the 1950's. The use of these correlations suffers from inaccurate geometry representation; inaccurate gravity orientation; ambiguous length scale; and lack of detailed validation. This study uses first-principles based CFD methodology to compute heat transfer from the tank wall to the cryogenic fluids and extracts and correlates the equivalent heat transfer coefficient to support reduced-order thermal model. The CFD tool was first validated against available experimental data and commonly used correlations for natural convection along a vertically heated wall. Good agreements between the present prediction and experimental data have been found for flows in laminar as well turbulent regimes. The convective heat transfer between the tank wall and cryogenic propellant, and that between the tank wall and ullage gas were then simulated. The results showed that the commonly used heat transfer correlations for either vertical or horizontal plate over-predict heat transfer rate for the cryogenic tank, in some cases by as much as one order of magnitude. A characteristic length scale has been defined that can correlate all heat transfer coefficients for different fill levels into a single curve. This curve can be used for the reduced-order heat transfer model analysis