Diminishing Test Resources and Aerodynamic Data Base Generation
2013. 12. 5 안 승 기 국방과학연구소
Page 1 Treaty of Versailles
PART V Military restrictions - Limitation of Germany's army to 100,000 men with no conscription, no tanks, no heavy artillery, no poison-gas supplies, no aircraft and no airships. - Enlisted men will be retained for at least 12 years; officers to be retained for at least 25 years. - German naval forces will be limited to 15,000 men, 6 battleships, 6 cruisers, 12 destroyers and 12 torpedo boats. The German Navy vessels to be under 100,000 tons. No submarines are to be included. - And ………
Page 2 5th VOLTA Congress – 1935, Rome High Speeds in Aviation - Organized by Prof. G. Arturo Crocco
Compressible Flow - L. Prandtl - G.I. Taylor - Th. Von Karman - E. Pitolesi - A. Busemann - J. Ackeret
Page 3 Swept-back wing by Adolf Busemann
Page 4 German Secret Weapons V-1 Me-262
V-2 Me-163
Page 5 Chase for the German Technology
United States - Operation LUSTY (Luftwaffe Secret Technology) - Operation Overcast / Paperclip UK - Operation Surgeon Russia - Operation Osoaviakhim (Bosch, Zeiss …) France - Hiring of German Engineers
Page 6 Theodore Von Karman
High Speed Enthusiast PhD from Göttingen (1908) - Buckling of Columns Karman Vortex Street (1911) Professor, Director GALCIT (Oct. 1930) US citizen (1936) Establish JPL (1944) SAG (1944 ~ 1945) Organize NATO-AGARD, Chairman (1951~1963)
Page 7 USAAF Scientific Advisory Group (1945)
Hugh L. Theodor Dryden von Karman
Ludwig Tsien Prandtl Hsue Shen
Page 8 Wind Tunnels in Germany (by 1943)
Towards New Horizons ( 13 volume Reports, 1945) Technical Intelligence Supplement_Vol-3 by Tsien Location Low Speed High Speed Institutes AVA, KWI, DVL, DFS, FGZ, LFA 18 11 Aachen, Berlin, Technical Braunschweig, Danzig, Hochschule Darmstadt, Dresden, Graz, Hannover, Kothen, Stuttgart, Wien 14 4 BKF, Dornier, Focke, Industry Heinkel, Junkers, Messerschmitt 8 2 Under Control Poland, France, Holland 13 Total 53 17
Page 9 Supersonic WTs at Peenemünde / Kochel
V-2 Model
Tunnels installed at Kochel Rudolf Hermann
Page 10 Wind Tunnels at Völkenrode - Braunschweig
Page 11 George Schairer & XB-47 Configuration
Page 12 Large Wind Tunnel (LFA-M) _ Tyrol, Austria
Mid 1945, 40 percent of the tunnel was on the site (Ö tztal), but only 20 to 30% was assembled at the end of the war (diffuser, test section, part of circuit…).
Page 13 Engine Altitude Test Chamber (BMW)
Page 14 Messerschmitt Project P1101 (Oberammergau)
X-5
Page 15 Journey from Ö tztal to Modane
1945-1946, transfer of the wind tunnel started on December 12 1945 first freight train, June 23 1946 last freight train, in all 13 freight trains were necessary for moving the parts (4364 tons).
Page 16 ONERA-S1-MA (1952) _ France
860m
Page 17 ONERA-S2-MA _ France
Page 18 Dismantling of Völkenrode A-9 Tunnel _UK
Page 19 NAE(RAE) – Bedford _ UK
3ft x 4ft 8ft x 8ft HSST HSWT
Vertical Spin Tunnel 3ft SWT
13ft x 9ft LSWT
Page 20 Breaking the Sound Barrier October 14, 1947 Chuck Yeager Bell X-1
Page 21 Arnold Engineering Development Center(1951)
Page 22 AEDC_ETF_Complex (2011)
Page 23 AEDC Propulsion Wind Tunnels (PWT)
Page 24 Naval Ordnance Lab - White Oak MD
Page 25 Clash of Winds _ Korean War (1950)
Page 26 Tsien Hsue Shen (1911 ~ 2009)
Dr. Hsue-Shen Tsien Principal Author-Editor of the entire USAAF SAG report series, later after returning to The People's Republic of China, was the founder of China's ballistic missile programs and became known as the "Father of Chinese Rocketry".
Page 27 Aircraft Research Association (1956)
Page 28 NLR-HST (1960) Von Kármán changed the Max Mach number from 0.95 to 1.3
Page 29 DLR _ Germany (1960s) Transonic WT 1m x 1m Göttingen (1963)
Trisonic WT 0.6m x 0.6m Köln- Portz(1965)
Page 30 NAL(JAXA) 2m Transonic WT (1960)
Page 31 High RN Low Speed Wind Tunnels (’70s)
DNW RAE LLF(1980) Farnborough ONERA (1977) Fauga- Mauzac (1974)
Page 32 US National Transonic Facility (NTF) _1983
Page 33 European Transonic Windtunnel (ETW) _ 1994
Page 34 Best Aerodynamic Estimates Prior to Flight
Wind Tunnel Data Comprises the Basic Aerodynamic Foundation of the Database Aerodynamic Database
Flight-Test-Derived Flight Increments Test Improve the Fidelity of the Database
On a Proven Aircraft , Wind Wind Tunnel Testing is an Inexpensive Tunnel Means to Estimate the Aerodynamic Impact of a New External Analytical Increasing Store or Sensor Methods Fidelity & Cost Protrusion
Page 35 Aerodynamic Modeling _ Delta Method
Page 36 Force and Moment Accounting System
Page 37 Rafale Test in ONERA-S2MA_1989
6300 Polars in 370 UOH ( 29 Working Days) 1 Million Measuring point AoA : -5 deg ~ +40 deg, Sideslip : -10 deg ~ +10 deg ONERA TP-1991-203, ONERA TP-1994-163
Page 38 Change in Test Requirement & Efficiency
1950 2007 % change Test Hours / Program 1746 40444 2300 % Total Data Runs (/1000) / Program 2.88 241.6 8300 % Test Efficiency Changes (Runs / Hour) 1.7 6.0 350 %
Page 39 Wind Tunnel Test Hours _ De facto standard
Page 40 US Aerospace Industry Consolidation (’80s~’90s)
42 4
Page 41 New Aircraft Designs _ RAND TR-134 (2004)
Page 42 NASA’s Facility Reduction Program ( 2007~ )
Page 43 An Endangered Species _ AIAA 2007
Page 44 North American Aviation TWT
Page 45 NASA - LaRC East (2011)
Page 46 NASA - LaRC West (2011)
Page 47 NASA - LaRC Hypersonic Complex (2013)
Mostly Closed
Page 48 NASA - ARC (2011)
Page 49 US Wind Tunnel Reduction (1985 ~ 2009)
Page 50 Ages of NASA Facilities (2010)
Page 51 AEDC and TVA - 2012
Page 52 CALSPAN Transonic _ built in 1947 Only Commercially Operating Transonic WT in USA
Page 53 Demolition of RAE - Bedford _ UK RAE _ DRA _ DERA _ QinetiQ Bedford No more Indigenous Fighter Development
Page 54 A-9b Compressor Casing is back _ 2004
Page 55 ONERA-S1MA _ New Blades (2008)
Page 56 ONERA-S2MA _ New Honeycomb (2005)
Page 57 Epilogue for new Wind
Tsien Hsue Shen (Qian Xuesen) returned to China in 1955 and became the farther of Chinese Rocketry. AEDC started Power Meeting every morning after 2 years of operation and German engineers confirmed that their idea of using hydraulic power was right. 1/2 of US wind tunnels are closed due to the lack of projects to support them. ONERA upgrades their wind tunnels for the highest productivity and refurbished them for the next 50 years A-9b Compressor Casing back to Germany in 2004
Page 58 COMSAC _ 2004 Computational Method for Stability and Control S&C is a key enabling technology for all flight vehicles - ~ 65% of wind tunnel test hours - Extensive simulator studies - Major impact on design of flight control system - Requires unique flight vehicles and flight tests
Complication - Wind tunnel closures further reduce the availability of experimental data - Extensive Aero data package required for automatic control system
Page 59 Legacy (Mental) Differences
Page 60 Expanded CFD Role _ Boeing
Page 61 Proven History - HiMAT (1975)
High risk approach - 800 Hrs WTT before fabrication (Nominally 2000 Hrs/10,000 Hrs) Computerized aerodynamic Methods as design tools - Linear theory for configuration design - Non-linear Analysis for transonic Maneuverability - Performance Analysis at subsonic supersonic speed - Minimum Wind tunnel test
Page 62 America’s Cup 1983 _ Australia II
Winged Keel Defender USA (1851 ~ 1980) Tank Testing
Page 63 America’s Cup 1987 _ Stars & Stripes
Aerodynamics - Mast - Sails - Rigging
Hydrodynamics - Wave Drag - Keel(Fins) - Bulb - Wings - Rudders VSAERO
Page 64 CFD and Wind Tunnel Compliment
Page 65 High Performance Computing - Boeing
Number of Wings tested in Wind Tunnels (NASA-CP-2004-213028 : COMSAC)
B-767 (80s) Testing 77 Wings
B-737NG (90s) Testing 11 Wings
B-787 (2000s) Testing 5 Wings
Page 66 High Performance Computing HW _ 2013
Machine Affiliation Processor Speed Power Remark NUDT NSCC 16,000 nodes 33.86 24 China Inspur Guangzho Xeon Phi chips Petaflops MW Tianhe-2 u 3,120,000 cores Cray Oak Ridge 18,688 AMD 17.59 8.2 Titan Nat’l Lab Opteron 6274 Petaflops MW 16-core CPUs IBM Lawrence 98,304 nodes 16.32 7.9 Sequoia Livermore 16-core Petaflops MW Nat’l Lab PowerPC A2 SGI NASA 162,496 2.87 2.35 + Upgraded Pleides Ames Intel Xenon Petaflops MW 2013 Exaflops >100MW Current Tech ~ NTF power Exaflops ~ 20 By MW 2020
Page 67 CFD App. # 1 _ X-51A_Overview
Page 68 X-51A _ WT Test
Page 69 X-51A _ CFD
Page 70 Euler Calculation _ Example (CART3D)
Page 71 X-51A WT- CFD Correlation
Page 72 CFD App. # 2 _ Ares-I CEV Aeroscience Project
Directed to use CFD to develop aero database to save costs WTT program largely designed to validate CFD based database models and Apollo models Budgeting and resource allocations were way under for supporting and characterizing the configurations Configuration has been very difficult to test and to analyze with CFD
Page 73 Ares-I CFD based DB Assessment
Page 74 New Directions for Wind Tunnel Test
DOE based Test Matrix : Test Optimization Efficient Wind Tunnel Test : High-Low Mix Test Quality Enhancement for CFD Verification and Validation
Page 75 DOE based Test Matrix
Page 76 Response Surface Method (RSM)
Page 77 OFAT and MDOE _ Accuracy & Resource
Page 78 Fusion of Experimental and CFD data(NEAR)
ARES-I Aero Data Base
Page 79 Efficient WT Test (High-Low Mix) Ares-I Solid Rocket Booster Aero DB WT Test
Page 80 Ares - I SRB Aero DB WT Test
Page 81 Ares - I SRB Aero DB WT Test (Summary)
MSFC-ARF 14 inch Trisonic Boeing 4 FT Polysonic Wind Tunnel NASA LaRC Unitary Plan Wind Tunnel (4 FT)
Ascent Total Descent Total Ascent Testing Roundup (UOH) 6069.25 Descent Testing Roundup (UOH) 2376 ARF 856 PSWT 1246 ARF 1928 CLV Rev 4 120 DAC-1 Force & Moment 88 Low Alpha FS Entry 232 DAC-0 5.5m US 72 DAC-1 Pressure 616 FS Descent Database 536 CLV Rev 4.2 88 DAC-1, 605, ALAS-1, -2, & -3 Force & Moment 40 ASA Baroswitch (1st Stage) 288 1.5% DAC-1 LAS 56 DAC-2 & ALAS-11 Force & Moment 120 Nozzle Extension Increment Test 104 1.0% DAC-1 LAS 88 ADAC-2B A103 F&M 64 10 BDM Increment Test 120 Horowitz LAS Concept 32 ADAC-2B A103 Pressure 168 8 BDM Increment Test 88 DAC-0 6.5m US 40 A106 1% Force nad Moment Test 150 First Stage Pressure Test 320 LAS Parametric 96 ARC 91.5 First Stage Parametricc(Thruster Pod & ) 40 CEV CRC3 64 CLV Rev 4.2 37 First Stage Reentry Test 200 DAC-1 16 Dynamic Damper 54.5 LaRC 20" Mach 6 Pre DAC-2 32 TDT 1408 .65% FS Descent 328 Post Abort Stack 48 Ares I (DAC-1) GWL Checkout Model 224 PSWT DAC-1/PreDAC-2 Repeat 40 Ares I-X Rigid Buffet Model 384 First Stage Wall Interference Test 120 Ares 1-X post Sep 40 Ares I-X GWL Model 448 Ares 1-X Post Sep2 24 Ares I Rigid Buffet Model 352 UPWT 1920.75 NTF 0.5% CLV Rev 4.2 128 ADAC-2B A103 Pressure 141 1% ADAC-1 F&M 72 AEDC 153 1% Clean ADAC-1 Pressure Model 544 1% Stage Separation (Ares I-X + Ares I) 131 1% ADAC-2A F&M (Including ALAS-11) 336 A103 Strake Test 22 Ares 1-X Stage Separation Studies 433.5 14x22 ADAC-2B A103 167.25 A106 Lift-Off Transition 133 A106 1% Force and Moment Test 240 Mach 6 CF4 and Mach 10 Aeroheating 120
Page 82 Test Quality Enhancement
Test Techniques for Verification & Validation - High density measurement techniques - Nonintrusive measurements - Detailed model representation and surface finish - Inclusion of Aeroelastic Effects
Page 83 Pressure Sensitive Paint _ ADD 2010
Page 84 Missile Aero Paradigm Shift Initiation (2012)
OLD PROCESS NEW PROCESS
Low fidelity AP AP High fidelity
Configuration Configuration Bulk Data DB by CFD but HPC DB by W/T High Cost Long time Verification by W/T Large Man Hour
6-DOF (AP: Aero Prediction) 6-DOF
Page 85 CFD Based Missile Aero DB _ 1st Experience M=0.8,M=0.8, phi=90.0phi=90.0 0.60.6 55 3030 17010.4 pts calculation 20 0.4 0 20 4 weeks / 3 users 0 0.2 10 Cx 0.2 Cy Cz 10 Cx 243 equivalent runs Cy Cz -5-5 00 00
-0.2-0.2 T1202, RUN19928 -10-10 -10-10 -5-5 00 55 1010 1515 2020 2525 3030 -5-5 00 55 1010 1515 2020 2525 3030 -5-5 00 55 1010 1515 2020 2525 3030 EulerAngleAngle Code ofof attack, attack,Prediction degdeg AngleAngle ofof attack,attack, degdeg AngleAngle ofof attack,attack, degdeg
11 2020 2020
00 0.50.5 1010
Cl -20
Cn
Cm
Cl -20
Cn
Cm 00 00 -40-40
-0.5-0.5 -60-60 -10-10 -5-5 00 55 1010 1515 2020 2525 3030 -5-5 00 55 1010 1515 2020 2525 3030 -5-5 00 55 1010 1515 2020 2525 3030 AngleAngle ofof attack,attack, degdeg AngleAngle ofof attack,attack, degdeg AngleAngle ofof attack,attack, degdeg
Page 86 Rolling Moment _ M=1.4, = 16
Page 87 Aero Data Base _ Now and Future
Time has come for COMSAC !
Page 88 Closing Thoughts
CFD and WTT each have inherent strength and weakness
CFD is ready for S&C analysis and configuration trades
Project needing a huge aerodynamic database, WTT is still required for now with DOE WTT should be ready as a V&V Tool
We should be more of a designer than CFD analysts or WTT engineers Gaining confidence is also very important
Page 89 Further Reading
1 Trichet, P Paperclip, French Style, AIAA-2009-0962
2 Launius, R D NACA/NASA and the National Unitary Wind Tunnel Plan, 1945 - 1965 Irvine, T B AIAA-2002-1142 Arrington, E A
3 Elsenarr, A DNW-HST 50-Year Anniversary, AIAA 2010-575 Philipsen, I van der Poel, M
4 NAL, Japan NAL 2m x 2m Transonic Wind Tunnel Plan and Structure, NAL-TR-25, 1962
5 Melanson, M R An Assessment of the Increase in Wind Tunnel Testing Requirements for Air Vehicle Development over the Last Fifty Years, AIAA 2008-830
6 Anton, P S Wind Tunnel and Propulsion Facilities, RAND-TR-134, 2004 et al
7 Melanson, M R Wind Tunnel Testing’s Future : A Vision of the Next Generation of Wind Tunnel Chang, M Test Requirements and Facilities, AIAA 2010-142 Baker, W M
8 Armand, C Main ONERA Wind Tunnels for the Success of the Future Supersonic Transport Quemard, C Aircraft, ONERA-TP-1994-163 Fournier, G
9 Fremaux, C M COMSAC : Computational Methods for Stability and Control, Hall, R M NASA-CP-2004-213928/PT1/PT2
Page 90 Further Reading
10 Hall, R M Computational Methods for Stability and Control(COMSAC) : The Time has et al Come, AIAA 2005-6121
11 Ball, D N Contributions of CFD to 787 – and Future Needs, IDC HPC User Forum, 2008
12 Malik, M R Role of Computational Fluid Dynamics and Wind Tunnels in Aeronautics R&D, Bushnell, D M NASA-TP-2012-217602
13 Mutzman, R X-51 Development : A Chief Engineer’s Perspective, 17th AIAA International Murphy, S Space Planes and Hypersonic Systems and Technologies Conference, 2011
14 Hanke, J L Assessment of CFD-based Response Surface Model for Ares I Supersonic Ascent Aerodynamics, AIAA 2011-3648
15 Kraft, E DOE Application to Ground Testing – Advances and Challenges, AIAA AF T&E Days Conference, 2010
16 DeLoach, R Comparison of Resource Requirements for a Wind Tunnel Designed with Micol, J R Conventional vs. Modern Design of Experiments Methods, AIAA 2011-1260
17 Reisenthel, P H Innovative Fusion of Experiment and Analysis for Missile Design and Flight Lesieutre, D J Simulation, RTO-MP-AVT-135, 2006 Dillenius, M F E
18 Purinton, D C Aerodynamic Characterization and Simulation of Solid Rocket Booster During et al Reentry Flight, AIAA 2011-14
Page 91 Further Reading
19 Meier, H-U Die Pfeilflügelentwicklung in Deutschland bis 1945 RAeS Lecture, 3 March 2011 (www.fzt.haw-hamburg.de)
20 National Aeronautical Establishment-Bedford Wind Tunnel Site ARP, Report No.24, December 2003, (www.airfieldresearchgroup.org.uk)
21 Hamel, P. Der Busemann Ü berschallkanal A-9 der LFA-Entwicklung, Nutzungund Verbleib , DGLR-2006-190/191, Deutscher Luft- und Raumfahrtkongress 2006 Braunschweig-Forschungsflughafen, 9. November 2006
Page 92
Thank You for Listening !
Page 93 America’s Cup 2013 _ Oracle Team USA wins!
Page 94