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Cold Flow Performance of a Ramjet Engine

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Cold Flow Performance of a Ramjet Engine COLD FLOW PERFORMANCE OF A RAMJET ENGINE A Thesis Presented to the Faculty of California Polytechnic State University San Luis Obispo In Partial Fulfillment of the Requirements for the Degree Master of Science in Aerospace Engineering by Harrison G. Sykes December 2014 ©2014 Harrison G. Sykes ALL RIGHTS RESERVED ii COMMITTEE MEMBERSHIP TITLE: Cold Flow Performance of a Ramjet Engine AUTHOR: Harrison G. Sykes DATE SUBMITTED: December 2014 COMMITTEE CHAIR: Eric Mehiel, Ph.D. Associate Professor Aerospace Engineering Department COMMITTEE MEMBER: Patrick Lemieux, Ph.D. Associate Professor, Mechanical Engineering Department COMMITTEE MEMBER: Daniel J. Wait, M.S. Systems Engineer, Tyvak Nano-Satelite Systems LLC iii ABSTRACT Cold Flow Performance of a Ramjet Engine Harrison G. Sykes The design process and construction of the initial modular ramjet attachment to the Cal Poly supersonic wind tunnel is presented. The design of a modular inlet, combustor, and nozzle are studied in depth with the intentions of testing in the modular ramjet. The efforts undertaken to characterize the Cal Poly supersonic wind tunnel and the individual component testing of this attachment are also discussed. The data gathered will be used as a base model for future expansion of the ramjet facility and eventual hot fire testing of the initial components. Modularity of the inlet, combustion chamber, and nozzle will allow for easier modification of the initial design and the designs ability to incorporate clear walls will allow for flow and combustion visualization once the performance of the hot flow ramjet is determined. The testing of the blank ramjet duct resulted in an error of less than 10% from predicted results. The duct was also tested with the modular inlet installed and resulted in between a 13-30% error based on the predicted results. Hot flow characteristics of the ramjet were not achieved, and the final cold flow test with the nozzle installed was a failure due to improper configuration of the nozzle. The errors associated with this testing can largely be placed on the poor performance of the Cal Poly supersonic wind tunnel and the alterations made to the testing in an attempt to accommodate these flaws. The final tests were halted for safety concerns and could continue after a thorough safety review. iv ACKNOWLEDGMENTS I would Like to thank the following people for their contributions in completing my thesis: Dr. Mehiel for his help and guidance during several difficult events, Dr. Dianne DeTurris for her expertise in both combustion and supersonics, Dr. Patrick Lemieux for having the insight to point the project down the right path, Cody Thompson for his help with the construction of the ramjet, Kelsey Selin for help with the fuel system design and the early ramjet designs, Andrew Carter for designing the variable geometry inlet, Paul Stone for the design of the combustion chamber, Clinton Humphreys for his work on the variable geometry nozzle and Dr. John Chen for his help with the high speed camera. I would especially like to thank Sal Est´eves for his help with construction and making the project his own. You not only help me with the physical construction but you made the time I spent in the lab more enjoyable. I had an easier time with this project than I would've had I not had your help. I also want to thank you for the mattress you lent me on some of those late weekend nights when I didn't have a place to stay. I want to thank Dan Wait for all he has done for this project. You always gave me sound advice and always had the broader picture in your mind when I was getting dirty with minor details. You always knew the right course of action whether it was to spend the night at the wind tunnel or to take the night to blow off steam. I appreciate every piece of knowledge and best practice you passed on to me, even if I didn't follow it exactly at the time. This project has come a long way from when Kelsey and I originally approached you about making an after burner and it is largely because of your help. I was very lucky to have you as an advisor on this project. I would also like to thank my parents for the financial and emotion support you've given me throughout my years in the undergraduate and graduate programs at Cal Poly. I would also like to thank my brother Sam Sykes and my good friend Joe Bauer for spending an entire weekend machining my plates for me and showing me what can be accomplished with a hand mill. I want to thank my sister Chelsea for her help with setting up the picture of the oblique shock. Finally, I would like to thank my girlfriend Maya who as helped me out since before this thesis had even begun to take shape in my head. I could not have completed this without the help of every one of you. {Harrison G. Sykes v TABLE OF CONTENTS List of Tables ix List of Figures xi 1 Introduction 1 1.1 Demand for Ramjet Propulsion..............................1 1.2 Types of Ramjet Engine Testing Facilities........................2 1.2.1 Direct Connection Testing.............................3 1.2.2 Free Jet Testing..................................3 1.2.3 Semi-Free Jet Testing...............................4 1.3 Combustion Chamber Alternatives............................4 1.4 Thesis Objective......................................5 1.5 Organization of Thesis...................................7 2 California Polytechnic State University Supersonic Wind Tunnel and Modifications9 2.1 Background......................................... 10 2.2 Modifications........................................ 19 2.2.1 Data Acquisition.................................. 19 2.2.2 Pressure Relief System............................... 24 3 Analytical Model 27 3.1 Assumptions........................................ 28 3.2 Inlet............................................. 31 3.3 Combustor......................................... 38 3.4 Nozzle............................................ 41 4 Solidworks Model and Construction 51 4.1 Modular Plates....................................... 51 4.2 Complete Design...................................... 54 5 Testing 60 5.1 Fuel System Testing.................................... 60 5.2 Ignition System Testing.................................. 62 5.3 Safety Buildup Approach................................. 63 5.3.1 Blank Test..................................... 66 5.3.2 Inlet Test...................................... 68 5.3.3 Inlet and Nozzle Test............................... 69 5.4 Hot Fire Testing...................................... 71 5.5 The Wedge Test...................................... 73 vi 6 Results and Discussion 74 6.1 Fuel System Testing Results................................ 74 6.2 Ignition System Testing Results.............................. 77 6.3 Previous SSWT Testing.................................. 78 6.4 Ramjet Preliminary Test Results............................. 82 6.5 Ramjet \Blank" Test Results............................... 85 6.6 Ramjet \Inlet" Test Results................................ 89 6.7 Ramjet \Inlet + Nozzle" Test Results.......................... 93 7 Conclusions and Future Work 95 Bibliography 98 Appendices 101 A MatLab Code Verification 101 B Basic Inner Plate 118 C Ramjet { Standard Operating Procedures 121 C.1 Installing the SSWT Pressure Relief System....................... 121 C.1.1 Installing the SSWT Pressure Relief System................... 121 C.2 Assembling the Ramjet.................................. 123 C.2.1 Chassis Set Up................................... 123 C.2.2 Chassis Tear Down................................. 124 C.2.3 Blank Setup..................................... 124 C.2.4 Inlet Setup..................................... 125 C.2.5 Inlet and Nozzle Setup............................... 126 C.2.6 Full Setup { Cold.................................. 127 C.2.7 Full Setup { Hot.................................. 128 C.2.8 Blank Tear Down.................................. 129 C.2.9 Inlet Tear Down.................................. 130 C.2.10 Inlet and Nozzle Tear Down............................ 130 C.2.11 Full Tear Down { Cold............................... 131 C.2.12 Full Tear Down { Hot............................... 131 C.3 Running the Ramjet { COLD FLOW.......................... 132 C.3.1 Job Descriptions.................................. 132 C.3.2 Hand Signals.................................... 133 C.3.3 Emergency Shutdown Procedures......................... 133 C.3.4 Cold Flow Blank Run Procedures......................... 135 C.3.5 Cold Flow Inlet Run Procedures......................... 137 vii C.3.6 Cold Flow Inlet and Nozzle Run Procedures................... 140 C.3.7 Cold Flow Full Setup Run Procedures...................... 142 C.4 Running the Ramjet { Hot Fire Run (Untested).................... 144 C.4.1 Job Descriptions.................................. 145 C.4.2 Hand Signals.................................... 146 C.4.3 Emergency Shutdown Procedures......................... 146 C.4.4 Hot Fire Run Procedures............................. 147 D Jet-A Fuel Specifications 152 E Structure Study 155 viii LIST OF TABLES 2.1 Plenum Pressure related to Pilot Valve adjustment length................. 11 2.2 Isentropic Flow Table Excerpt................................ 13 2.3 Pressure Transducer Wiring stations 3 and 5........................ 24 2.4 Pressure Transducer Wiring station 7............................ 24 3.1 Static Property Values with the Inlet............................. 35 3.2 Stagnation Property Values with the Inlet.......................... 36 3.3 Mass
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