diminishing test resources and aerodynamic data base generation
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Page 1
Diminishing Test Resources
and
Aerodynamic Data Base Generation
2013. 12. 5
안 승 기
국방과학연구소
Page 2
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 3
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 4
Swept-back wing by Adolf Busemann
Page 5
German Secret Weapons
V-1
V-2
Me-262
Me-163
Page 6
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 7
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 8
USAAF Scientific Advisory Group (1945)
Hugh L.
Dryden
Ludwig
Prandtl
Theodor
von Karman
Tsien
Hsue Shen
Page 9
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
Technical
Hochschule
Aachen, Berlin,
Braunschweig, Danzig,
Darmstadt, Dresden, Graz,
Hannover, Kothen,
Stuttgart, Wien
14
4
Industry
BKF, Dornier, Focke,
Heinkel, Junkers,
Messerschmitt
8
2
Under Control Poland, France, Holland 13
Total 53 17
Page 10
Supersonic WTs at Peenemünde / Kochel
Tunnels installed at Kochel
V-2 Model
Rudolf Hermann
Page 11
Wind Tunnels at Vö lkenrode - Braunschweig
Page 12
George Schairer & XB-47 Configuration
Page 13
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 14
Engine Altitude Test Chamber (BMW)
Page 15
Messerschmitt Project P1101 (Oberammergau)
X-5
Page 16
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 17
ONERA-S1-MA (1952) _ France
860m
Page 18
ONERA-S2-MA _ France
Page 19
Dismantling of Vö lkenrode A-9 Tunnel _UK
Page 20
NAE(RAE) – Bedford _ UK
3ft x 4ft
HSST
Vertical
Spin
Tunnel
13ft x 9ft
LSWT
8ft x 8ft
HSWT
3ft SWT
Page 21
Breaking the Sound Barrier
October 14, 1947
Chuck Yeager
Bell X-1
Page 22
Arnold Engineering Development Center(1951)
Page 23
AEDC_ETF_Complex (2011)
Page 24
AEDC Propulsion Wind Tunnels (PWT)
Page 25
Naval Ordnance Lab - White Oak MD
Page 26
Clash of Winds _ Korean War (1950)
Page 27
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 28
Aircraft Research Association (1956)
Page 29
NLR-HST (1960)
Von Kármán changed the Max Mach
number from 0.95 to 1.3
Page 30
DLR _ Germany (1960s)
Trisonic WT
0.6m x 0.6m
Köln- Portz(1965)
Transonic WT
1m x 1m
Göttingen (1963)
Page 31
NAL(JAXA) 2m Transonic WT (1960)
Page 32
High RN Low Speed Wind Tunnels (’70s)
DNW
LLF(1980)
ONERA
Fauga-
Mauzac
(1974)
RAE
Farnborough
(1977)
Page 33
US National Transonic Facility (NTF) _1983
Page 34
European Transonic Windtunnel (ETW) _ 1994
Page 35
Best Aerodynamic Estimates Prior to Flight
Wind Tunnel Data
Comprises the Basic
Foundation of the
Aerodynamic
Database
Flight-Test-Derived
Increments
Improve the Fidelity
of the Database
On a Proven Aircraft ,
Wind Tunnel Testing
is an Inexpensive
Means to Estimate the
Aerodynamic Impact
of a New External
Store or Sensor
Protrusion
Analytical
Methods
Wind
Tunnel
Aerodynamic
Database
Flight
Test
Increasing
Fidelity & Cost
Page 36
Aerodynamic Modeling _ Delta Method
Page 37
Force and Moment Accounting System
Page 38
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 39
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 40
Wind Tunnel Test Hours _ De facto standard
Page 41
US Aerospace Industry Consolidation (’80s~’90s)
42
4
Page 42
New Aircraft Designs _ RAND TR-134 (2004)
Page 43
NASA’s Facility Reduction Program ( 2007~ )
Page 44
An Endangered Species _ AIAA 2007
Page 45
North American Aviation TWT
Page 46
NASA - LaRC East (2011)
Page 47
NASA - LaRC West (2011)
Page 48
NASA - LaRC Hypersonic Complex (2013)
Mostly
Closed
Page 49
NASA - ARC (2011)
Page 50
US Wind Tunnel Reduction (1985 ~ 2009)
Page 51
Ages of NASA Facilities (2010)
Page 52
AEDC and TVA - 2012
Page 53
CALSPAN Transonic _ built in 1947
Only Commercially Operating
Transonic WT in USA
Page 54
Demolition of RAE - Bedford _ UK
RAE _ DRA _ DERA _ QinetiQ Bedford
No more Indigenous
Fighter Development
Page 55
A-9b Compressor Casing is back _ 2004
Page 56
ONERA-S1MA _ New Blades (2008)
Page 57
ONERA-S2MA _ New Honeycomb (2005)
Page 58
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 59
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 60
Legacy (Mental) Differences
Page 61
Expanded CFD Role _ Boeing
Page 62
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 63
America’s Cup 1983 _ Australia II
Winged
Keel
Defender
USA
(1851 ~ 1980)
Tank
Testing
Page 64
America’s Cup 1987 _ Stars & Stripes
Hydrodynamics
- Wave Drag
- Keel(Fins)
- Bulb
- Wings
- Rudders
VSAERO
Aerodynamics
- Mast
- Sails
- Rigging
Page 65
CFD and Wind Tunnel Compliment
Page 66
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 67
High Performance Computing HW _ 2013
Machine Affiliation Processor Speed Power Remark
NUDT
Inspur
Tianhe-2
NSCC
Guangzho
u
16,000 nodes
Xeon Phi chips
3,120,000 cores
33.86
Petaflops
24
MW
China
Cray
Titan
Oak Ridge
Nat’l Lab
18,688 AMD
Opteron 6274
16-core CPUs
17.59
Petaflops
8.2
MW
IBM
Sequoia
Lawrence
Livermore
Nat’l Lab
98,304 nodes
16-core
PowerPC A2
16.32
Petaflops
7.9
MW
SGI
Pleides
NASA
Ames
162,496
Intel Xenon
2.87
Petaflops
2.35 +
MW
Upgraded
2013
Exaflops >100MW Current Tech
~ NTF power
Exaflops
~ 20
MW
By
2020
Page 68
CFD App. # 1 _ X-51A_Overview
Page 69
X-51A _ WT Test
Page 70
X-51A _ CFD
Page 71
Euler Calculation _ Example (CART3D)
Page 72
X-51A WT- CFD Correlation
Page 73
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 74
Ares-I CFD based DB Assessment
Page 75
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 76
DOE based Test Matrix
Page 77
Response Surface Method (RSM)
Page 78
OFAT and MDOE _ Accuracy & Resource
Page 79
Fusion of Experimental and CFD data(NEAR)
ARES-I Aero Data Base
Page 80
Efficient WT Test (High-Low Mix)
Ares-I Solid Rocket Booster Aero DB WT Test
Page 81
Ares - I SRB Aero DB WT Test
Page 82
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) Total Descent Total
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
Ascent
Ascent Testing Roundup (UOH)
Page 83
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 84
Pressure Sensitive Paint _ ADD 2010
Page 85
Missile Aero Paradigm Shift Initiation (2012)
AP
Configuration
DB by W/T
6-DOF
Bulk Data but High Cost Long time Large Man Hour
AP
Configuration
DB by CFD
Verification by W/T
HPC
6-DOF
OLD PROCESS NEW PROCESS
(AP: Aero Prediction)
Low fidelity High fidelity
Page 86
CFD Based Missile Aero DB _ 1st Experience
-5 0 5 10 15 20 25 30-0.2
0
0.2
0.4
0.6
Cx
Angle of attack, deg
-5 0 5 10 15 20 25 30-10
-5
0
5
Cy
Angle of attack, deg
M=0.8, phi=90.0
-5 0 5 10 15 20 25 30-10
0
10
20
30
Cz
Angle of attack, deg
-5 0 5 10 15 20 25 30-0.5
0
0.5
1
Cl
Angle of attack, deg
-5 0 5 10 15 20 25 30-60
-40
-20
0
20
Cm
Angle of attack, deg
-5 0 5 10 15 20 25 30-10
0
10
20
Cn
Angle of attack, deg
-5 0 5 10 15 20 25 30-0.2
0
0.2
0.4
0.6
Cx
Angle of attack, deg
-5 0 5 10 15 20 25 30-10
-5
0
5
Cy
Angle of attack, deg
M=0.8, phi=90.0
-5 0 5 10 15 20 25 30-10
0
10
20
30
Cz
Angle of attack, deg
-5 0 5 10 15 20 25 30-0.5
0
0.5
1
Cl
Angle of attack, deg
-5 0 5 10 15 20 25 30-60
-40
-20
0
20
Cm
Angle of attack, deg
-5 0 5 10 15 20 25 30-10
0
10
20
Cn
Angle of attack, deg
T1202, RUN19928
Euler Code Prediction
1701 pts calculation
4 weeks / 3 users
243 equivalent runs
Page 87
Rolling Moment _ M=1.4, = 16
Page 88
Aero Data Base _ Now and Future
Time has come for COMSAC !
Page 89
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 90
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 91
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 92
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 93
Thank You for Listening !
Page 94
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