diminishing test resources and aerodynamic data base generation

Diminishing Test Resources

and

Aerodynamic Data Base Generation

2013. 12. 5

안 승 기

국방과학연구소

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 ………

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

Swept-back wing by Adolf Busemann

German Secret Weapons

V-1

V-2

Me-262

Me-163

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

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)

USAAF Scientific Advisory Group (1945)

Hugh L.

Dryden

Ludwig

Prandtl

Theodor

von Karman

Tsien

Hsue Shen

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

Supersonic WTs at Peenemünde / Kochel

Tunnels installed at Kochel

V-2 Model

Rudolf Hermann

Wind Tunnels at Vö lkenrode - Braunschweig

George Schairer & XB-47 Configuration

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…).

Engine Altitude Test Chamber (BMW)

Messerschmitt Project P1101 (Oberammergau)

X-5

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).

ONERA-S1-MA (1952) _ France

860m

ONERA-S2-MA _ France

Dismantling of Vö lkenrode A-9 Tunnel _UK

NAE(RAE) – Bedford _ UK

3ft x 4ft

HSST

Vertical

Spin

Tunnel

13ft x 9ft

LSWT

8ft x 8ft

HSWT

3ft SWT

Breaking the Sound Barrier

October 14, 1947

Chuck Yeager

Bell X-1

Arnold Engineering Development Center(1951)

AEDC_ETF_Complex (2011)

AEDC Propulsion Wind Tunnels (PWT)

Naval Ordnance Lab - White Oak MD

Clash of Winds _ Korean War (1950)

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".

Aircraft Research Association (1956)

NLR-HST (1960)

Von Kármán changed the Max Mach

number from 0.95 to 1.3

DLR _ Germany (1960s)

Trisonic WT

0.6m x 0.6m

Köln- Portz(1965)

Transonic WT

1m x 1m

Göttingen (1963)

NAL(JAXA) 2m Transonic WT (1960)

High RN Low Speed Wind Tunnels (’70s)

DNW

LLF(1980)

ONERA

Fauga-

Mauzac

(1974)

RAE

Farnborough

(1977)

US National Transonic Facility (NTF) _1983

European Transonic Windtunnel (ETW) _ 1994

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

Aerodynamic Modeling _ Delta Method

Force and Moment Accounting System

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

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 %

Wind Tunnel Test Hours _ De facto standard

US Aerospace Industry Consolidation (’80s~’90s)

42

4

New Aircraft Designs _ RAND TR-134 (2004)

NASA’s Facility Reduction Program ( 2007~ )

An Endangered Species _ AIAA 2007

North American Aviation TWT

NASA - LaRC East (2011)

NASA - LaRC West (2011)

NASA - LaRC Hypersonic Complex (2013)

Mostly

Closed

NASA - ARC (2011)

US Wind Tunnel Reduction (1985 ~ 2009)

Ages of NASA Facilities (2010)

AEDC and TVA - 2012

CALSPAN Transonic _ built in 1947

Only Commercially Operating

Transonic WT in USA

Demolition of RAE - Bedford _ UK

RAE _ DRA _ DERA _ QinetiQ Bedford

No more Indigenous

Fighter Development

A-9b Compressor Casing is back _ 2004

ONERA-S1MA _ New Blades (2008)

ONERA-S2MA _ New Honeycomb (2005)

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

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

Legacy (Mental) Differences

Expanded CFD Role _ Boeing

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

America’s Cup 1983 _ Australia II

Winged

Keel

Defender

USA

(1851 ~ 1980)

Tank

Testing

America’s Cup 1987 _ Stars & Stripes

Hydrodynamics

- Wave Drag

- Keel(Fins)

- Bulb

- Wings

- Rudders

VSAERO

Aerodynamics

- Mast

- Sails

- Rigging

CFD and Wind Tunnel Compliment

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

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

CFD App. # 1 _ X-51A_Overview

X-51A _ WT Test

X-51A _ CFD

Euler Calculation _ Example (CART3D)

X-51A WT- CFD Correlation

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

Ares-I CFD based DB Assessment

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

DOE based Test Matrix

Response Surface Method (RSM)

OFAT and MDOE _ Accuracy & Resource

Fusion of Experimental and CFD data(NEAR)

ARES-I Aero Data Base

Efficient WT Test (High-Low Mix)

Ares-I Solid Rocket Booster Aero DB WT Test

Ares - I SRB Aero DB WT Test

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)

Test Quality Enhancement

Test Techniques for Verification & Validation

- High density measurement techniques

- Nonintrusive measurements

- Detailed model representation and surface

finish

- Inclusion of Aeroelastic Effects

Pressure Sensitive Paint _ ADD 2010

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

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


M=0.8, phi=90.0

-5 0 5 10 15 20 25 30-10

0

10

20

30

Cz


-5 0 5 10 15 20 25 30-0.5

0

0.5

1

Cl


-5 0 5 10 15 20 25 30-60

-40

-20

0

20

Cm


-5 0 5 10 15 20 25 30-10

0

10

20

Cn


-5 0 5 10 15 20 25 30-0.2

0

0.2

0.4

0.6

Cx


-5 0 5 10 15 20 25 30-10

-5

0

5

Cy


M=0.8, phi=90.0

-5 0 5 10 15 20 25 30-10

0

10

20

30

Cz


-5 0 5 10 15 20 25 30-0.5

0

0.5

1

Cl


-5 0 5 10 15 20 25 30-60

-40

-20

0

20

Cm


-5 0 5 10 15 20 25 30-10

0

10

20

Cn


T1202, RUN19928

Euler Code Prediction

1701 pts calculation

4 weeks / 3 users

243 equivalent runs

Rolling Moment _ M=1.4, = 16

Aero Data Base _ Now and Future

Time has come for COMSAC !

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

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

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

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

Thank You for Listening !

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diminishing test resources and aerodynamic data base generation

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