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July7 1o
July7 1o
Qunzhen Wang
ATK Thiokol Propulsion
P.O. Box 707, M/S 252
Brigham City, UT 84302
38th AIAA/ASME/SAE/ASEE
Joint Propulsion Conference and Exhibit
July7-1o,2002
Ind=anapol_s, Indiana
I III
For permission to copy or to republish, contact the American Institute of Aeronautics and Astronautics,
1801 Alexander Bell Drive, Suite 500, Reston, VA, 20191-4344.
Assessment of Various Flow Solvers Used to Predict the Thermal
Environment Inside Space Shuttle Solid Rocket Motor Joints
Qunzhen Wang §
ATK Thiokol Propulsion Corp., Brigham City, UT
1
American Institute of Aeronautics and Astronautics
(5) transient
flowwithareachange, (6)transientflow
withheattransfer, (7)transient
flowwithareachange,
CapoA , ]27(p_)2'r[1 (p_l _r-'''r-
friction,andheattransfer,
and(8)volumefilling.
Thedetailsofvarious
flowsolversarediscussed
innext
section
followedbythecomparison ofpredictions
from If the pressure ratio PJPo is smaller than the critical
various
flowsolverswiththeexactsolutions. pressure ratio, the flow is choked and the mass flow rate
is obtained from
NUMERICAL METHODS
y+l
V = M, y.ff-_, (4) where % is the wall shear stress and V,, is the bulk
velocity inside the flow path. In general, the loss
parameter K should also include pressure loss due to
sudden expansion or contraction and turns or bends in
(5) the flow path.
(6)
T_ =7"o(1 -1 _ -i 7"
Lapple Method
A= 1--2---1
1+ K (13)
For steady adiabatic flows in a pipe with constant cross-
2 section area and no mass addition, Lapple J° derived a
C__
method to calculate the mass flow rate as
(1 + K)(y- 1) 2 (14)
3 37/-1
B__
(15) (18)
(l+K)(7-1) (y-l) 2
The mass flow rate is then obtained from In particular, for K>200, the mass flow rate is calculated
by
Y
t'_[ x,0.1522-0.O451p_/po+O.3275(pb/Po)"
The Mach number M in equation (17) is the choked Note that, similar to the ORING2 method, iteration
Mach number Mc if the back pressure to inlet stagnation methods should also be applied for calculating the mass
pressure P_Po is smaller than the critical pressure ratio flow rate due to the fact that the loss factor usually
and is the unchoked Mach number Me if the flow is not depends on the mass flow rate. The Lapple method also
choked. It can be shown that, for flows with no form does not take into account the effects of heat transfer
loss (i.e., K=0), equation (17) is identical to equations and mass addition when the mass flow rate is calculated.
(7) and (8) of the isentropic method.
Figure 1 and Figure 2 show the mass flow rate for
Note that the ORING2 method does not take into
different pressure ratios as well as loss factors. The ratio
account the effects of heat transfer and mass addition
of specific heats used in these figures is 1.4. As
when the mass flow rate is calculated using equation expected, the flow rate increases with decreasing
(17). Note also that, in real problems, the loss factor is friction and with decreasing pressure ratio but the flow
usually a function of mass flow rate and, thus, an rate is constant for very large friction or small back
iteration method has to be applied to calculate the mass pressure due to choking.
flow rate from equation (17). In SFLOW, a loss factor is
first guessed and then equation (17) is used to calculate
the mass flow rate. A new loss factor is obtained from
this mass flow rate and equation (17) is applied again to
_ 1,5
1.__
t.-,
"_ I£
"_ 1.[ <
<
g
-°- K=5 "', :.
E
02 .... K=100 - 0.5
.... K= 1000 "_ \
II
0.£ o I i | - - -
Figure 1: Mass flow rate vs. pressure ratio for different Figure 3: Comparison of mass flow rate vs. pressure
loss factors in the Lapple method, ratio for isentropic and Lapple methods.
The mass flow rate vs. pressure ratio from ORING2 and
].0t • • • i • • • i • • • ! • • ' ! • " '
Lapple methods for different loss factors are compared
L
in Figure 4 and Figure 5 with a specific heat ratio of 1.4.
0.8 In general, the ORING2 method predicts a mass flow
_ p_b/p_0=0 rate smaller than that from the Lapple method.
...... p_b/p (_-'0.25
"¢ 0.6 --° p b/p_0=0.5
_ .... p_b/p (_-'0.75
• • • ! , • • i • , , i , • • ! , • ,
0.4
-.3
E
............................ --_
0.2 p_b,r_o=o.9s 1
I- .................................. L-.'."=..............
0.0/ _:--:-.;-.;-..:
0 200 400
K
.'"," ," :"
6O0 800 10_ < ..... .........
c 02
Lapple K 5 •
--- ORING2 K=I
Figure 2: Mass flow rate vs. loss factor for different .... ORING2 K=5
0,15
< tni+ 1 = rh i + rn. i (25)
k
= 0.I0
0.05
........... ZTZ.:::::::............
_'72.7::::::::::
where q, and m,.i are the heat transfer and mass addition
to the gas at cell i. For a real problem, the inlet Mach
number is usually unknown and the known values are
0,00 • , , i . . . ! . , ° i , , - i . . .
0,0 0.2 0.4 0.6 0.8 1.0 the stagnation pressure and temperature at the inlet and
p_blp 0 the back pressure at the outlet. Moreover, the friction
factor, heat transfer, and mass addition are often
functions of mass flow rate. Therefore, an iteration
Figure 5." Comparison of mass flow rate vs. pressure
ratio from ORING2 and Lapple methods for K= 100 and method has to be applied to calculate flow properties
K= I O00. using the generalized method. In SFLOW, the inlet
Mach number is first guessed, the friction factor, heat
Generalized Method transfer, and mass addition are then evaluated• Next,
equation (21) is solved for Mach number at every flow
Both the ORING2 and Lapple methods discussed above cells using the forth-order Runge-Kutta method. Finally,
do not take into account the effects of heat transfer and the pressure and temperature at every cell are calculated
mass addition when the mass flow rate is calculated. A from equations (22) and (23). The process is repeated
until the outlet pressure matches the known value.
generalized steady flow equation relating the Mach
number and area change, friction, heat transfer as welt
SHARP Method
as mass addition parameters can be derived as
b__Q_Q
+ a___E_E
=S (26)
at Ox
Q=A u (27)
Toi< l+_1Mi21
• ( z .)_ (23)
5
American Institute of Aeronautics and Astronautics
should also be correct for steady flows. Note that, unlike
the generalized method, no iteration is needed since the
(28) mass flow rate is calculated separately before the
generalized steady equation is solved.
a
(e+p)uJ
.1 (29)
problems where the inlet stagnation pressure
temperature as well as the outlet pressure are know. The
area of the pipe as well as the magnitudes
and
of friction,
heat transfer, and mass addition are also specified. The
Mach number, pressure and temperature inside the pipe
The source term in equation (26) is
are calculated using various methods discussed above.
The gas in all test problems is assumed to be perfect gas
rhA with a specific heat ratio of 1.4 and gas constant-of 287
v m2/s2-K.
fApu lu l
S _ (30)
2D
Steady Flow with Area Change
•a ;API.I'
-qv 2D The following adiabatic frictionless steady flow
problem with no mass addition is considered in this
where V is the volume of the flow cell. section. Air at stagnation pressure of 0.1215 MPa and
temperature of 368.34 K enters a nozzle having a cross-
Note that, unlike the other solvers, both SHARP and section area of
generalized methods do not solve the mass flow rate
directly. Instead, the Mach number, pressure, and A- C3 (31)
temperature in the flow path are calculated and the mass Cox + C2
flow rate can then be obtained as th = pAu. Note also
that the predicted mass flow rate from SHARP is not The axial distance of the nozzle is from x=-0 to x=20 m.
necessary constant at different cells of a flow path The constants C3=1 and C2=100. Two cases are studied:
whereas all other four methods predict the same mass (1) Co =1 and outlet pressure of 84.63 kPa for the
flow rate at different cells.
converging nozzle and (2) Co=-I and outlet pressure of
132.41 kPa for the diverging nozzle.
Pressure, Temperature_ Mach number in Flow Path
The Mach number and pressure distribution inside the
The isentropic, Lapple and ORING2 methods only give converging nozzle predicted by isentropic, ORING2,
a way to calculate the mass flow rate in the flow path. Lapple and generalized methods are compared with the
For the solid rocket joint simulations, the pressure, exact solution in Figure 6 and Figure 7, respectively.
temperature and Mach number in the flow path are also Note that a discharge coefficient of unity is applied for
needed to calculate the heat transfer from the hot
the isentropic method. It is evident that the predict Mach
combustion gas to the cold solid surfaces. In this paper, number and pressure from isentropic method, ORING2,
the pressure, temperature and Mach number in the flow and generalized methods agree very well with the exact
path for these methods are calculated by the generalized solution. For the Lapple method, the predicted Mach
method using the calculated mass flow rate. number is slightly smaller whereas the pressure is
Specifically, the inlet Mach number is obtained from the slightly larger than the exact solution because of the
inlet pressure and temperature as well as the mass flow lower predicted mass flow rate as suggested in Figure 3.
rate. Then the generalized steady flow equation (21) is
solved to obtain the Mach number at every flow cell.
Next, the pressure and temperature at every cell inside
the flow path are calculated from equations (22) and
(23). This way, if the mass flow rate calculated is
correct, the Mach number, pressure and temperature
0.70
.... 20 cells
0.65 0.65
z Z
.c
_ generahzed
_ 0.60 2_ 0.60
0"5'
F- ° oe c, 1
0.501 .... i .... * .... I .... , 0.50 .... i . , , , i , , . . t ....
0 5 l0 15 20 5 l0 15 20
x (m) x _m)
Figure 6: Comparison of Mach number predicted from Figure 8: Comparison of Mach number predicted from
different methods with the exact solution. SHARP with different number of cells and the exact
solution.
....... Lapple
0.09(3
0.09(
0.085 .'.l_
.... J _ i , , -- , • -
5 10 15 20
0.0_
x (m) 5 10 15 20
x (m)
08£
.... i .... ! .... f ....
0.75
0,65
za_ 07el __'_t n.... [] exacttSentr°plc
0.6£ .... 20 cetk_
0 D exact
0.55
0.f£
0.5{ | . . . ! .... I , , , - i ....
5 t0 15 2O
x (m)
x (m)
Figure 12: Comparison of Mach number predicted from
SHARP with different number of cells and the exact
Figure 10: Comparison of Mach number predicted from solution for the diverging nozzle.
different methods with the exact solution for the
diverging nozzle.
0'135 I .... i .... i .... i .... .
O. 130 I
0"1356 .... _ .... ) .... _ .... t
0.1_1
0,120"
0'125 I
0.130[ _-
0.115
01_"
_
,_ 0.115
/ .... O. 105 ;; 27
o.o .I 2;27 0.1(_ a - - - a .... t • • - - i ....
0 5 10 15 20
0.105 / x (m)
0 5 10 15 20
x (m)
Figure 13." Comparison of pressure predicted from
SHARP with different number of cells and the exact
Figure 11: Comparison of pressure predicted from solution for the diverging nozzle.
different methods with the exact solution for the
diverging nozzle. Steady Flow with Friction
Figure 12 and Figure 13 show the Mach number and The following adiabatic steady flow problem with no
pressure distribution for the diverging nozzle predicted area change and no mass addition is considered in this
by the SHARP method, respectively. Similar to the section. Air enters a pipe at a stagnation pressure of
diverging nozzle, the predicted Mach number and 0.1007 MPa and temperature of 300.6 K. This pipe has
pressure using 200 flow cells agree very well with the a diameter of 0.1 m, length of 274.385 m, and friction
exact solution whereas the predictions with 20 cells are factor of 0.024. The pressure at the pipe exit is 19.54
not as good. That is, more flow cells are usually kPa.
required to obtain accurate results using SHARP than
other methods. The Mach number and pressure distribution predicted
by SHARP, ORING2, Lapple and generalized methods
are compared with the exact solution in Figure 14 and
Figure 15, respectively. It is evident that the predict
8
--- cd=0,174
0.6/ .... u .... i .... I .... I .... n ,j,
i
0 tl exact _j
E_ 03C /-
e Z
SHARP l
0.4
......
---
.... oRiNo:
generalized
Lapple
'1
l
d
z;
03£
...J.
t,-u D exact tI
E
O.IC
, , . , .... t .... ! . , . . i .... i . o
..... generalized
_" 0.04
-o- Lapple _,%'_
0.02/, . • • , .... t .... a .... , .... , ._1
.... ORING2 0 50 100 150 200 250
0.02 O 0 exact x (m)
Figure 16 and Figure 17 show the Mach number and The following frictionless steady flow problem with no
pressure distribution predicted by the isentropic method, area change and no mass addition is considered in this
respectively. Since this method does not take into section. Heat is added to a pipe with a diameter of 0.01
account the effect of friction when the mass flow rate is m and length of 20 m at a rate of 200 J/re. Air enters
calculated, a discharge coefficient smaller than unity this pipe at a stagnation pressure of 0.1007 MPa and
should be applied to obtain the correct mass flow rate. temperature of 300.6 K. The pressure at the pipe exit is
9
....... cd=0.034
0._ .... ! .... ! .... l ....
0._
0
......
---
....
0
gener',dized
Lapp_e
ORING2
exact .._.:.'-:"'0
., ,.,;_,_'2"""
..ff.
,.,;_.'.-';"" -
" 0
z 0.4
..°.o.°.°.°.°°°°°'°.
.......... .::.Z.Z:.Z-Z
0.2
()(_ .... I • • , * I * * I " I ....
5 I0 15 20
x _m)
0.0
0 5 10 15 20
x (m)
Figure 20: Comparison of Mach number predicted from
the isentropic method with different discharge
Figure 18: Comparison of Mach number predicted from coefficients and the exact solution.
different methods with the exact solution.
0.100
0.090
0.090
o oHo
0.08C
...... genevahzed "'¢:_._.
--- Lapple "'._.?_ --- cd=0.02
0.070
.... ORING2 "".'_'_ 0 0 exact
O.07G t] [] exact ",,._
-%-
0.(_: .... i . . • , I . - . - | ....
5 10 15 2O
006C , • • . , .... , .... ' .... :
x(m)
5 10 15 20
x (m)
10
5 i0 15 2O
Figure 23, respectively. The predict Mach number and x (m)
from ._
0I
0.8
0.6
.... cd=O.02 / ,
04
0.2
0 0"40 I_ 0"40 I_ 1_40 0"4D B'O _ 0 0 0
. ....j.._ ,....- r', "" "' ._- I''n_''_'v'_r'-'_''''''_'_r
5 10 15 20
x (rn)
11
• , • i , • • J , • • i • • • i • • •
p = Const
200 _ _ SHARP
p = const ...... generalized
(32)
2C0 (Cox + C2) _. --- Lapple
U_----
.... ORING2
2Cot + CI N _ a a exact
whereas the velocity and pressure inside the nozzle are Tm'ae (s)
calculated.
12
"d "%
>
250
10(3
*',t_ --
...... cd=l.0
cd=l.15
......
2"2222 200
_ --- cd=l.3
, , I - - • I . • • I , , • i . . . ",h D
100
0.095 . . . i . . , , • • • , • • • ' -
0,0 0.2 0.4 0.6 0.8 1.0
Tmqe (s)
Figure 30: Comparison of outlet velociO, predicted from
the isentropic method with different discharge
Figure 28." Comparison of inlet and outlet pressure coefficients and the exact solution.
predicted by SHARP and generalized methods with the
exact solution. The velocity at the inlet and outlet from ORING2,
Lapple, SHARP, and generalized methods are compared
Figure 29 and Figure 30 show the velocity at the inlet with the exact solution in Figure 31 and Figure 32,
and outlet from the isentropic method compared with respectively, for the diverging nozzle problem. Similar
the exact solution. As expected, the predicted velocity is to the converging nozzle problem, the velocity predicted
larger for larger discharge coefficient. Unlike the by SHARP method agrees very well with the exact
13
0.095
300 • , • ! • • . ! . . • | • . , I ' 7 "
l
/
/ 0.090
SHARP / "
0.0 0.2 0.4. 0.6 0.8 1.0 predicted by SHARP and generalized methods with the
Time (s)
exact solution for the diverging nozzle.
Figure 31: Comparison of inlet velociO' predicted by Figure 34 and Figure 35 show the velocity at the inlet
various flow solvers with the exact solution for the and outlet from the isentropic method compared with
diverging nozzle. the exact solution. As expected, the predicted velocity is
larger for larger discharge coefficient. Unlike the
steady-state problems, however, there is no single value
250 • , • i • • • I , • • I • • " i • • •
of discharge coefficient which matches the exact
velocity. A time dependent discharge coefficient near
m SHARP
0.8 could be used to match the outlet velocity at
200 ...... generalized I
different times, but the predicted inlet velocity using
:.-: // this discharge coefficient will not match the exact
solution.
.=
:a
150 ,.I"
>
100
5(
0.0
• • .
0.2
I , , • i
0.4
. . . I
0.6
. . .
08
I . . .
1.0
, ..............
__......_
_.......6,0
.....7'..
";1
.' n n exact so ,.. []
Time (s)
2-
f........
_cd0........
,'°t ......
**-
cd=0.g
cd=l.0
•
,,/
/
[I .."
.:
::
whereas those from Lapple and generalized
not agree well. For ORING2
with a discharge coefficient
and isentropic
methods do
15
[]
0.2
_,_.O'tl,.,11..g . X X X X X X
0.(] • , - i . . . i . , , I , - - i . . . o.o_
0.0 0.2 0.4 0.6 0. g 1.0
0,0 0.2 0.4 0.6 0.8 1.0
Tune (s)
Ttn_ (s)
Figure 38: Comparison of inlet and outlet Mach number Figure 40: Comparison of inlet and outlet Mach number
predicted from the Lapple method with the exact predicted from isentropic method with different
solution. discharge coefficients and the exact solution.
1
x-_...._.
_le "_" x-_..,x ,x. A = (36)
0._ C4 e xp (- _-7_l x l+ _vC-_Dr
4
(37)
0.( • . t . , . ! . • . i . . . ! • . • f = 4cl(C, exp(- _3/-_-_tx)+ C_,[_)
0.0 0.2 0.4 0.6 0.8 1.0
Ta"ne (s)
Figure 39." Comparison of inlet and outlet Mach number q =-_/_-1 / " _ / (38)
predicted from the ORING2 method with the exact
solution. the exact solution is
p = const
t_ = const
(39)
U _
C: t + C 3
300 • • • i • , • i , • , i , • • i • • •
-- SHARP
25O 100
...... gcneratt/,ed
Y
--- Lapple
(I,(.XX)
........ i .........
O,OlO
i .........
0,020
i .........
0030 (L(HO
| ....... .--
00__)
Tune (s)
f'"% ..
c. "'%
17