ABSTRACT Title of Document: MULTIDISCIPLINARY OPTIMIZATION OF NON-SPHERICAL, BLUNT-BODY HEAT SHIELDS FOR A PLANETARY ENTRY VEHICLE Joshua E. Johnson Master of Science, 2006 Directed By: Professor Mark J. Lewis Department of Aerospace Engineering Gradient-based optimization of the aerodynamic performance, static stability, and stagnation-point heat transfer has been completed to find optimal heat shield geometries for blunt-body planetary entry vehicles. In the parametric study, performance trends have been identified by varying geometric parameters that define a range of cross-sections and axial shapes. Cross-sections considered include oblate and prolate ellipses, rounded-edge polygons, and rounded-edge concave polygons. Axial shapes consist of the spherical-segment, spherically-blunted cone, and power law. By varying angle-of-attack and geometric parameters, the aerodynamics, static stability, and heat transfer are optimized based on Newtonian impact theory with semi-empirical shock-standoff distance and stagnation-point heat transfer correlations. Methods have been verified against wind tunnel and flight data of the Apollo Command Module and are within 15% for aerodynamic coefficients and stagnation-point heat fluxes. Results indicate that oblate parallelogram configurations provide optimal sets of aerothermodynamic characteristics. MULTIDISCIPLINARY OPTIMIZATION OF NON-SPHERICAL, BLUNT-BODY HEAT SHIELDS FOR A PLANETARY ENTRY VEHICLE By Joshua E. Johnson Thesis submitted to the Faculty of the Graduate School of the University of Maryland, College Park, in partial fulfillment of the requirements for the degree of Master of Science 2006 Advisory Committee: Professor Mark J. Lewis, Chair Professor Roberto Celi Associate Professor James Baeder ? Copyright by Joshua Elijah Johnson 2006 ii Dedication To my parents John and Caroline who have given me immeasurable knowledge in life and have encouraged me to be a part of furthering human space exploration. To my sisters Justine and Lucia Maria who are just starting out in this world. iii Acknowledgements I would like to express my gratitude to Dr. Mark Lewis for the opportunity to conduct this research, who through his achievements in the field of hypersonics, has inspired me to strive forward in my studies and aerospace career. I would like to thank Dr. Ryan Starkey for his endless patience and time given in assisting me with my research. I would also like to thank the other members of my committee Dr. Roberto Celi, who taught me gradient- based optimization theory, and Dr. James Baeder, who taught me the basic theories of computation fluid dynamics. I also would like to acknowledge the NASA funding that supported this work. This research was supported by the Space Vehicle Technology Institute (SVTI), one of the NASA Constellation University Institute Projects (CUIP), under grant NCC3-989, with joint sponsorship from the Department of Defense. Appreciation is expressed to Dr. Ken Yu, director of the SVT Institute at the University of Maryland, Claudia Meyer of the NASA Glenn Research Center, program manager of CUIP, and to Dr. John Schmisseur and Dr. Walter Jones of the Air Force Office of Scientific Research, the support of whom is greatly appreciated. Finally, I would like to thank my fellow SVTI graduate students, who have given me friendship and support, and especially to Adam Dissel for the early hours of company and learning that has greatly enhanced my graduate school experience. iv Table of Contents Dedication?..............................................................................................................ii Acknowledgements................................................................................................iii Table of Contents.....................................................................................................iv List of Tables.............................................................................................................vi List of Figures.........................................................................................................vii List of Symbols..........................................................................................................x Chapter 1. Introduction.......................................................................................1 1.1. Motivation.....................................................................................................1 1.2. Previous Work..............................................................................................2 1.2.1. Heat Shield Geometries........................................................................2 1.2.2. Heat Transfer......................................................................................12 1.2.3. Misconceptions...................................................................................17 1.3. Research Objectives....................................................................................19 1.4. Thesis Overview.........................................................................................20 Chapter 2. Blunt-Body Heat Shield Geometries...........................................22 2.1. Axial Shapes...............................................................................................22 2.1.1. Spherical-segment...............................................................................23 2.1.2. Spherically-blunted Cone....................................................................25 2.1.3. Power Law..........................................................................................25 2.2. Cross-section Shapes..................................................................................27 2.3. Generating Blunt-Bodies............................................................................29 2.4. Geometric Properties..................................................................................32 Chapter 3. Aerodynamics and Static Stability..............................................37 3.1. Modified Newtonian Impact Theory..........................................................38 3.2. Shock-standoff Distance: Kaattari?s method..............................................44 3.2.1. Method Implementation......................................................................45 3.2.2. Accounting for Nonaxisymmetric Shapes & Angle of Attack...........53 3.3. Static Stability.............................................................................................61 3.4. Correcting Misinterpretations.....................................................................64 3.4.1. Static Roll Stability Requirement.......................................................64 3.4.2. Determining the Location of the Center of Pressure..........................66 Chapter 4. Heat Transfer...................................................................................69 4.1. Convection..................................................................................................70 4.2. Radiation.....................................................................................................73 Chapter 5. Description of Code and Optimization Process........................77 5.1. Code Layout................................................................................................77 5.2. Design Optimization Tools (DOT).............................................................80 5.3. Choosing Objective Functions....................................................................82 Chapter 6. Design Code Validation................................................................85 6.1. Aerodynamics and Static Stability..............................................................85 v 6.1.1. Comparison with Apollo Wind Tunnel Data......................................86 6.1.2. Comparison with Apollo Flight Test Data..........................................90 6.1.3. Comparison with Additional Sources.................................................93 6.2. Stagnation-Point Heat Transfer...................................................................94 6.2.1. Apollo 4..............................................................................................95 6.2.2. FIRE II..............................................................................................102 Chapter 7. Parametric Analysis......................................................................105 7.1. Selecting a Superelliptical Base................................................................105 7.2. Heat Shield Shapes and Aerodynamic Performance................................106 7.3. Hypersonic Aerodynamic Performance and Stability...............................109 7.4. Effect of Eccentricity on Aerodynamic Performance...............................115 7.5. Comparison of Aerothermodynamic Performance on Two Heat Shields 119 Chapter 8. Optimal Configurations..............................................................126 8.1. Maximizing LV/D and ?VLV/D.................................................................132 8.2. Maximizing (LV/D)/qs,tot...........................................................................138 8.3. Minimizing qs,tot........................................................................................141 8.4. Minimizing Cm,cg,?.....................................................................................146 8.5. Limitations of this Optimization...............................................................150 Chapter 9. Conclusions....................................................................................152 9.1. Summary of Results..................................................................................152 9.1.1. Parametric Analysis..........................................................................152 9.1.2. Optimization Results.........................................................................153 9.2. Suggestions for Future Work....................................................................155 Appendix A: Optimization Iteration Histories...............................................158 A.1 Maximizing LV/D and ?VLV/D.................................................................158 A.2 Maximizing (LV/D)/qs,tot...........................................................................161 A.3 Minimizing qs,tot........................................................................................163 A.4 Minimizing Cm,cg,?.....................................................................................165 Bibliography..........................................................................................................167 vi List of Tables Table 2.1. Superformula parameters for rounded-edge polygons (n3 = n2)................28 Table 5.1. Most useful objective functions.................................................................83 Table 5.2. Questionable objective functions...............................................................84 Table 5.3. Objective functions to use with caution.....................................................84 Table 6.1. Percent error of Newtonian computations compared to wind tunnel data, M? = 9, in Ref. [9], Percent error averaged over -30o ? ? ? 0o...........................89 Table 6.2. Comparison of Apollo AS-201 Data and Computations, M? = 14, ? = - 16.5o at 4900 s.....................................................................................................91 Table 6.3. Comparison of Apollo 4 Data and Computations, M? = 30, ? = -25o at 30040 s................................................................................................................92 Table 6.4. Apollo 4 Comparison of Total Heat Transfer..........................................100 Table 7.1. Variable ranges and constants for each axial shape.................................108 Table 7.2. Effects of geometric parameters and ? on aerodynamic performance....111 Table 7.3 Aerodynamic comparison of spherical-segments (? = 5o)........................118 Table 8.1. Optimization design variables with side constraints................................127 Table 8.2. Initial and Optimal Designs for maximizing LV/D for different m..........133 Table 8.3. Aerothermodynamic comparison of LV/D and ?VLV/D results at M? = 32.8255 (m = 4).................................................................................................136 Table 8.4. Aerothermodynamic comparison of (LV/D)/qs,tot results at M? = 32.8255 (m = 4)....................................................................................................................139 Table 8.5. Aerothermodynamic comparison of qs,tot results at M? = 32.8255 (m = 4). ...........................................................................................................................143 Table 8.6. Aerothermodynamic comparison of Cm,cg,? results at M? = 32.8255 (m = 4). ...........................................................................................................................148 Table A.0.1. Optimized (LV/D)/qs,tot for M? from 30 to 41, m = 4...........................162 Table A.0.2. Optimized qs,tot for M? from 30 to 41, m = 4......................................164 vii List of Figures Figure 1.1. The two most familiar heat shield geometries............................................3 Figure 1.2. Apollo 4 Trajectory from Ref. [7]..............................................................4 Figure 1.3. Viking Landing Capsule System from Ref. [19]........................................6 Figure 1.4. Raked cone from Ref. [21].........................................................................7 Figure 1.5. AFE flight vehicle configuration from Ref. [21]........................................8 Figure 1.6. Bent biconic configuration from Ref. [24].................................................9 Figure 2.1. Fixed-body coordinate system, spherical-segment, ? = 30o, ?s = 60o, n2 = n3 = 2...................................................................................................................22 Figure 2.2. Spherical axial profiles and heat shields..................................................24 Figure 2.3. Power law axial shape..............................................................................26 Figure 2.4. Cross-section shapes produced using parameters from Table 2.1............29 Figure 2.5. Spherically-blunted cone, rn/d = 0.25, ?c = 70o, e = 0.95, m = 5, n1 = 1.75, n2 = 2...................................................................................................................31 Figure 2.6. Spherical-segment, ?s = 40o, e = -0.85, m = 12, n1 = 10.75, n2 = 1..........31 Figure 2.7. Power law, A = 3, b = 0.75, e = 0.5, m = 5, n1 = 1.75, n2 = 5..................31 Figure 3.1. Coordinate systems with positive ? and ? and moment conventions......37 Figure 3.2. Spherically-blunted cone profile shock-standoff distance variance.........58 Figure 3.3. Cl,cg,? distribution for spherical-segment, elliptical base (n2 = 2), varying e and ?s, ? = 20o, ? = 5o.........................................................................................65 Figure 3.4. Variation in Cm,cg with angle of attack.....................................................67 Figure 4.1. Stagnation-point shock-standoff distance wind tunnel data with empirical curve-fit, Ref. [48]..............................................................................................75 Figure 5.1. Diagram of Overall Code.........................................................................78 Figure 5.2. Diagram of Analysis Code.......................................................................79 Figure 6.1. Cm,cg comparison between modified Newtonian and wind tunnel data, Ref. [8]........................................................................................................................86 Figure 6.2. Cl,0 comparison between modified Newtonian and wind tunnel data, Ref. [8]........................................................................................................................87 Figure 6.3. Aerodynamic force comparisons between modified Newtonian and wind tunnel data, Ref. [8]............................................................................................88 Figure 6.4. Normal-shock density and specific heat ratios for the high radiative heat flux portion of the Apollo 4 trajectory................................................................95 Figure 6.5. Shock-standoff distance method comparison...........................................96 Figure 6.6. Apollo 4 reff for stagnation-point radiative heat transfer..........................97 Figure 6.7. Validation of radiative heat flux correlations for Apollo 4......................98 Figure 6.8. Apollo 4 radiative heat transfer code validation.......................................99 Figure 6.9. Apollo 4 Trajectory from Ref. [36]..........................................................99 Figure 6.10. Convective heat flux distribution of Apollo Command Module at ? = - 25o from Ref. [36].............................................................................................102 Figure 6.11. FIRE II Total heat flux comparison with flight data from Ref. [47]....103 Figure 7.1. Cm,0,? distribution varying m-gon and e with spherical-segment axial shape and rounded-edge concave cross-sections, ?=-20o, ? = 5o................................106 viii Figure 7.2. Chosen heat shield shapes for parametric analysis.................................107 Figure 7.3. Cm,0,? distribution for power law A and n2, b = 0.75, e = 0.5, ?=-20o, ? = 5o.......................................................................................................................109 Figure 7.4. Cm,cg,? distribution for power law A and n2, b = 0.75, e = 0.5, ?=-20o, ? = 5o.......................................................................................................................110 Figure 7.5. Effects of ?s, ?c (rn/d = 0.25), A (b = 0.75) on stability coefficients and derivatives, ? = -20o, ? = 5o..............................................................................113 Figure 7.6. Effects of ?s, ?c (rn/d = 0.25), A (b = 0.75), and b (A = 2) on ?v, ? = -20o, ? = 5o....................................................................................................................114 Figure 7.7. ?v distribution for spherical-segment, elliptical base (n2 = 2), varying e and ?s.................................................................................................................115 Figure 7.8. Cl,cg,? distribution for spherical-segment, elliptical base (n2 = 2), varying e and ?s, ? = 20o, ? = 5o.......................................................................................116 Figure 7.9. LV/D distribution for spherical-segment: elliptical base (n2 = 2), varying e and ?s, ? = 20o, ? = 5o.......................................................................................117 Figure 7.10. Spherical-segment ?s = 90o, e = -0.95 with an increase of 56% in LV/D. ...........................................................................................................................117 Figure 7.11. ,totsq& distributions for m = 4 and 6, spherically-blunted cone axial shape, ?c = 55o, rn/d =0.05, varying e and n2 = 1.3 to 2.3, M? = 32.8, ? = -20o.120 Figure 7.12. ,totsq& distributions for m = 4 and 6, spherically-blunted cone axial shape, ?c = 55o, rn/d =0.05, varying e and n2 = 1.3 to 4.0, M? = 32.8, ? = -20o...........121 Figure 7.13. LV/D distribution for m = 4 and 6, spherically-blunted cone axial shape, ?c = 55o, rn/d =0.05, varying e and n2 = 1.3 to 4.0, M? = 32.8, ? = -20o...........122 Figure 7.14. ,convsq& and ,radsq& distributions for parallelogram base (m = 4, n2 = 1.4 ), spherically-blunted cone axial shape, ?c = 55o, varying e and rn/d, M? = 32.8, ? = -20o....................................................................................................................123 Figure 7.15. ,totsq& distribution for parallelogram base (m = 4, n2 = 1.4 ), spherically- blunted cone axial shape, ?c = 55o, varying e and rn/d, M? = 32.8, ? = -20o....125 Figure 8.1. Optimized geometries from Table 8.2....................................................133 Figure 8.2. Optimized geometries from Table 8.3....................................................137 Figure 8.3. Maximized (LV/D)/qs,tot geometries from Table 8.4...............................140 Figure 8.4. Maximized (LV/D)/qs,tot results for M? = 30 ? 41..................................141 Figure 8.5. Minimum qs,tot configurations, spherical-segment axial shape..............142 Figure 8.6. Minimum qs,tot geometries from Table 8.5............................................144 Figure 8.7. Minimized qs,tot results for M? = 30 ? 41...............................................146 Figure 8.8. Minimum Cm,cg,? geometries (m = 4) in Table 8.6..................................147 Figure A.0.1. Iteration history for maximum LV/D hexagonal shape (m = 6) in Table 8.2......................................................................................................................158 Figure A.0.2. Iteration history for maximum LV/D power law/parallelogram (m = 4) in Table 8.3...........................................................................................................159 Figure A.0.3. Iteration history for maximum ?VLV/D spherically-blunted cone/parallelogram (m = 4) in Table 8.3...........................................................160 Figure A.0.4. Iteration history for maximum (LV/D)/qs,tot spherically-blunted cone axial shape (m = 4) in Table 8.4................................................................................161 ix Figure A.0.5. Iteration history for minimum qs,tot spherical-segment axial shape (m = 4) in Table 8.5...................................................................................................163 Figure A.0.6. Iteration history for minimum Cm,cg,? power law axial shape (m = 4) in Table 8.6...........................................................................................................165 Figure A.0.7. Iteration history for minimum Cm,cg,? spherical-segment axial shape (m = 4) in Table 8.6................................................................................................166 x List of Symbols A = Coefficient of power law Ab = Area of the base (m2) Ap = Planform area (m2) AFE = Aeroassist Flight Experiment a = Speed of sound (m/s) a1 = Semimajor axis length of a superellipse (m) a2 = Semimajor axis length of a blunt body(m) b = Exponent of power law b1 = Semiminor axis length of a superellipse (m) b2 = Semiminor axis length of a blunt body (m) C = Aerodynamic coefficient CEV = Crew Exploration Vehicle CFD = Computational fluid dynamics CM = Command Module, refers to Project Apollo unless noted otherwise DOT = Design Optimization Tools d = Diameter (m) d1, d2 = Distances from mesh point to point as indicated in the text d(j,k),(j+1,k) = Distance from mesh point (j,k) to point (j+1,k) dA = Differential surface area dAp = Differential planform area dr = Differential distance from mesh point to origin dV = Differential volume d? = Differential theta d? = Differential sweep angle E = Search direction for optimization e = Eccentricity FIRE = Flight Investigation of the Reentry Environment Gr = Vector of constraints Gq = qth constraint F = Integration of f with respect to x f = Function of x g1, g2, g3 = Radiation correlation parameters gw = Ratio of wall enthalpy to total enthalpy H = Correlation exponent h = Altitude (ft) = Step size j = Mesh point index in ?-direction jmax = Maximum mesh points in ?-direction k = Mesh point index in x-direction kmax = Maximum mesh points in x-direction l = Length of heat shield from nose to base (m) lb = Length from differential surface to base (m) xi lM = Length of the semimajor axis of the cross-section L/D = Lift-to-drag ratio MMFD = Modified Method of Feasible Directions M? = Freestream Mach number m = Number of sides of the superellipse in the superformula N = Total number of sections in which to divide the conical base NCON = Number of constraints NDV = Number of design variables n = Number of the section of the conical base n1, n2, n3 = Superelliptic parameters n? = Outward normal of a surface OBJ = Objective function O(Xr ) = Objective function as a function of Xr PEV = Planetary entry vehicle p = Index corresponding to a specific design variable Xp q = Index corresponding to a specific constraint Gq q? = Freestream dynamic pressure (Pa) sq& = Stagnation-point heat flux (W/m2) RCS = Reaction control system r = Base radius (m) rc = Corner radius (m) reff = Effective radius of curvature for radiative heat transfer (m) rn = Nose radius for spherically-blunted cone axial shape (m) rs = Radius of curvature for spherical-segment axial shape (m) rst = Length from the central axis to the stagnation point (m) rsh = Radius of curvature for the spherical shock (m) S = Surface area of cross-section (m2) Shs = Surface area of heat shield without base area (m2) SCRAMP = Slotted Compression Ramp TPS = Thermal Protection System u = Iteration number V? = Freestream velocity magnitude (m/s) Vhs = Volume of heat shield (m3) Vx, Vy, Vz = Freestream velocity components normalized by V? v = Exponent of superellipse equation WT = Wind tunnel w = Distance from point (j,k) to x-axis wv = Wind angle Xr = Vector of design variables Xp, in which p = 1 to NDV Xp = pth design variable x, y, z = Coordinate directions xs = The streamwise distance from the apex of the shock to the point on the shock at distance y* from the central axis ? = Angle-of-attack (deg) ?* = Scalar parameter for optimization ? = Sideslip angle (deg) xii ? = Ratio of specific heats ?so = Shock-standoff distance (ft) ? = Inclination on forward body surface at the tangent point with corner radius, also mentioned as tangency angle ?v = Volumetric efficiency (surface area comparison) ?c = Half-cone angle (deg) ?s = Half-spherical-segment angle (deg) ?* = Shock surface inclination at a point opposite of the sonic point on a body with respect to a plane normal to the freestream direction ?*o = Shock surface inclination at a point opposite of the sonic point on a flat disk ? = Lagrange multiplier ? = Density (kg/m3) ?* = Sonic angle of a blunt body, which is the body surface inclination of a blunt body at the sonic point with respect to a plane normal to freestream direction ?*1, = Sonic angle of a sphere ? = Sweep angle (rad) = Azimuth angle ? = Angle from x-axis and in the xy plane (rad) Subscripts 0 = Location at tip of nose, stagnation point, moments normalized by base diameter d 1 = Before the normal shock 2 = After the normal shock 75 = 75% of value assuming uniform density A = Axial force cg = Location of center of gravity conv = Convective cp = Location of center of pressure D = Drag eff = Effective H = Horizontal component with respect to the body j = xy-plane index L = Lift l = Rolling moment lower = Lower constraint value m = Pitching moment N = Normal force nd = Non-dimensionalized vector n = Yawing moment R = Resultant rad = Radiative sl = Sea level tot = Total xiii UD = Uniform density upper = Upper constraint value V = Vertical component with respect to the body Y = Side force ? = Derivative with respect to angle-of-attack (per rad) ? = Derivative with respect to sideslip angle (per rad) ? = Freestream conditions 1 Chapter 1. Introduction 1.1. Motivation A blunt-bodied planetary entry vehicle (PEV) requires a proper combination of aerodynamic performance, stability, and heat transfer for it to successfully follow its designed planetary entry trajectory. The simplest blunt-bodied planetary entry vehicle is the re-entry space capsule. It is covered with thermal protection material, with heat shield materials that can withstand very high temperatures on the surface of the vehicle that faces the freestream. The heat shield is designed to protect a majority of the vehicle from entry temperatures, and because the flow typically separates from the vehicle past the heat shield, its geometry generally defines the capsule?s hypersonic aerodynamic performance. The design also provides passive protection from entry flow disturbances that could destabilize the vehicle and endanger the astronauts, and active protection from rolling is also provided on human planetary entry vehicles with a reaction control system (RCS). The passive protection is acquired through the aerodynamic design of the heat shield, and it is common during an initial analysis for aerodynamic performance, stability and heat transfer characteristics to be satisfied mostly through the design of a vehicle?s heat shield. Blunt-bodied capsules, such as the one that will be used by NASA?s Crew Exploration Vehicle (CEV), will re-enter Earth?s atmosphere at high hypersonic velocities, with projected Mach numbers ranging from 30 to 50. Such high Mach numbers deliver high heat fluxes greater than 300 W/cm2 along the frontal surface 2 and heat loads greater than 30000 J/cm2. Since it is not clear that the classic spherical- segment1 or spherically-blunted cone2,3 provides optimal aerothermodynamic performance, executing an optimization on the aerodynamics, static stability, and heat transfer for a broad range of heat shield shapes may assist in ascertaining an optimal, stable configuration with higher lift-to-drag (L/D) and lower heat transfer fluxes and loads. A parametric formulation of the aerodynamic performance and stability of heat shields based on Newtonian impact theory is completed in this work, with the addition of semi-empirical methods for the calculation of the stagnation-point heat fluxes. An optimizer is applied to this formulation to analyze the aerothermodynamic performance of heat shield geometries. 1.2. Previous Work 1.2.1. Heat Shield Geometries The two primary classes of shapes that have been developed by NASA are the spherical-segment and the spherically-blunted cone, shown in Figure 1.1(a) and (b) respectively. Extensive research on spherical-segments led to its use as the heat shield for human re-entry space capsules including the NASA Gemini and Apollo missions. The spherical-segment is described by a spherical radius rs and maximum spherical- segment angle ?s measured from the central axis. The Project Gemini Re-entry Module4,5 included a 38o spherical-segment heat shield (?s = 19o) with rs = 3.712 m, and a base diameter of 2.32 m. The Project Apollo Command Module (CM) had a 50o spherical-segment (?s = 25o) with rs = 4.694 m, and a base diameter of 3.912 m. 3 a) Spherical-segment heat shield, ?s = 60o. b) Spherically-blunted cone heat shield, rn/d = 0.25, ?c = 60o. Figure 1.1. The two most familiar heat shield geometries. Specific Apollo mission aerodynamic flight data is provided for Apollo mission AS-202 and Apollo 4 in Ref. [6] and Ref. [7] respectively. The Command Module in AS-202 re-entered Earth?s atmosphere at 8.23 km/s (27,000 ft/s) to produce planetary entry conditions that occur when entering from satellite orbit. The Apollo 4 (AS-501) followed an elliptical orbit around Earth that produced the expected re-entry velocity from lunar return of 10.7 km/s (35,100 ft/s). Rather than passing by the Moon, Apollo 4 had a second Service Module Propulsion System (SPS) burn at trajectory location 13 marked in Figure 1.2 to produce lunar return re- entry conditions and reduce the mission time to 8.5 hours (from six days). Hillje7 provided Apollo flight data which was used for code validation and is presented in Chapter 6. Note that most of the aerodynamic data from the Apollo flights can be reproduced accurately by this work, except for the normal coefficient CN which can have up to 40% difference compared to the available flight-derived data. x z ? ?s rs y rn d l ?c 4 Figure 1.2. Apollo 4 Trajectory from Ref. [7]. Moseley analyzed the aerodynamic stability characteristics of the Apollo Command Module in Refs. [8] and [9]. Both of these NASA Technical Notes provide aerodynamic, static and dynamic stability wind tunnel data on several Command Module configurations with their schematics and relative dimensions. From this set, only two figures are dedicated to rolling moment stability in Ref. [8], and so a discussion of the Command Module?s roll static stability is provided in Chapter 6. DeRose10 provides an analysis of the center-of-gravity offset from the central axis of the vehicle and also discusses the proper way to compare wind tunnel measurements of a non-ablative model to a flight vehicle with an ablative heat shield. Horstman11 compares the Apollo and Gemini wind tunnel models with center-of-gravity offsets. The spherically-blunted cone is another commonly-used blunt-body space capsule configuration, as shown in Figure 1.1(b). It is defined by half-cone angle ?c, the nose radius rn, and base diameter d. It is common to see the ratio rn/d as a listed characteristic. Because convective heat transfer increases while radiative heat transfer decreases with a reduction in radius for a blunt-body, there is an optimum rn that minimizes the heat transfer to the vehicle. The advantage of this configuration is that it can offer designs with the same base radius as a spherical segment without 5 constraining the nose radius. If the optimal heat shield design for a given set of mission requirements has a smaller nose radius than can be offered by a spherical- segment with base radius r, then that nose radius could be generated with a spherically-blunted cone configuration. Also, the equations that render the spherically-blunted cone can be setup to account for the entire spherical-segment regime. Chrusciel3 provides a method for calculating the aerodynamic characteristics of spherically-blunted cones. Chrusciel provides the change in the center-of-pressure location with an increase in nose radius and was used in this work to determine a reasonable range of center-of-pressure locations. A discussion on the misunderstanding present in several sources concerning the calculation of the center- of-pressure location is included in Chapter 3 and those sources are mentioned later in this section. Jones12 has completed a wind tunnel investigation on model comparison of the pressure distributions on sharp-nosed and spherically-blunted cones with large cone angles ?c at hypersonic speeds in air (M? = 7.9), helium (M? = 20.3), and tetrafluoromethane CF4 (M? = 6.2). The pressure distributions from the three different gases for the tested configurations almost always overlap each other at ? = 0o. These results are also compared to theoretical methods including Newtonian theory and concluded that the Newtonian theory does not predict the surface pressure distribution properly near the edges of the configuration. It also shows that there are significant differences in the actual distribution and the one rendered by Newtonian theory. It is shown in this work that although this may be true, Newtonian theory can predict the 6 aerodynamic forces and moments of the Apollo Command Module (spherical- segment) within 15% and the trim angle-of-attack within 1.2o. Additional work on spherically blunted cones has been completed by Tauber13 and Bernot.14 The spherically-blunted cone configuration was used on the Viking2,15 and Pathfinder16,17,18 missions to Mars. Two Viking missions consisted of an orbiter and a lander. The orbiter mapped the surface of Mars, and the landers of the Viking I and II missions had the first successful Mars landings in 1976. The Viking space capsule,19 shown in Figure 1.3, housed the lander and had a superlight ablative (SLA) heat shield of dimensions ?c = 70o, rn/d = 0.25, and d = 3.505 m. Figure 1.3. Viking Landing Capsule System from Ref. [19]. In 1997, the Mars Pathfinder mission had a Mars rover that was thermally protected during planetary entry by an aeroshell thermal protection system (TPS). Once on the surface, the Pathfinder rover would photograph the immediate vicinity and acquire data that would be sent back to Earth for analysis. Although higher heat fluxes were expected during planetary entry, the Pathfinder mission had a heat shield with the same ?c and rn/d as the Viking capsules. 7 More recent heat shield designs include the raked cone, the biconic and bent biconic cones, the parashield, and the flare-skirt aft-body. The raked cone geometry20,21 is a spherically-blunted cone raked at an angle as shown in Figure 1.4. Figure 1.4. Raked cone from Ref. [21]. This geometry offers a way to produce positive lift at zero angle-of-attack. Since the bottom surface of the heat shield has greater surface area than the upper half by design, the flow accelerates more over the bottom surface. This produces positive lift because a larger portion of the surface pressure contributes to lift from the bottom surface than the top surface. The raked cone geometry can be designed to render higher L/D at negative angles-of attack than its axisymmetric analogue. An example of the raked cone geometry is the Aeroassist Flight Experiment (AFE) that NASA worked on and cancelled in the early 1990s. It had a 14 ft diameter and was planned to participate in ten Shuttle-launched experiments. Figure 1.4 shows a few of the dimensions of the AFE?s heat shield geometry. It has a 60o half-cone angle and a 73o cone rake angle. One additional feature of the AFE?s rendition of the 8 raked cone is its ellipsoid nose with an ellipticity equal to 2. The AFE geometry is shown in Figure 1.5. Figure 1.5. AFE flight vehicle configuration from Ref. [21]. At zero angle-of-attack, the L/D is approximately 0.30 while it is approximately 0.43 at ? = ?10o.22 Wells presents the aerodynamic performance and shock shapes of the AFE from wind tunnel results in Ref. [22]. Micol gives the wind tunnel results for its hypersonic lateral and directional stability in Ref. [21] and discusses a simulation of real gas effects on the AFE in Ref. [23]. The biconic and bent biconic bodies have been looked at for an aero-assisted orbital-transfer vehicle application, but it can be argued that they can be used for planetary entry vehicle applications as well. The biconic heat shield is a spherically- blunted cone with an additional conical frustum that has a smaller half-cone angle. The bent biconic heat shield24,25 has this conical frustrum tilted at an angle with the spherically-blunted cone as shown in Figure 1.6(a). Davies and Park24 present the aerodynamics characteristics of a bent biconic with a fore half-cone angle of 12.84o and an aft half-cone angle of 7o tilted at 7o. This configuration enables a blunt-nosed 9 body to have L/D > 1 at positive angle-of-attack as shown in Figure 1.6(b). Because of its slenderness due to its low half-cone angle, it can be argued that this is an atypical example of a blunt-body. a) Bent biconic geometry b) Aerodynamic characteristics Figure 1.6. Bent biconic configuration from Ref. [24]. The common blunt-body produces positive L/D at negative angle-of-attack. Davies and Park acknowledge that a half-cone angle larger than 45o is required to produces positive lift values at negative angle-of-attack for an axisymmetric 10 spherically-blunted cone. The reason for this is that at negative angle-of-attack, the axial force has a larger contribution to lift than the normal force. The axial force?s contribution is positive while the normal force?s is negative, thereby rendering positive lift. Slender designs are usually not considered for planetary entry because they produce higher heat transfer rates at the leading edges than blunter designs. Although the presented bent biconic configuration is slender, it will become a feasible design when more advanced high temperature materials are available. In fact, one could argue that this configuration could be feasible today if an ablative material is applied and if the nose radius-of-curvature is larger than that of the edge of the Apollo CM?s heat shield, which was the location of highest heat transfer (not the stagnation point). Either way, its forebody half-cone angle can be easily modified for planetary entry applications. Other more recent vehicle geometries are the parashield and the Slotted Compression RAMP probe. The parashield is a flexible, umbrella-like planetary entry, aerobrake, or aeroassist vehicle.26 Magazu, Lewis, and Akin completed an analysis of a parashield with a ballistic coefficient of 181 Pa composed of twelve radial spars for LEO re-entry. This configuration has a mass of 150 kg and could be scaled by at least a factor of ten if desired. They determined that this parashield has a hypersonic L/D of 0.18 at ? = 15o and that there is increased pressure at each spar whether or not concavity exists.26 The portability of this geometry in closed configuration is a feature unique to parashield and inflatable ballute geometries. Murbach27 has examined the Slotted Compression RAMP (SCRAMP) probe, which has undergone several sub-orbital test flights under his supervision. This 11 geometry has a long cylindrical forebody with a hemispherical nose and an aft flare of high half-cone angle (?70o) attached to the rear of the vehicle. The aft flare creates most of the drag on the vehicle but also produces a compression ramp leading to flow recirculation. As a result, several slots are placed where the aft flare meets the cylindrical fore body to minimize the flow recirculation and thereby increase vehicle drag. The payload in the SCRAMP probe is located inside the front of the cylindrical forebody in order to place the center of gravity far forward. Since the aft flare produces most of the drag on the vehicle, the location of the center of pressure is far behind this center of gravity, rendering a negative Cm,cg,?. Murbach observed that by increasing the slot size, the maximum pressure on the aft shield is increased. This configuration has a negative Cm,cg,? which is considerably better than the Apollo CM?s value of -0.143/rad,9 rendering an outstanding, longitudinally stable entry vehicle. Note that the described configuration does not produce significant lift but may be designed to in future flight tests. Several of the classic and more recent design configurations were analyzed as lunar-return planetary entry applications in the work of Whitmore.28 Whitmore?s computational results for aerodynamics and stability are consistent with the results presented in this thesis. Bertin29 provides a thorough overview and several correlations concerning hypersonic aerothermodynamics, and Rasmussen30 provides an in-depth look at hypersonic aerodynamics. 12 1.2.2. Heat Transfer Extremely high heat transfer rates may be experienced during planetary entry. Since the PEV undergoes high heat transfer rates for several minutes, the heat transfer load is equally important. In this section general references for planetary entry heat transfer are first mentioned. Since the heat transfer results of this work consist of stagnation-point heat fluxes, the corresponding references are mentioned and referred to throughout the text. For calculating the heat flux, there are more sources and emphasis in this work given to radiation than convection because radiation is an ongoing research topic. The drawback of this work is that the heat load is not determined, but it is mentioned as an important topic for future work. In recent analyses, Park31 and Rochelle32 discuss the aerothermodynamic environments for Mars entry and return, as well as lunar return. Park presents an analysis of two human missions (one is 330 days and the other is 436 days) to Mars and notes that the existence of an optimum nose radius for the tradeoff between convective and radiative heat transfer. Rochelle analyzes several capsule geometries including the biconic and modified AFE aeroshell capsules for Mars entry and notes that with an increase in entry velocity from 10 km/s to 12 km/s, the radiative heat flux goes from 13% to 42% of the total heat flux. Two classic references from Rose33 and Kemp34 at the Avco-Everett Research Laboratory give a general overview of stagnation-point and laminar heat transfer in dissociate air. Kemp notes that the maximum heat transfer flux can be larger than the stagnation-point heat flux, as is the case for a flat-nosed body in which the convective 13 heat transfer flux is approximately 30% larger at the corner than that at the stagnation-point. This is noticed in the wind tunnel results for the Apollo CM presented by Lee,35 in which the corner has a heat flux that is 80% larger than at the stagnation-point at ? = 33o at M? = 9.07. The main Apollo missions that included the astronauts did not re-enter at 33o, and so the maximum heating rate was lower. This wind tunnel test was completed to find out the worst-case scenario with the crew compartment (aftbody) being tangent with the freestream flow. Lee also offers a thorough explanation of the convection and radiative heat transfer and gives the heat flux and pressure distributions about the heat shield. Note that the radiative heat flux correlation is analyzed in Chapter 6, but is not recommended for use since there are simpler correlations that follow the Apollo flight data better. Two Apollo CM were instrumented for aerothermodynamic analysis. Lee36 compares the flight results from superorbital entry, as is the case in lunar return, with predictions (note that Ref. [35] was written before the Apollo missions were completed). Lee also gives an aerothermodynamic evaluation in Ref. [37] that presents the highlights of the re-entry aerodynamics and heat transfer for the Apollo missions. The heat shield of the Apollo CM is the main part of the Apollo?s Thermal Protection System (TPS). Pavlosky38 details the history of designing the Apollo TPS and the manufacturing process. Also, he includes a summary of the predicted maximum heat transfer rates and loads for Apollo missions 8 and 10-16. Park and Tauber39 provide a current review of heat shielding problems experienced by the Apollo 4, 6, Pioneer-Venus, and Galileo Probe missions. Also, Scotti40 presents a 14 compilation of TPS technologies that were current in 1992 including the shuttle tiles, a TPS design for the cancelled NASA Aeroassist Flight Experiment (AFE), and proposed future materials. The amount of stagnation-point heat transfer is one of the main aerothermodynamic benchmarks for comparing the capability of one entry vehicle to another. The stagnation-point heat transfer is not necessarily analogous with the point of maximum heat transfer, as was the case for the Apollo CM and the flat-nosed body. As a result, a more appropriate benchmark would be to compare the point of maximum heat transfer. Because this requires a more computationally expensive process that is beyond the focus of this thesis, previous work concerning the convective and radiative heat transfer at the stagnation-point has been acquired. Lovelace41 provides correlations for both convective and radiative heat transfer at the stagnation point; it will be shown in Chapter 6 that the radiative heat transfer correlation is one of two that matches the Apollo flight data the closest. For convective heat transfer, Tauber42 provides the stagnation-point, laminar and turbulent flat plate correlations that he validates against the US Space Shuttle heating rates. Tauber applies the well-known Fay and Riddell43 relation that assumes that convection is inversely proportional to the square root of the nose radius. This would suggest that the convective heat transfer approaches zero as the nose radius is increased, but Zoby44 notices that blunt bodies have more enthalpy than expected by this theory. Zoby shows that an adjustment that is based on the change in the velocity gradient from that of a hemisphere can produce an effective radius that can be applied to improve the theory?s accuracy. 15 For radiative heat transfer, Tauber45 also provides the stagnation-point correlations for Earth and Mars entries. This is one of the two correlations that match the Apollo flight data the closest. Originally, Tauber?s correlations were not meant to be applied to the entire altitude regime on Earth, but this thesis will show that there is not much difference from Lovelace?s correlation41 when following the Apollo 4 trajectory. A review of the stagnation-point radiation from the Apollo 4 is available by Park.46 Cauchon47 provides the radiative heating results from the Second Flight Investigation of the Reentry Environment (FIRE II) experiment at the superorbital entry velocity of 11.4 km/s (37,400 ft/s), which is slightly larger than the fastest Apollo entry at 10.7 km/s (35,000 ft/s) for Apollo 4.7 Cauchon compares the theory to the few flight test data points. The FIRE II had three spherical-segment heat shields layered over each other. After initiating planetary entry, heat transfer data is obtained for the first heat shield. Then it is jettisoned from the entry vehicle at a chosen point in the trajectory, leaving the second heat shield surface to face the freestream flow. Data is obtained for the second heat shield, and then it is jettisoned, leaving the third heat shield surface to protect the vehicle for the remainder of the trajectory. The three heat shields had different nose radii: 0.935 m, 0.805 m, and 0.702 m for the first through third heat shields respectively. Cauchon shows that the theory is closer to the FIRE II calorimeter data by accounting for radiation cooling and coupling; otherwise, the theory overshoots the calorimeter data by 30%. Ried48 compares the flight measurements and engineering predictions on the Apollo CM for mission four. Ried also provides a computational approximation of 16 the total radiative heating rate near the stagnation point including ultraviolet lines and continuum, which were not measured by the radiometers on the heat shield of Apollo 4. The shock-standoff distance over the time of maximum radiative heat transfer is also provided. A correlation that closely matches the behavior of how the stagnation- point shock standoff distance varies with normal-shock density ratio is included and could be used along with Lovelace?s41 or Tauber?s45 correlations to calculate stagnation-point heat transfer fluxes. For planetary entry at velocities larger than that of the Apollo missions, curve fits of inviscid heating rates and cooling factors have been produced by Suttles.49 It is recommended that these curve fits be validated before use in future work. Determining how the stagnation-point radiative heat transfer rate varies as a function of angle of attack for the Apollo CM is investigated by Walters.50 By accounting for the stagnation-point shock-standoff distance, Walters is able to approximate this behavior, although the wind tunnel data is noticeably scattered. Additionally, he applies Kaattari?s correlation51 to produce an outstanding match of the Apollo CM?s experimental shadowgraph of the shockwave shape at Mach 19.5 and 31.5o angle of attack. The Kaattari method approximates the shock-standoff distance of a blunt- body at zero angle of attack52 and the shock envelope of spherical-segment blunt- bodies at large angles of attack.51 This highly empirical method uses the normal shock density ratio to approximate the location of the sonic line on the body as well as the shock and body surface inclinations at the sonic point along with theory to determine the ratio of the shock-standoff distance to the nose radius. Since a planetary entry 17 vehicle enters the atmosphere at high velocities, high temperatures are produced in front of the heat shield, and so high temperature gas correlations from Srinivasan53 (an updated version of the Tannehill54 correlations) can be used to determine the effective specific heat ratio to determine the normal-shock density ratio. This thesis work applies the Kaattari method, with its implementation described in Chapter 3, to apply Lovelace?s41 and Tauber?s45 radiative heat flux correlations to blunt-bodies at any angle of attack. 1.2.3. Misconceptions Misunderstandings and discrepancies in publications have been noticed throughout the literature survey. The most common misunderstanding is the theory behind calculating the x-location of the center of pressure of a blunt body. This location is dependent on both the axial force and normal force?s contributions to the pitching moment; neither can be ignored. However, several references calculate the x- location by assuming the axial force?s contribution to the pitching moment is negligible. This thesis explains in Chapter 3 that the axial force?s contribution to the pitching moment is at least the same order of magnitude as the normal force?s contribution and thereby must be accounted for in the case of a blunt body. From here, it is possible to match the Apollo CM?s pitching moment wind tunnel data as will be shown in Chapter 6. Bertin,29 Rasmussen,30 and Regan55 have textbooks that assume the axial force?s contribution to the pitching moment is negligible in sections concerning blunt bodies. However, Bertin?s textbook29 also has the correct derivation, and the example 18 in which the assumption is made in the first edition of Regan?s textbook55 has been removed from Regan?s second edition. Figure 9 in the work of Levine56 provided the x-location of the center of pressure of several spherical and blunt cone geometries. However, they are different from the values of this thesis by one order of magnitude except for one case. Because the work of this thesis was able to match the aerodynamic and stability results of the Apollo wind tunnel and flight test data and basic conical shapes, the use of Levine?s values of the x-location is not recommended. Arora57 maximizes the center of pressure?s x-location for a spherically-blunted cone-flare configuration. However, Arora?s work assumes that the axial force?s contribution to the pitching moment is negligible. As a result, the optimized x- location value is infeasible. Because the x-location is incorrect, it is not possible to find the correct pitching moment value about the blunt-body?s center of gravity. An active researcher concerned with the aerodynamic performance and the stability of blunt-body planetary entry geometries should be attentive to this issue. Papadopoulos58,59 has figures that are mislabeled as trajectories for Apollo missions AS-201, 4, and 6. The only relations between the figures and the Apollo missions are the mentioned missions? entry flight-path angles. The plots are meant to show code output according to a particular Apollo mission?s entry flight-path angle. Because several plots on a single page have legends with Apollo mission numbers, it is easy for one to assume that these must be the flight velocities, decelerations, and Reynolds numbers experienced by the Apollo missions listed. This is a simple 19 miscommunication and not suggesting that Papadopoulos?s results are not accurate; he has validated his results with POST. Several sources that are not suggested for estimating the radiative heat transfer at the stagnation-point for an Apollo-like capsule include Barter60 and Gupta.61 It is possible that both sources have typographical errors in the equations, but this is not certain. However, it is shown in Chapter 6 that these equations do not match the behavior of flight test data from Apollo 4. There are other correlations that match the flight test data closely. 1.3. Research Objectives The primary objective of this research is to determine if and how the aerodynamic performance, static stability, and stagnation-point heat transfer can be improved over those of previously developed blunt-body planetary entry vehicles. Running a computerized optimization over a range of heat shield geometries is one way to efficiently search an entire design space for such an answer. Ideally, this design space would be controlled by several geometric parameters that could vary the shape of the heat shield to a great extent. The classic spherical-segment and spherically-blunted cone heat shield geometries were originally developed since these shapes are simple yet satisfy the mission requirements of Apollo and Viking respectively. Another common shape is the power law that has been applied to reduce drag on the nose of hypersonic missiles. One of the goals of this research is to explore a wide design space, one beyond that of previous work. This is accomplished by extending these geometries to 20 vary eccentricity and transform the base cross-section shape from an ellipse to any rounded-edge polygon. There are indications that better aerothermodynamic performance is possible, and using today?s technology, it is possible that these heat shields could be produced at costs similar to reproduction costs of previous work. All of the past heat shield geometries except for the raked cone and the bent-biconic configuration are axisymmetric designs. The main advantages of the raked cone and the bent-biconic are their larger lift-to-drag ratios compared to their axisymmetric counterparts, and so it is expected that the non-axisymmetric designs will produce higher lift-to-drag ratios. It is also possible that an optimum nose radius exists that could reduce the heat transfer load on the vehicle during lunar or Mars return. These questions are answered in this work, limited to the blunt-body?s hypersonic performance. 1.4. Thesis Overview This thesis is organized to first introduce the investigated blunt-body geometries and their geometric parameters in Chapter 2. Then Chapter 3 describes the Newtonian aerodynamic theory and a method for approximating the shock-standoff distance from the stagnation point. It also includes the equations for determining the static stability of a given heat shield geometry and provides explanations for a couple misinterpretations of basic theory. Chapter 4 gives the main assumptions and correlations for convective and radiative heat transfer at the stagnation point. A description of the code?s layout and the chosen optimization process is included in Chapter 5. Then the design code is validated against Apollo wind tunnel and flight 21 test data in Chapter 6. In order to better understand the design space, a parametric analysis has been conducted. The results are included in Chapter 7 and happen to provide better initial designs for optimization. Chapter 8 presents the optimized configurations of this work in detail, and the final conclusions of this thesis along with suggested future work are detailed in Chapter 9. 22 Chapter 2. Blunt-Body Heat Shield Geometries Each heat shield in this work is defined by two geometries: the base cross- section of the heat shield and the axial shape that is swept about the central axis and modified to match the base cross-section. The coordinate system for this work is included in Figure 2.1 with the sweep angle ? and conventional directions for positive moments. One change from convention that is not shown occurs when the vertical lift coefficient CL,V < 0, in which the direction of the positive rolling moment switches in order for a negative Cl,? to still indicate a statically roll stable shape. An explanation of the sign reversal is included in the stability section of Chapter 3. Figure 2.1. Fixed-body coordinate system, spherical-segment, ? = 30o, ?s = 60o, n2 = n3 = 2. 2.1. Axial Shapes The shape of the heat shield that protrudes from the base is called the axial shape in order to easily differentiate the protruded shape from the cross-section. The axial shape of the heat shield by itself represents the shield?s profile if its base cross- x y z Pitching Yawing Rolling ? ? 23 section were to be circular. If the base cross-section is not circular, then the axial shape is at least the top half of the shields profile at sweep angle ? = 0o. Then the axial shape is modified to follow the outline of the base cross-section. Three axial shapes: the spherical-segment, the spherically-blunted cone, and the power law are applied in this work and described in the following sections along with how they are generated. 2.1.1. Spherical-segment A general spherical-segment is a region of a sphere that is left after the sphere is cut by two parallel planes. A closed spherical-segment is a region of a sphere encompassed by spherical-segment angle ?s, in which ? = 90o - ?s, in which only one plane, parallel to the yz-plane divides the sphere. A closed spherical-segment, one shown in Figure 2.1, is also known as a spherical cap and is the type that is applied to previous and present heat shield design. For this work, only the profile of the spherical-segment is utilized by using the following equations for the xy-plane at zero sweep angle: rmax = xmax/(1-cos(?s)), (2.1) xk = rmax(1-cos(?k )), (2.2) yk = rmaxsin(?k), (2.3) in which xmax = 1 in order to normalize the geometry to the length of the heat shield l = xmax. This set of equations produces the axial shapes shown in Figure 2.2 (a) for 24 the Apollo CM (?s = 25o) and a hemisphere (?s = 90o). The corresponding spherical heat shields, which have circular cross-sections, are shown in Figure 2.2 (b) and (c). a) Spherical-segment axial profiles at ? = 0o. (b) Spherical heat shield, ?s = 25o. (c) Spherical heat shield, ?s = 90o. Figure 2.2. Spherical axial profiles and heat shields. ?s = 25o ?s = 90o 25 2.1.2. Spherically-blunted Cone The spherically-blunted cone?s geometric parameters have been introduced in the previous work section of Chapter 1. Figure 1.1(b) is an example of the spherically-blunted cone heat shield. Its axial profile has two parts, a spherical nose and the conical body. The spherical nose is generated by producing a spherical- segment with ?s = pi/2-?c to provide slope continuity from the spherical nose to the conical body. If the conical base is divided into N vertical sections that are equally spaced along the x-direction, then the spherically-blunted cone profile in the xy-plane is generated with the system of equations ?? ??? =+?? 0 corresponds to prolate geometries. The semimajor and semiminor axes are determined from the following equation sets ( ) ?? ??? 2 about the horizontal axis. As a result, to keep consistency when varying n2, the reflection was removed by setting yj,k = - yj,k and zj,k = -zj,k. Examples of generated blunt bodies are included to show the variety of shapes that can be created from this set of axial and cross-section shapes. Figure 2.5 shows a prolate (approximately 4:1 axes length ratio) spherically-blunted cone blunt body. Figure 2.6 shows an oblate (approximately 3:1 axes length ratio) 12-sided polygon blunt body with a spherical-segment axial profile. Figure 2.7 shows a slightly prolate, concave rounded-edge pentagon with a power law axial profile. Note that the angled views do not correspond to any specific orientation. 31 a) Front view. b) Side view. c) Angled view. Figure 2.5. Spherically-blunted cone, rn/d = 0.25, ?c = 70o, e = 0.95, m = 5, n1 = 1.75, n2 = 2. a) Front view. b) Side view. c) Angled view. Figure 2.6. Spherical-segment, ?s = 40o, e = -0.85, m = 12, n1 = 10.75, n2 = 1. a) Front view. b) Side view. c) Angled view. Figure 2.7. Power law, A = 3, b = 0.75, e = 0.5, m = 5, n1 = 1.75, n2 = 5. 32 2.4. Geometric Properties The main geometric properties calculated in this work are the surface and planform areas, the volume, the volumetric efficiency of the heat shield, and the location of the center of gravity. The following is a description of how the areas and volume are determined. Each point (j,k) is a part of a quadrilateral with four points (j,k), (j-1,k), (j,k-1), and (j-1,k-1). The distance between points (j,k) and (j-1,k) is indicated by d1,a, ( ) ( ) ( ) ,2,1,2,1,2,1,,1 kjkjkjkjkjkja zzyyxxd ??? ?+?+?= (2.12) and the distance between points (j,k-1) and (j-1,k-1) is d1,b. These two distances are then averaged to produce d1. The distance between points (j,k), and (j,k-1) is d2,a, and the distance between points (j-1,k) and (j-1,k-1) is d2,b. Likewise, they are averaged to produce d2. The product of d1 and d2 is the differential surface area dA. All the differential surface area components are summed to produce surface area Shs, which is a term in determining the volumetric efficiency described later in this section. The differential planform area dAp is the product of w1 and w2, which are the distances from and to the same point-locations as d1 and d2 if they were assumed to have equal x-components. In other words, the planform area dAp, which is equal to part of the heat shield?s base area, depends only on the area projected onto the yz-plane, in which ( ) ( ) ,2,1,2,1,,1 kjkjkjkja zzyyw ?? ?+?= (2.13) 33 and likewise for w1,b, w2,a, and w2,b. Then the sum of the differential planform areas is equal to the heat shield?s base area. The planform area is used in part to non- dimensionalize the aerodynamic forces and moments. The differential volume is the product of the differential planform area and the distance from the differential surface to the shields base written as lb ??? ? ??? ? +++?= ???? 4 1,1,11,, max kjkjkjkj b xxxxxl . (2.14) Then a summation of all the differential volumes produces the volume of the heat shield Vhs. The volumetric efficiency is one way to benchmark how much volume is available for a given amount of surface area. In the case of a heat shield shape, which is not a closed-shape, the volumetric efficiency is normalized to a hemisphere ( ) .18 3231 hs hs v S Vpi? = (2.15) As a result, the most volumetrically efficient shape is the non-eccentric spherical- segment with ?s = 90o. The following equations calculate the location of the center of gravity of a uniform density body { } .,,,, ?? ??? ?? ???= ??? ??? ??? ??? ??? ??? dV zdV dV ydV dV xdV ZYX cgcgcg ??? (2.16) This equation is applied to a 3D mesh through numerical integration. One numerical integration method is Simpson?s rule,64 34 ? + = 12 1 )()( nx x dxxfxF (2.17) ( ) ( )( )1212532421 ...2...43 +? +++++++++? nnn ffffffffh , which is fifth-order accurate in h. For this work, h is a space step size. Additionally, this method requires an odd number of points to be integrated, and so the final point in the mesh is represented by the index 2n+1. Because the space step h may not necessarily be the same for each pair of points, this work applies a modified version of Simpson?s Rule that uses individual step sizes. ? + = 12 1 )()( nx x dxxfxF (2.18) ( ) ( )( )12121212553322442211 ...2...431 ++?? +++++++++? nnnnnn fhfhfhfhfhfhfhfh . It is likely that more than one integration is required to determine each term of the center-of-gravity location since the triple integrals indicate a three-dimensional shape that requires integration in three directions. It is easier to use the polar coordinate system in Figure 1.1(a). This allows one to conduct two integrations instead of three. The method applied in this work for determining the center of gravity?s location with numerical integration is detailed in this section. In the applied form, the general equation that is equal to Eqn. (2.16) is { } .,,,, 3,3,3, ?? ? ?? ?= NVol f NVol f NVol fZYX zyx cgcgcg (2.19) The term NVol is a volume-related term, but it is not necessarily equal to the volume of the heat shield. For the spherical-segment axial shape, NVol is equal to Vhs, but for 35 the spherically-blunted cone and power law axial shapes, NVol is equal to the terms that are not cancelled out from being common to the numerator and denominator of Eqn. (2.16). NVol is defined as , max 1 max 1 ,? ? = = = k k j j kjdNVolNVol (2.20) in which dNVolj,k is the differential volume-related term defined as ? ? ? ? ? ? ? ? ? ?????? ? = law,Power ,2 cone blunted-ySphericall,2 segment-Spherical,2cos2 ,, 2 , ,, 2 , ,, 2 , , kjkj kj kjkj kj kkjkj kj kj drdw drdw drdw dNVol ? ? ?pi? (2.21) in which spherical-segment angle ?k only varies with x-location, d?j,k is the differential sweep angle in the yz-plane. This differential angle is determined from the law of cosines ,2acos ,1, 2 ),(),,1( 2 ,1 2 , , ?? ? ? ??? ? ?+= + ++ kjkj kjkjkjkj kj ww dwwd? (2.22) and drj,k is the average of the distances between the points (j+1,k) and (j+1,k-1) and the points (j,k) and (j,k-1), which is the numerical analogue to a differential length, ( ).21 )1,(),,()1,1(),,1(, ??++ += kjkjkjkjkj dddr (2.23) Since there are two differentials in dNVol, it is noted that it will be integrated twice to produce the denominators of Eqn. (2.19). With these equations, the denominator is 36 fully defined. For the numerator, the subscript letter on the function f corresponds to the x, y, and z-components, and the subscript number 3 corresponds to the result after the two integrations. The subscript number 2 corresponds to the result after one integration, and the subscript number 1 corresponds to the initial case before integration. The initial variables fx,y,z,1 that are integrated twice to produce fx,y,z,3 are defined as { } { }.,,,, ,,,,,,1,1,1, kjkjkjkjkjkjzyx dNVolzdNVolydNVolxfff = (2.24) These are integrated first with respect to ?, and there are a kmax-number of values for fx,y,z,2 ( ) k x x xkx n ff ?? ? ? ??? ?= ?+12 1 1,2, . (2.25) ( ) ( )( ) k nxnxxxnxxxx ffffffff ?? ?? ? ? +++++++++? +? 12,1,12,1,5,1,3,1,2,1,4,1,2,1,1,1, ...2...43 1 , and likewise for fy,2 and fz,2. Note that the fx,1 includes the differentials d? and dr, and thus they are not written in Eqn. (2.25) and (2.26). The fx,y,z,2 are integrated with respect to r, and so there is one value for each component of f3 ? + = 12 1 2,3, nx x xx ff (2.26) ( ) ( )( )12,2,12,2,5,2,3,2,2,2,4,2,2,2,1,2, ...2...431 +? +++++++++? nxnxxxnxxxx ffffffff , and likewise for fy,3 and fz,3. With these definitions, the location of the center of gravity of a given three-dimensional shape can be determined. 37 Chapter 3. Aerodynamics and Static Stability The theory behind the aerodynamics and the static stability is presented in this section. The aerodynamic characteristics are then transformed into the quantities that are applied in the code of this work. The method for determining the shock-standoff distance to the stagnation point is introduced also, and modifications to the method to account for angle of attack are stated. Then this chapter finishes with a couple corrected misinterpretations of general aerodynamic theory. Two coordinate systems applied in this work are the freestream coordinate system shown in Figure 3.1(a) with the positive angle of attack and sideslip angle conventions, and the fixed coordinate system shown in Figure 3.1(b), which is slightly different from Figure 2.1. a) Freestream coordinate system with ? and ?. b) Fixed coordinate system with aerodynamic moment conventions. Figure 3.1. Coordinate systems with positive ? and ? and moment conventions. M? ? (+) ? (?) x y z Pitching Yawing x z ? ?s rs y Rolling CL,V > 0 CL,V < 0 38 3.1. Modified Newtonian Impact Theory After the heat shield geometry is generated, its aerodynamic characteristics are calculated based on a modified Newtonian surface pressure distribution. Simple Newtonian theory is equivalent to the limit of exact oblique shock theory as M? approaches infinity and ? approaches one.65 This work is currently being applied to Earth atmospheric entry by assuming ? = 1.4, and a similar analysis can be applied to a Martian atmosphere of CO2 by assuming ? = 1.3. However, when calculating the shock-standoff distance, the effective specific heat ratio after the blunt-body shock is determined using the empirical correlations of high temperature air from Tannehill,54 as explained in Section 3.2 on shock-standoff distance. Because Newtonian theory allows aerodynamic performance to be determined within a fraction of a second of computation time, it has been chosen over more complicated, time-intensive methods for optimization reasons. Results from the code that apply modified Newtonian theory are compared to wind tunnel and flight test data from Apollo Command Module (CM) in Chapter 6. The pressure coefficient, which is the pressure difference normalized by the dynamic pressure, is given by the equation ??? ? ??? ? ?=?=?= ???? ? ? ? 12 2 1 22 p p MV pp q ppC p ? ? . (3.1) Newtonian theory assumes that the component of a particle?s momentum that is normal to the surface is destroyed when impinging on the face of the blunt body while its tangential momentum is conserved.29,30,55 The Newtonian model is 39 2 max, ? ??? ? ??? ? ?= ? ? V nVCC pp r (3.2) for .0? 0 to be equivalent to the pitching moment coefficient Cm,0 for an oblate shape at a given angle-of-attack (the condition ?2 = ?1, ?2 = 0, e2 = -e1). This definition was chosen over defining lM as the span of the heat shield. In validation, it is shown that the rolling moment calculations rendered a z- location of the center of pressure, Zcp, that is inconsistent with the calculations of the other two moments, and so the yawing moment coefficient was used to calculate Zcp. One observation is that the components of Cl,0 are of such small magnitude that the values may have numerical error on the same order, thereby producing inconsistent values for Zcp. One reason for this may be that Simpson?s rule has difficulty integrating numbers that have values near zero. Since the value of Cl,0 is orders of magnitude lower than the pitching and yawing moment coefficients, it is possible that Simpson?s rule reached its limit around the value of Cl,0 without affecting Cm,0 and Cn,0. 3.2. Shock-standoff Distance: Kaattari?s method Kaattari?s method for calculating the shock-standoff distance to the stagnation point is semi-empirical.51,52 Kaattari?s method assumes that the shock shape is 45 spherical with radius rsh. There are several curves that relate the normal shock density ratio ?2/?1 to characteristics empirically derived, including the shock-standoff distance at the sonic point for several shapes such as a cone, paraboloid, and sphere. Then there are several aerodynamic and geometric theory-based equations applied in determining the shock-standoff distance from the chosen geometry. Kaattari?s method is not completely explained in this work because it is well detailed for the general blunt-body case at zero angle of attack in Ref. (52) and for a spherical-segment blunt- body at large angles of attack in Ref. (51). To introduce the method, this section does include the main equations. Then a description of how this method is implemented on the computer is included since it was originally an iterative process completed by hand. Afterwards, modifications to the method accounting for angle of attack in Ref. (51) are included to estimate the shock-standoff distance for the general blunt-body case. 3.2.1. Method Implementation Kaattari gives two similar methods for determining the shock-standoff distance, one for conic-section bodies and the other for non-conic-section bodies. Kaattari recommends using the conic-section shock equations with ellipsoids and the non-conic-section shock equations with the spherically-blunted cone. For this work, the non-conic-section shock equations were chosen to be used for all three axial shapes because they account for edge bluntness while the conic-section equations do not. Also, for the spherical-segment blunt-bodies, it was noticed that the conic section equations and non-conic section equations produced similar results for a spherical 46 body. Additionally, ellipsoid relations assume a complete ellipsoid is present rather than a segment of an ellipsoid, and this may become problematic at angles of attack. Kaattari originally calculated the shock characteristics of axisymmetric shapes by hand using plots of several geometric and aerodynamic characteristics that varied with the normal-shock density ratio. He needed to iterate his solution until the method found a converged value of the shock-standoff distance. This work uses the computer to automate Kaattari?s process. Part of this is accomplished by curve-fitting the necessary semi-empirical plots. This section supplies the curve-fit equations that were generated for this work. Note that all the given digits are required in order for the curve-fits to register the corresponding norm of the residuals or R2 values (which is given for most of the curve-fit equations). Also, even though all these digits are required to have an accurate curve-fit, this does not mean that the resulting value has a correspondingly large number of significant digits. It is suggested that the calculated results of the given curve-fits do not have more than three significant digits. As noted previously, this section does not detail the entire Kaattari method; it only includes the main modifications and additions to the method including curve-fit equations. This section also refers to figures that are not included in this work, but the reference numbers are given. The G function relates the ratio of the shock-standoff distance to the shock radius, ?o/rsh, to the blunt-body?s radius of curvature at the nose ,11 sh o shn sho sh o n o rrr r rrG ? ??? ? ??? ? ?+=? ??? ? ??? ? ?+= (3.30) which can be manipulated to become 47 . 2 141 ??? ? ??? ? ??? ? ? ??? ?+ =? n sh n sh sh o r r r rG r (3.31) These relations52 are based on a given normal-shock density ratio. Figure 1 from Ref. [52] provides a relation for the G function to the normal-shock density ratio for ?- values of 1.0 and 1.4 ? ? ? ? ? ? ? ? ? ? ?? ? ? ? ? ? ? ? ? ? =+?? ? ? ??? ?+ ??? ? ??? ? ??? ? ??? ? ??? ? ??? ? = ??? ? ??? ?+ +?? ? ? ??? ? ??? ? ??? ?+ ??? ? ??? ? = 1.4. 0025566,0. :residuals of Norm ,0.00062937 0.69906 0.047552 -1.4794 - 2.4242 1,0.0033845, :residuals of Norm ,0.00024476 -0.81267 1.4354 - 2.9402 2.2378- 2 1 2 2 1 3 2 1 4 2 1 2 1 2 2 1 3 2 1 4 2 1 ??? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? G (3.32) If ?1/?2 < 0.15, then the two curves converge and the curve-fit equation for ? = 1.0 must be used. Otherwise, interpolation between the two curves can be completed for 0.15 < ?1/?2 < 0.45. The shock-standoff distance at the sonic point ?* is non- dimensionalized by y*, which is the normal distance from the axis of symmetry to the sonic point on the body. Figure 2 (Ref. [52]) relates the ?*/y* to the ?1/?2 for two specific heat ratio values for 0.01 < ?1/?2 < 0.45, 48 ? ? ? ? ? ? ? ? ? ? ?? ? ? ? ? ? ? ? ? ? =+?? ? ? ??? ?+ ??? ? ??? ? ??? ? ??? ? = ??? ? ??? ?+ ??? ? ??? ? ??? ? ??? ? =? 1.4. 0.0076548, :residuals of Norm ,0.00052448 1.9834 0.80536 -1.4064 1,0.0087586, :residuals of Norm 0.0018741, +2.7174 4.3473 - 6.418 2 1 2 2 1 3 2 1 2 1 2 2 1 3 2 1 * * ??? ? ? ? ? ? ? ? ? ? ? ? y (3.33) Kaattari validates these curve-fits with experimental data for spherical, disk, and cone shapes, as well as with theoretical results for spherical and parabolic shapes for zero angle of attack. From these two equations, the shock surface inclination at a point opposite the sonic point on a flat disk ?*o can be determined .atan * * * ?? ? ? ? ? ?? ? ? ? ? ?= y G o? (3.34) The sonic angle for a sphere ?*1 is defined as the body surface inclination of a sphere at the sonic point, with respect to a plane normal to the freestream direction. The variation of the sonic angle for a sphere ?*1 with ?1/?2 is given in Figure 4 from Ref. [52] for 0.025 < ?1/?2 < 0.45, 49 ?? ? ? ? ? ? ? ? ?? ? ? ? ? ? ? ? ? = +?? ? ? ??? ?+ ??? ? ??? ? ??? ? ??? ? ??? ? ??? ? =?? ? ? ??? ?+ ??? ? ??? ? ??? ? ??? ?+ ??? ? ??? ? =? 1.4. 32.589, 61.984 99.371 - 7.2046 - 104.8 1,33.383, +80.348 380.2 - 908.77 797.1- (deg) 2 1 2 2 1 3 2 1 4 2 1 2 1 2 2 1 3 2 1 4 2 1 1* ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? (3.35) If ?1/?2 < 0.15, then the curve-fit equation for ? = 1.0 must be used. Otherwise, interpolation between the two curves can be completed for 0.15 < ?1/?2 < 0.45. The sonic angle for a rounded-corner blunt-body ?* varies with rc/r ( )( ) ? ? ? ? ? ? ? ? ?? ? ? ? ? ? ? ? ? 37o, then ? is set equal to 37o since that is the limit of Kaattari?s dataset. The spherically-blunted cone does not approach this limit since it would require a half-cone angle ?c < 53o, and the limit for the half-cone angle in the optimizer is set at 55o. Kaattari?s method also notes that if the sonic angle ?* < ?, then the sonic point is assumed to be taken at the tangency angle ?, and so ?* is set equal to ? for this case. To determine ?*, Kaattari supplies Figure 6(b) from Ref. [52] that relates the difference ?* ? ?*o as a function of ?*. This relation varies with the normal-shock density ratio, and their corresponding curve-fit equations with ?* limits are included 51 ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ??<= ?? ??? ???? ??<=?? ?? ???? ??<= ?? ?? ???? ???? ??<=+?? ??? ???? ??<=?? ??? ???? ??<=?? ??? ???? ??<=?? ??? ???? =? .401,20 0.11582, :residuals of Norm 0.012458, +0.040357 -0.020612 + 0.0014138 -106.7379 + 101.4433 -101.2753 405.17,16 0.0795, :residuals of Norm 115.89, + 24.509 -2.1177 + 0.094787 -0.0023397 + 103.0006 -101.5644 400,12 0.067392, :residuals of Norm ,0.00075942 -0.0075298+0.0034554 - 0.0028275+0.00035965 - 102.3289 +108.0148- 101.4038 +109.8112- 404,8 0.0583, :residuals of Norm 0.0038209,0.0016152-0.00034058 + 0.00053225 +102.7801 - 106.9855 +106.0809- 404,6 0.0793, :residuals of Norm 0.0085934,-0.019362 +0.0054599- 0.00087115 +103.7688 - 108.0483 +106.2549- 401,4 0.04381, :residuals of Norm 0.0031709, +0.01135 +0.01933 - 0.0021927 +109.1189 - 101.7632 +101.3002- 401,3 0.10637, : residuals of Norm 0.026591, +0.036272 - 0.01669 - 0.0017384 +106.5557- 101.1554 + 107.8164- (deg) * 1 2 * 2 * 3 * 4 * 5- 5 * 6-6 * 8- * 1 2 * 2 * 3 * 4 * 5 * 5-6 * 7- * 1 2 * 2 * 3 * 4 * 5 * 5-6 * 7- 7 * 8-8 * 11- * 1 2 * 2 * 3 * 4 * 5- 5 * 7-6 * 9- * 1 2 * 2 * 3 * 4 * 5- 5 * 7-6 * 9- * 1 2 * 2 * 3 * 4 * 5- 5 * 6-6 * 8- * 1 2 * 2 * 3 * 4 * 5- 5 * -66 * -9 ** ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?? o (3.39) For all equations in this set except ?2/?1 = 12, for 0 < ?* < 1 it is assumed that the difference ?* ? ?*o is zero. For this region, the equation for ?2/?1 = 12 is applied for normal-shock density ratios of twelve and greater. The equation for ?2/?1 = 16 is not 52 applied until ?* > 17.5, and if it is used before this, the results could be erroneous since the curve fit was designed only for the noted ranges. Linear interpolation between two of the curves within this range of ?2/?1 can be exercised to approximate the values of the difference for normal-shock density ratios that are not listed. The main non-conic-section body shock equation relates the shock radius rsh to the stagnation shock-standoff distance, the corner radius, sonic shock-standoff distance and the tangency angle ( ) ( )( ) ( )( ) ( ) ( )( ) ?? ? ? ? ? ? ? ? ? ? ? ??? ??? ? ??? ? ???+ ??? ? ??? ? ?+ ??+=?? ? ? ??? ? ? * * * * ** sin11 coscossin1cos 1costan r r r r r r yy x ry r c cn s sh osh ? ? ? ?? , (3.40) in which xs is the streamwise distance from the apex of the shock to the point on the shock at distance y* from the central axis. This relation along with the shock solution nomograph equation, ( )??? ? ??? ? ?= *** tan 1 ?y r y xB shs s , (3.41) and the initial value of ?o/rsh set equal to G, determine the values of Bs, y*/r, rsh/r, and ?o/r, ( )*2 2 * tan 1 ????? ? ??? ?= y rB sh s , (3.42) ( )( ),sin11 ** ???= rrry c (3.43) ,* * r y y r r r shsh = (3.44) 53 ,* * n sh n sh r r r y y r r r = (3.45) r r rr sh sh oo ?=? . (3.46) From here, the value of ?o/rsh based on Eqn. (3.31) is calculated and the process is repeated. Once the value of ?o/rsh converges within 0.001, the iterative process has been completed, and the shock properties of the blunt-body have been determined for zero angle of attack. The main output variable is ?o/rn. The complete process with referenced figures and examples is included in Ref. (52). 3.2.2. Accounting for Nonaxisymmetric Shapes & Angle of Attack Kaattari51 offers a way to account for angle of attack for spherical-segment axisymmetric blunt bodies. In this section, a basic method is described for determining how ?o/rn changes both for a nonaxisymmetric blunt body and with angle of attack based on Kaattari?s method. It also has been modified to account for the spherically-blunted cone and power law axial shapes. These modifications are meant to produce results that follow expected trends only. Although there is confidence in the expected trends, the results should not be accepted as unequivocal since several of the more exotic shapes have not been studied before from a re-entry heat transfer standpoint. The expectation is that these modifications produce shock-standoff distances for nonaxisymmetric geometries within the proper order of magnitude. The reason for using this method is to approximate the stagnation-point radiative heat flux, and Chapter 4 explains how it can be approximated for a blunt body using the shock-standoff distance. 54 For an axisymmetric spherical-segment geometry, Kaattari provides the process for estimating the shock-standoff distance in Ref. (51), and the equation ( ) ( )??? sincos 3 max 3 max 1 ? ? ? ? ? ? ? ? ??? ? ??? ?+??=? r rc r rc dd ststo (3.47) relates the shock-standoff distance at angle of attack to that at zero angle of attack. Note that for this work, the angle of the azimuth ? is assumed equal to zero. To determine how the value of ?o/rn varies with angle of attack, semi-empirical data of shock correlation functions from Kaattari in Ref. (51) have been curve-fit. Applying these curve-fits is described in the next section, including the modifications required to use Kaattari?s method to approximate how the shock-standoff distance changes with angle of attack. Figure 9(a) from Ref. [51] shows how the shock correlation coefficient c1 varies with the normal-shock density ratio and the tangency angle ? and is curve-fitted (input ? in degrees) with indicated limits of applicability ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?<=?? ?? ?+? ?<=? ?? ?<=? ?? = ,450,5 0.9999, = R 20.23026450 + 102.21715933 -101.15717926 - 104.78956150 +102.31598093 - 105.39975415 104.12212802- ,450,4 9998, 0.= R 10.22140328 +107.60025063- 108.78810663 -109.63317384 ,450,3 0.9987, = R 30.21438038 +107.64482284- 101.16661976 + 101.93013729- 1 2 2 3-24- 36-47- 59-611- 1 2 2 4- 25-37- 1 2 2 4- 2-53-7 1 o o o c ????? ?? ?? ???? ?? ???? ?? (3.48) 55 ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?<= ? ?? ?? ?<=? ?? ?? ?<=? ?? ?? ?<= + ?? ?? ?? ?<=?? ?? ?? ?<=? ?? ?? ?<=? ?? ?? = .400,22 0.9990, = R 10.20014809 +109.52531793- 103.29553862 -102.95290942+ 106.46122093 -104.60808129 ,400,20 0.9991, = R 30.21011300 +109.44613956- 103.50334207 -103.16638882+ 107.49638803 -106.06112566 ,400,16 0.9997, = R 40.22155108 +108.09283123 - 103.58846154 -102.54224815+ 105.34031912 -104.06700008 ,400,12 0.9998,= R 232157648 .0 109.22392526 -102.01204775 + 102.69805855 -101.52078813 + 103.32278424 -102.56915093 ,400,10 0.9999, = R 30.23240649 + 108.40015875 -103.31432550 + 103.65809838 -101.62858238 + 102.99995789 -102.00439718 ,5.420,8 0.9999, = R 40.23184113 +104.54631057- 101.56690529 -102.18083922 + 106.32411067 +109.07434828- ,5.420,6 0.9999, = R 232732751 0.+ 102.50199798- 102.09241117 -104.08148122+ 102.69993388 -102.92464389- 1 2 2 3- 24-35- 47-59- 1 2 2 3- 24-35- 47-59- 1 2 2 3- 24-35- 47-59- 1 2 2 3-24- 35-46- 58-610- 1 2 2 3-24- 35-46- 58-610- 1 2 2 3- 24-36- 48-510- 1 2 2 3- 24-36- 4-95-10 1 o o o o o o o c ??? ? ?? ?? ???? ?? ?? ???? ?? ?? ????? ?? ?? ????? ?? ?? ???? ?? ?? ???? ?? ?? (3.49) 56 Note that all the digits have to be included in order to maintain accuracy. If digits are removed, it is strongly recommended that the modified curve-fit be plotted to verify that the curve-fit is still valid throughout the entire range and to verify none of the curve-fits intersect each other. Interpolation for cases with normal-shock density ratios in-between the given curve fits has been tested and is completely feasible. The correlation constant c3 is also supplied in Figure 9(b) from Ref. [51], and the curve-fit equations (input ? in degrees) have been generated in this work ( ) ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?<= ? ?? ?+? ?<=? ?? ?? ?<=? ?+? ?? ?<= ? ?? ?+? ?? ?<=? ?? ?<=? ?? =?? ? ? ??? ? ,400,8 0.9994, = R 480.01414886 +101.32633841 - 102.21510280 +102.15386203 - 106.22306898 105.69532428- ,450,7 0.9995, = R 149288590 0.0+ 101.21889535 - 101.66417857 +101.56325253- 104.33744906 +103.80921614- ,450,6 0.9995, = R 440.01593340 +101.27550983 - 109.92739734 107.24637110- 101.63488703 +101.13917530- ,450,5 0.9998, = R 101.77036651 + 101.14702612 -104.96819914- 108.56040487 104.49628934- 109.54110294 +107.15150540- ,450,4 0.9995, = R 300.02011174 + 101.35288319 - 101.72390334 +101.48406667- ,450,3 9994, 0.= R 430.02318882 + 101.82847314- 103.89964215 +103.39744191- sin 1 2 2 4- 25-36- 48-510- 1 2 2 4- 25-36- 48-510- 1 2 2 4- 26-37- 48-510- 1 2 2 2- 4-26- 37-48- 510-612- 1 2 2 4- 26-38- 1 2 2 4- 2-63-8 2 3 o o o o o o n d rc ??? ? ?? ?? ???? ?? ?? ???? ?? ?? ????? ?? ?? ???? ?? ???? ?? ? (3.50) 57 ( ) ?? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?<= ? ?? ?? ?<= ? ?? ?? ?<= ? ?+? ?? ?<= ? ?+? ?? ?< ?< = = ? ?? ?+? ? ?? ?? =? ? ?? ? ? .400,22 0.9996, = R 109422874 0.0+ 104.37257752- 102.90105343 +101.56703453 - 106.12012384 + 106.61739779- ,400,20 0.9996 = R 740.01115478 +104.37257752- 102.90105343 +101.56703453 - 106.12012384 + 106.61739779- ,400,18 0.9996 = R 740.01137978 +104.37257752 - 102.90105343 101.56703453 - 106.12012384 +106.61739779- ,400,16 0.9996, = R 116297874 0.0+ 104.37257752- 102.90105343 101.56703453 - 106.12012384 +106.61739779- ,400 ,400 ,14 ,10 0.9993, = R 119228070 0.0+ 104.76005398- 105.67714535 +101.73419068 - 106.54759070 107.03151544- 0.9995, = R 160.01314489 +101.27943518 - 102.06298722 +102.32498214- 107.25696594 +107.04675716- sin 1 2 2 5- 26-36- 48-510- 1 2 2 5- 26-36- 48-510- 1 2 2 5- 26-36- 48-510- 1 2 2 5- 26-36- 48-510- 1 2 1 2 2 5- 26-36- 48-510- 2 4- 25-36- 4-85-10 2 3 o o o o o o n d rc ??? ? ?? ?? ??? ? ?? ?? ??? ? ?? ?? ??? ? ?? ?? ? ? ? ? ? ? ? ?? ?? ? ?? ?? ? (3.51) Because density ratios over sixteen may occur in the regions of maximum heat transfer during planetary entry, it was decided to extrapolate the curve-fit for ?2/?1 > 16 listed in Eqns. (3.49) and (3.51). With all of these equations, it is possible to approximate the shock-standoff distance. This is the full extent of Kaattari?s method. To account for nonaxisymmetric geometries, it is assumed that the change in the shock-standoff distance for shape variance and an angle of attack is dependent on 58 eccentricity and the axial shape of the upper half at ? = 0o (j = 1) and the lower half at ? = 180o (j = (jmax-1)/2). An example geometry is shown in Figure 3.2 to show how Kaattari?s method is applied. Figure 3.2. Spherically-blunted cone profile shock-standoff distance variance. Kaattari?s method is applied to determine the radii of the shock for the upper profile rsh,upper = 4.827 and the lower profile rsh,lower = 11.30 separately. This is accomplished by accounting for the different half-cone angles for the upper and lower surfaces, ?c,upper = 70o and ?c,lower = 76o respectively. Also the different upper and lower base radii, rupper = 1.958 m, and rlower = 2.864 m respectively are accounted for and added together to produce the base diameter. The shock-standoff distances for each case is calculated ?o,upper = 0.4175 m and ?o,lower = 0.9215 m. After the shock- standoff distances are determined this work assumes that this cone shape must have a zero angle of attack shock-standoff distance ?o that is in-between the two calculated shock-standoff values. It is assumed that each has equal effect on ?o, and so it is set 59 equal to the average of the two and produces the open circle in Figure 3.2 corresponding to ?o = 0.6695 m. Originally, to account for angle of attack, Kaattari?s Eqn. (3.47) was applied, but for the case of Figure 3.2, ??<0 > ??>0, which does not follow the most probable trend. At ?<0, the upper profile faced the freestream more than the lower profile, and so it should have more effect on ?? than the lower profile. Because rsh,lower > rsh,upper, it is expected that ??=-(90-?) < ??=90-?, which is the opposite of the trend produced by Eqn. (3.47). As a result, the following basic method is applied to guarantee that this trend is held. This work assumes that the shock-standoff distance at ? = 90o - ?c,lower, which is ?>0o, can be approximated by the distance from the lower shock with radius rsh,lower that is perpendicular to the lower face. This distance is the length between the two inverted triangles shown in Figure 3.2. For ?<0, the shock-standoff distance at ? = - (90o - ?c,upper), can be approximate by the distance from the upper shock with rsh,upper that is perpendicular to the upper face. This distance is the length between the two triangles shown in Figure 3.2. As a result, this also means that if rsh,lower < rsh,upper, then ??=-(90-?) > ??=90-?, thus this method accounts for either case. Linear interpolation between ?o and ?? is applied once the endpoints ??=-(90-?.upper) and ??=90-?,lower are determined. This simple method is implemented only so that the shock-standoff distance is varied and follows an expected trend. To account for eccentricity, the average base radius is determined; then it is divided by the maximum base radius to produce the non-dimensional average base radius ravg,nd. This term is then used to calculate the upper and lower shock radii 60 ? ? ? ??? ? < ? = ,0, ,0, , , , , , errrrrr errrrrr r ndavg upper upper n n uppersh ndavgupper upper n n uppersh uppersh (3.52) and ? ? ? ??? ? < ? = .0, ,0. , , , , , errrrrr errrrrr r ndavg lower lower n n lowersh ndavglower lower n n lowersh lowersh (3.53) Eccentricity is accounted for through this approach so that the calculated shock radii of a prolate shape with eccentricity e at ? and those of an oblate shape with the same eccentricity are affected equally. This is one way of producing consistency throughout the results. Note that this addition does not provide true consistency when calculating the radiative heat transfer, as the value of qrad varies up to 33% at eccentricity |e| > +/- 0.9 and up to 20% at |e| > +/- 0.8. As a result, any calculations for highly eccentric shapes should be seen only as approximate solutions. For rounded-edge concave shapes such as that shown in Figure 2.7, the profile could look similar to an inverted Figure 3.2. In this case, it is assumed that only the surface with the larger r (in the case of Figure 2.7 it would be rupper) is applied rather than using the average of shock-standoff distances because the surface with the larger r represents the primary radius of the shock-shape. This is assumed for the rounded- edge concave shapes since they have not been investigated experimentally or through computational fluid dynamics (CFD). It should be noted that the shock shape about rounded-edge concave shapes may have a radius that varies with sweep angle, and so only basic assumptions can be made at the level of this work?s analysis. 61 3.3. Static Stability The stability of a planetary entry vehicle is one of the main factors that determines whether a particular design is feasible. If the PEV requires quasi-steady flow in order for it to follow the designed trajectory, then the vehicle must be able to remain or return to the designed trim angle of attack ?trim after encountering flow disturbances. This can be determined by looking at the static and dynamic stability of the vehicle. This work analyzes the heat shields? static stability only for a first-look analysis. An in-depth, full vehicle analysis would require the study of both the static and dynamic stability since it is possible for a statically stable vehicle to be dynamically unstable. If a vehicle is statically stable, then it possesses the aerodynamic moments required to restore the vehicle to an equilibrium state after encountering a flow disturbance.67 One way to measure a vehicle?s static stability is to analyze its aerodynamic moments about the vehicle?s center of gravity. In this work, the aerodynamic moment coefficients Cm,0, Cn,0, and Cl,0 about the nose of the vehicle and the force coefficients CN, CA, and CY are calculated using modified Newtonian Impact Theory. Then the center of pressure location is determined from this information as previously explained. The center of pressure is the location at which the aerodynamic forces are applied. As a result, the aerodynamic moments, which are produced by the aerodynamic forces, are zero about the center of pressure. Once a center of gravity location is either chosen or calculated, moments produced by the aerodynamic forces about the center of gravity are calculated. 62 For a fixed body-axis moment with conventions for positive moments given in Figure 3.1(b), there are twelve possible center of pressure locations, with respect to the vehicle?s center of gravity and the central axis. For example, in longitudinal stability, the contributions of the normal and axial forces to the pitching moment about the center of gravity are determined. If the center of gravity is below the central axis, then the center of pressure can be below the center of gravity, above the center of gravity in the same quadrant (below the central axis), or above the center of gravity in a different quadrant (above the central axis). In each of these cases, the center of pressure could be in front of, aligned with, or behind the center of gravity. If the aligned case is grouped with either the in front or behind cases, then there are six different geometric cases. The other six cases correspond to the inverted case in which the center of gravity is above the central axis, thereby producing a total of twelve cases. After deriving each of the twelve cases for the pitching, yawing, and rolling moments about the center of gravity, it was observed that all twelve cases for each moment could be reduced into one equation, producing the following three equations ,, ?? ? ? ??? ? ?+ ??? ? ??? ? ?= d YYC d XXCC cgcp A cpcg Ncgm (3.54) ,, ?? ? ? ??? ? ?+ ??? ? ??? ? ?= d ZZC d XXCC cpcg A cgcp Ycgn (3.55) ? ? ? ??? ? 0, and there would not be a discontinuity. With the sign reversal, Figure 3.3 clearly divides the stable and unstable oblate geometries. Phillips68 includes a good discussion on roll stability in his flight mechanics textbook. 3.4.2. Determining the Location of the Center of Pressure One of the assumptions of aircraft stability, CL >> CD, cannot be followed in a blunt-body analysis since blunt bodies usually have an L/D < 1. The assumption of CL >> CD leads to the conclusion that the center of gravity must lie in front of the aircraft?s neutral point (or the vehicle?s center of pressure) to satisfy the requirement of Cm,cg,? < 0 for longitudinal static stability.31 Since this assumption does not apply to blunt-bodies, it may be possible to produce longitudinal static stability with the center of pressure in front of the center of gravity. From modified Newtonian results for Cm,cg shown in Figure 3.4 for -30o ? ? ? 0o, it is determined that the Xcp/l = 0.6556 and Ycp/l varied from 0.0000 to 0.5530 for a spherical-segment of ?s = 25o with a non- eccentric base. As a result, the code suggests that the Apollo CM with a Xcg/l = 2.171 is one successful example of maintaining longitudinal static stability with the center of pressure in front of the center of gravity. Similar to Xcp/l being constant over a range of ? for a spherical-segment e = 0, ?s = 25o, it has been proven that Xcp/l = 0.6667 for a sharp cone in a Newtonian surface pressure field, suggesting that Xcp/l is independent of half-cone angle ?c.29 Note that not all spherical-segments have Xcp/l = 0.6556, but at least one does with ?s 67 = 25o, e = 0 including the Apollo CM. The general pitching moment equations that relate Xcp and Ycp to Cm,0 are given as Eqns. (3.20-3.22). These equations follow the coordinate system shown in Figure 3.1(b) that has a positive Cm corresponding to a nose-up moment. Bertin29 notes that the axial force?s contribution to the pitching moment is commonly neglected in the definition of the center of pressure location at and near zero angle-of-attack. However, this assumption does not apply to blunt-body aerodynamics because Cm,A,0 is commonly the dominant term for a blunt-body. -0.08 -0.06 -0.04 -0.02 0 0.02 0.04 -35 -30 -25 -20 -15 -10 -5 0 Angle of Attack (deg) Cm ,cg Modified Newtonian Wind Tunnel Data Apollo Wind Tunnel Data, M = 6 Figure 3.4. Variation in Cm,cg with angle of attack. Cm,N,0 is not usually the dominating term for slender bodies, in which case the resulting formula29,30,55 for a circular cone at zero angle-of-attack Xcp/l = 2/(3cos2?c) can be used, but this equation complicates the analysis since Xcp/l is constant at 0.6667 without the assumption. When this assumption is applied to a blunt circular cone with ?c = 70o, then Xcp/l = 5.7, which is not close to the actual Xcp/l = 0.6667. This assumption is only close to the exact solution for small ?c, but a blunt-body cone 68 does not have a small ?c. For a general blunt-body shape, the following relation does not determine the x-location of the center of pressure .0, N mcp C C d X ?? (3.60) Instead, Xcp/l for a given blunt-body shape can be determined from the normal force?s contribution to the pitching moment Cm,N,0 as shown in Eqn. (3.21). Arora?s 2003 aerodynamic shape optimization work57 maximizes Xcp. Unfortunately, he equates Xcp to Cm,0/CN, which contradicts Eqn. (3.60). Since he does not account for the axial force?s contribution to the pitching moment, his work is an example of recent research that has made this incorrect assumption on basic blunt- body aerodynamics, rendering the published optimization results unusable. His conclusion is that the optimized Xcp value is 1.213 m, but a quick analysis of the geometry he chose accounting for the axial force?s contribution to the pitching moment suggests that the actual Xcp is less than approximately 1.1 m, suggesting that his optimization results are within an infeasible region of x-locations due to the incorrect definition of Xcp. Additionally, his optimization results could be significantly different when accounting for the general relation of Xcp and Cm,0 given by Eqn. (3.20). Note that the incorrect definition of Xcp for a blunt body is included in Regan?s first edition55 and Rasmussen.30 These are all examples of published work that show what Bertin29 mentions is the conventional definition of Xcp, not the true definition of Xcp that is required to complete an aerodynamic analysis of blunt-bodies. 69 Chapter 4. Heat Transfer Two heat transfer modes, convection and radiation, are considered in this work. The two arguably most important heat transfer characteristics are the heat flux and the heat load. The heat flux is power density in the form of heat per unit area. The heat load is equal to the heat flux integrated over the trajectory in time. It is common in the first analysis of a vehicle to look at the heat fluxes and heat loads at the stagnation point because this is usually accepted as the point of highest heat transfer. This is not true for the Apollo CM, which re-entered at an angle of attack that brought the stagnation point near the corner radius. In such cases, as noticed in Ref. (35), the heat transfer is higher at the edge of the heat shield than at the stagnation point. In fact, the Apollo Command Module at ? = ?33o had a heat transfer flux at the edge that is 92% larger than that at the stagnation point corresponding to ? = 0o, according to wind tunnel results,35 but the actual CMs did not necessarily travel trajectories that required this high an angle of attack. The most likely reason that this was one of the highest angles of attack tested is because the conical shaped crew compartment that connected to the heat shield was at a 33o angle with the horizontal. As a result, the flow would pass by the crew compartment flush at ? = ?33o. The Apollo 4 CM traveled with a maximum angle of attack of ?25o, in which the heat transfer at the edge is around 60% higher than at the stagnation point corresponding to ? = 0o, according to other wind tunnel results.36 In both the cases of ? = ?25 and ?33o, the stagnation-point heat flux is approximately 15% larger than it would be at ? 70 = 0o.35,36 As a result, the heat flux is higher at the edge of the heat shield than that at the stagnation-point of the Apollo CM. Both the heat flux and heat load are equally important; however, for this work, only the heat flux is analyzed as it has been decided that the heat load would be determined with use of a trajectory code at a later time. This chapter explains the correlations applied in this work and their assumptions. The correlations were originally designed to calculate the stagnation-point heat flux on a sphere. Applying these correlations allows for the heat flux to vary with the radius of curvature of a given blunt body. Explanations on how these correlations are applied to blunt-bodies are included in the following sections. These correlations also vary with altitude through a freestream density factor and with speed through a freestream velocity factor. For this work the ARDC 1959 Model69 and US Standard Atmosphere of 197670 have been applied. The 1976 standard atmosphere is applied for results, but the 1959 model atmosphere is used as noted throughout the text for the application of older correlations and code validation of results that used standard atmospheres before 1976. 4.1. Convection The stagnation-point convective heat transfer correlation of Tauber42 is applied in this work. Tauber assumes equilibrium flow conditions and a flight regime where boundary-layer theory is valid. Tauber produces a specific equation for planetary entry from satellite speed, but it is the objective of this work to approximate the heat transfer flux for planetary entry from both satellite and superorbital entry 71 speeds. To account for this, the general form of his correlations, which is given as Eqn. (4) of his article42, is applied to produce the following correlation for the stagnation-point convective heat flux ,convsq& ( ) 35.05.08, )1( 1083.1 ???? ??= Vgrq wnconvs ?& , (4.1) in which gw is the ratio of wall enthalpy to total enthalpy. It is assumed that gw << 1, and so gw is zero in this work. This correlation assumes a fully catalytic surface. This correlation also holds true to the Fay and Riddell43 derivation that states the ,convsq& is inversely proportional to the square root of the nose radius. Zoby44 presents evidence that this relation breaks down for blunt bodies with ratio values of base radius r to nose radius rn less than 0.6, in which rn > r. He suggests that this is due to the velocity gradient being higher than would be otherwise expected by the deriving ? ,convsq& rn-0.5. If possible, this would be a good addition for future work. This is only one example that these heat transfer derivations are not accepted as fact in their application to blunt bodies, but they generate trends that are accepted as generally true for stagnation- point heat transfer. The form of the correlation shown in Eqn. (4.1) was originally designed for calculating stagnation-point heat flux on a sphere. Since the stagnation-point convective heat flux relies mainly on the geometry nearby the stagnation-point, as opposed to the full body shape and size, it can be approximated by setting the radius of curvature equal to the nose radius. The nose radius is the term that relates the heat flux to the geometry in Eqn. (4.1). For the spherical-segment and spherically-blunted cone axial shapes, determining rn is a trivial calculation. For the power law axial 72 shape, the slope of the shape at the tip of the nose may not necessarily be continuous, as in the case of setting b = 1, in which a sharp cone axial shape is generated. As a result, the blunt-bodies with a power law axial shape must have an equivalent nose radius term produced. This equivalent nose radius is only an approximation and should not be accepted as a complete model for power law shapes. First, it is assumed that the power law shape?s nose tip is blunted if its slope is discontinuous. Then the profile of the power law shape is examined; for this analysis, a line that is normal to the power law profile and that produces a 15o angle with the horizontal is generated. A segment of that line that begins at the line?s intersection with the power law profile and ends at its intersection with the horizontal central axis is produced. The effective radius is assumed to be equal to the average of the length of that line segment and the distance to the nose from the end point of that line segment on the horizontal axis. If the normal line intersects the power law curve beyond the base of the geometry (the intersection occurs outside of the heat shield shape), then the geometry?s curvature is assumed sharp and given an effective radius value of 0.001 m. To produce a true method for determining the effective radius of the general power law shape for convective heat transfer is a research topic in itself. 73 4.2. Radiation Because radiation over a blunt-body can be primarily modeled as an elliptic problem, the radiation at the stagnation point depends on the body of the vehicle in addition to the nose radius. Also, the radiative heat flux is significantly more sensitive to the angle-of-attack of the blunt body than the convective heat flux. In this work, all these effects are incorporated into the term called the effective radius. In order to apply ,radsq& correlations for spheres to non-spherical blunt-bodies, the effective radius in this work is directly related to the spherical radius for a given set of freestream conditions. This is accomplished by estimating the shock-standoff distance ?so across from the stagnation point at a given normal shock density ratio ?2/?1 of the blunt body. To calculate the normal shock density ratio ?2/?1, high temperature properties of air must be determined in order to calculate an effective specific heat ratio after the normal shock ?eff,2. Tannehill54 supplies high temperature air correlations for this work, and they are also located in Chapter 11 of Anderson.65 The effective specific heat ratio after the normal shock is determined through an iterative process. First, a test variable for ?eff,2 is called ?test,2 and set equal to 1.4 as an initial condition. Then the corresponding pressure p2 and density ?2 after the normal shock are calculated based on ?test,2 ( ) ,1121 21 2, 2, 12 ??? ? ??? ? ? ++= Mpp test test ? ? (4.2) 74 ( ) ( ) ,21 1 2 12, 2 12, 12 ?? ? ? ??? ? +? += M M test test ? ??? (4.3) and these two variables are entered into Tannehill?s Fortran code that returns the corresponding enthalpy h2 and ?eff,2 ,1 2, 2, 2 2 2 ?? ? ? ??? ? ?= eff effph ? ? ? (4.4) ( )( ),exp1 11109 876543212, cYcXc YZcZcYccYZcZcYcc eff +++ ++++++++=? (4.5) in which , , 10013.1log ,292.1log 5 2 10 2 10 YXZY pX ?=? ? ?? ? ? ?=?? ?? ? ?= ? (4.6) and coefficients c1 through c11 are curve-fit values tabulated in Tannehill.54 For this work, only the ?eff,2 is used. The value of ?eff,2 is compared to ?test,2; then ?test,2 is set equal to the calculated ?eff,2, and the process is iterated until the absolute value |?eff,2 ? ?test,2| is less than 0.01. Once a converged value of ?eff,2 is determined, then the corresponding normal shock density ratio ?2/?1 has been calculated and could be used in Kaattari?s method described in Chapter 3 to approximate the shock-standoff distance. It is assumed that the effective nose radius for stagnation-point radiative heat transfer, reff, for a given blunt body is equal to the radius of a particular sphere that maintains an equal shock-standoff distance. After calculating the normal shock- standoff distance, the corresponding spherical radius still would have to be determined. 75 According to wind tunnel results shown in Figure 4.1, the ratio of the normal shock-standoff distance to a sphere of radius reff is constant for a given normal-shock density ratio. Figure 4.1. Stagnation-point shock-standoff distance wind tunnel data with empirical curve-fit, Ref. [48]. Ried48 offers an empirical curve-fit that renders an acceptable approximation, also shown in Figure 4.1: .1 12 1 1 1 2 1 2 2 1 2 ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?? ??? ? ??? ? ? =? ? ? ? ? ? ? eff so r (4.7) Then the reff from this equation replaces the sphere?s radius in the stagnation-point radiative heat flux correlations. Three ,radsq& correlations are applied over a range of velocities. For V? < 9000 m/s the correlation of the following form is applied 76 ,10000 32 1, gg sl effrads Vgrq ? ? ?? ? ? ??? ? ??? ?= ?? ? ?& (4.8) in which g1 = 100, g2 = 1.6, and g3 = 8.5 from Ref. [29] for velocities below 7620 m/s and g1 = 6.8, g2 = 1.78, and g3 = 12.5 for velocities from 7620 to 9000 m/s from Ref. [41]. For velocities above 9000 m/s, the Tauber and Sutton45 equation is applied )(10168.4 22.14, Vfrq Heffrads ??= ?& , (4.9) in which ,10072.1 325.088.16 ?????= ?VH and ? ? ? ? ?? ? ? ? ?< ? ?? ??? ?? = ? ?? ? ? ? ? ? ??? ? ? ? ? ? m/s 1600011500 .17168.3333 - V6.25525796 + V108.42982517 - V104.89774670 + V101.00233100- m/s 115009000,39494.8753 - V16.1078691 + V102.43598601 - V101.61370008 + V103.93206793- )( 24 38412 23 37412 V V Vf These curve-fit equations for f(V) have < 2% difference with the published values.45 Note that these curve-fit equations have coefficients with a high number of digits in order to produce the <2% error. It is suggested that all of these digits are maintained; if they are not, the values of f(V) may go below zero for low V? or produce extremely large values for high V?, either case producing erroneous results. The high number of digits does not correspond to the number of significant figures from this correlation. It is suggested that no more than three digits should be specified as significant for all three radiation correlations. 77 Chapter 5. Description of Code and Optimization Process All of the presented theory has been implemented into a Fortran code for this work. For optimization, this code is linked to VR&D?s Design Optimization Tools (DOT).71 This chapter presents the layout of the code written for this work, a brief introduction to DOT and a summary of the chosen optimization method, and a list of studied objective functions with each one?s value to this work. 5.1. Code Layout The overall code layout is composed of three main components: the operating code, analysis code, and DOT. The overall code layout is shown in Figure 5.1. The operating code is the primary program from which all the other programs are managed. The analysis code determines the aerothermodynamic characteristics of a chosen blunt-body shape at given freestream conditions. Then the operating code calls DOT to determine the values of the design variables to be sent into the analysis code for each iteration of the optimization process. The operating code includes all the settings and inputs required to operating the analysis and DOT codes. There are three operating modes available in this code. The single case mode can run the analysis code once at the given ? and ? to get the aerodynamic coefficients and the heat transfer determined. It can also run the analysis code five times in order to also calculate Cm,cg,?, Cl,cg,?, and Cn,cg,?, which require the values of Cm,cg, Cl,cg, and Cn,cg at four neighboring conditions (?+0.5o, ?), (?-0.5o, ?), 78 (?, ?+0.5o), and (?, ?-0.5o) for the second-order accurate finite-difference scheme mentioned in Chapter 3. Figure 5.1. Diagram of Overall Code. The second operating mode allows the user to conduct a parametric study of both geometric and freestream parameters for any geometric shape. It is possible to vary these variables at any resolution desired. Finally the third operating mode is the optimization setup that calls the DOT optimization routine. DOT determines the values of the design variables at which to run the analysis code based on a constrained method. DOT is setup in this work to use the modified method of feasible directions (MMFD) constrained method for optimization. Operating Code Single Case ? Analysis code single run ? Analysis code 5 runs Parametric Study ? Analysis code 10-10000 runs Optimization Setup ? Design variables and constraints Design Optimization Tools (DOT) Constrained method: Modified Method of Feasible Directions (MMFD) Analysis Code Required subroutines: ARDC 1959 Model Atmosphere US 1976 Standard Atmosphere Tannehill?s High Temp. Air Code Design results 79 The analysis code has three objectives: to generate the blunt-body geometry, to determine its geometric properties, and to calculate the aerodynamics, static stability, and the stagnation-point heat transfer. A diagram of the analysis code is given in Figure 5.2. Given the geometric parameters of a chosen base and axial shape, the shape generator produces a 3D mesh of the heat shield geometry. The aerodynamics calculator determines the aerodynamic characteristics of a given shape based on modified Newtonian surface pressure distribution at a given angle-of-attack, sideslip angle, and Mach number. The primary variables that are calculated in the aerodynamics code are M?, ?, CL, CD, L/D, CN, CA, Cm,0, Cl,0, Cn,0, Xcp/L, Ycp/L, Zcp/L. Figure 5.2. Diagram of Analysis Code. The aerodynamics calculator is acceptable for determining blunt-body shape hypersonic aerodynamics at fine mesh sizes with extremely low run times (usually a fraction of a second for a jmax = 121, kmax = 203 mesh). Additionally, the aerodynamics code uses Tannehill?s code to determine ?eff,2 and ?2/?1, and it uses Kaattari?s method to determine the shock-standoff distance ?so to the stagnation-point Cross-section Shape Shape Generator Aerodynamics Geometric Properties Aerodynamic Stability Design Results ?s, rn,/D, ?c, A, b m, n1, n2, n3, e Axial Shape Heat Transfer M?, ??, ?, ? Freestream conditions 80 that are used in the heat transfer portion of the code. The primary output of the heat transfer portion of the code are reff, ,,convsq& and .,radsq& The analysis code applies a 5th-order accurate Simpson?s Rule integration method to determine the aerodynamic characteristics and center of gravity location. The center of pressure location is then determined. Geometric properties such as the volume, surface area, and planform area are calculated in the analysis code. Additionally, a center of gravity can be either chosen or calculated assuming a uniform density volume. The static stability calculator uses the aerodynamics in conjunction with the location of the center of gravity to determine the moment coefficients about the center of gravity and the pitch, yaw, and roll stability derivatives. Note that the analysis code requires two atmospheric models and Tannehill?s high temperature air code. Two atmospheric models are programmed in order to use the older atmospheric model for part of the validation process of the heat transfer correlations. 5.2. Design Optimization Tools (DOT) Vanderplaats Research & Development, Inc.?s Design Optimization Tools (DOT)71 is professional software program that varies design variables based on a gradient-based minimization method to determine an optimum value of an objective function. DOT offers both unconstrained and constrained minimization methods. Broydon-Fletcher-Goldfarb-Shanno (BFGS) and Fletcher-Reeves (F.R.) are the two unconstrained minimization methods available in DOT. When DOT refers to unconstrained methods, it means that there are no constraints present except those on 81 the design variables that DOT varies. The constrained methods offer the ability to restrict values on non-design variables or a combination of variables based on theory limits or other reasons. The constrained minimization methods available in DOT include the Modified Method of Feasible Directions (MMFD), Sequential Linear Programming (SLP), and Sequential Quadratic Programming (SQP). MMFD is the most reliable of the three and requires less memory than the other two methods.71 The following optimization problem is solved by DOT: find the values of NDV design variables contained in Xr that will minimize or maximize )(OBJ XO r= , in which the OBJ is the objective function, subject to constraints Gq(Xr ) ? 0 for q = 1 to NCON, in which NCON is the number of constraints, and design variables Xp have side constraints UppLp XXX ?? for p = 1 to NDV, in which NDV is the number of design variables.71 For this work, DOT has been setup to use MMFD to vary the design variables to find an optimum value of an objective function, in this case, an aerothermodynamic parameter or combination of parameters. MMFD uses the following overall process. The objective function and constraints are first evaluated at the user inputted initial values of the design variables. Then the gradient of the objective function and constraints are calculated, and a search direction E is created. Then a one-dimensional search is completed to find the scalar parameter ?* that minimizes )(XO r . Scalar parameter ?* is used to find a new Xr that is set equal to the sum of the initial Xr and the product of ?* and the search direction, ,*1 uuu EXX ?+= ?rr (5.1) 82 in which u is the iteration number. If convergence is not satisfied, then iterations of the following process are completed until convergence requirements including the Kuhn-Tucker conditions are satisfied.71 The three Kuhn-Tucker conditions71 must be satisfied for obtaining convergence using MMFD. The first is that optimum design *Xr must be feasible, or produce constraint values Gq( *Xr ) ? 0 for q = 1 to NCON. The second condition is that the product of the Lagrange multiplier ?q and Gq( *Xr ) must be zero. The third condition is that the gradient of the Lagrangian becomes zero, in which the gradient of the Lagrangian is .0*)(*)( NCON q =?+? ? XGXO q q rr ? (5.2) Detailed descriptions of MMFD and the Kuhn-Tucker conditions are included in Appendix E of Ref. (71). A quick analysis of several different objective functions is discussed in the next section. 5.3. Choosing Objective Functions A quick analysis of the results of 57 unconstrained optimizations on 57 different objective functions has been completed to determine which objective functions to use, to observe any trends in the results, and to notice any unexpected results. For this analysis, each objective function was maximized. The design variables and their initial designs for this preliminary optimization for a hexagonal m = 6, n1 = 2.3 superellipse cross-section shape and spherical-segment axial shape are 83 . 2.0 5.2 35 2 0 ? ? ? ? ? ? ? ? ? ? ? = ? ? ? ? ? ? ? ? ? ? = o s e nX ?r (5.3) The ranges of values for these design variables are 5o ? ?s ? 89o, -0.95 ? e ? 0.95, and 1.50 ? n2 ? 4.0. The freestream conditions for the Newtonian flow model include M? = 30 and negative ? = 25o at an altitude of 200,000 ft. In addition to single term objective functions, the fifty-seven are composed also of linear combinations or products of aerodynamic coefficients, stability coefficients, and geometric parameters. The objective functions included in Table 5.1 rendered the better aerodynamic results out of the 57 objective functions and are thereby listed as the most useful objective functions. Each number in the left column corresponds to the number of variables in each objective function. Table 5.1. Most useful objective functions. Objective Functions 1 CL, CD, L/D, LV/D, LH/D, CL,V, CL,H, Cm,cg, -Cm,cg,?, C n,cg,?, -Cl,cg,?, ?v 2 CLCD, CL + L/D, Cn,cg,? -Cm,cg,?, -?v Cm,cg,?, ?vL/D 3 -Cm,cg,? + CL + L/D, -Cm,cg,? + Cn,cg,? - Cl,cg,? 4 -Cm,cg,? + Cn,cg,? - Cl,cg,? + L/D The better objective functions that are made up of three or four variables were noticed to not be multiplied, only added. The objective functions that produced results that were either not as good but still acceptable or produced mediocre results are as questionable objective functions in Table 5.2. 84 Table 5.2. Questionable objective functions. Objective Functions 2 -Cm,cg,? +CL, -(Cm,cg,?+Cl,cg,?), L/D-Cm,cg,?, Cm,cg - Cm,cg,?, Cm,cg Cm,cg,?, -Cm,cg,?Cl,cg,? 3 CL +CD + L/D, -(C m,cg,?+Cl,cg,?) Cn,cg,? Then there are several objective functions that produced results that were not acceptable from an aerodynamic and static stability standpoint. These objective functions are listed in Table 5.3. Table 5.3. Objective functions to use with caution. Objective Functions 1 CL2, Shs, Vhs 2 CL + CD, CL L/D, CD + L/D, -Cm,cg,?CL, -Cm,cg,? L/D, -Cm,cg,? Shs, -Cm,cg,? ?v, ?v Shs, L/D Shs, CL Shs, CD Shs, L/D Vhs 3 CL L/D+CD, -Cm,cg,? + CL L/D, Cm,cg,?Cn,cg,?Cl,cg,?, Cm,cg,?Cl,cg,? + Cn,cg,?, CL L/D((Cm,cg,?)2)1/4, -Cm,cg,? ?v Shs 4 Cm,cg,?Cl,cg,? + Cn,cg,? + L/D, -(C m,cg,?+Cl,cg,?)Cn,cg,? L/D Some of these results may not be intuitive. For example, this analysis suggests that maximizing surface area or volume individually produces results that are not as acceptable from an aerodynamic and static stability standpoint as maximizing objective functions from the other two sets. Note that this is not meant to be a perfect test of objective function effectiveness but just a way to determine which objective functions would be worth working with first. 85 sdff Chapter 6. Design Code Validation To validate the design code, and the corresponding implemented theories, results of the design code are compared to data from the Apollo and FIRE II missions. The results are divided into two areas: (1) aerodynamic performance and static stability and (2) stagnation-point heat transfer. The first section notes that the aerodynamic coefficients and stability derivatives match the Apollo data within 15%. The second section observes that the maximum heat transfer heat flux and heat load is within 15% of actual predictions after the stagnation-point heat transfer heat flux is related to the maximum heat flux according to wind tunnel data. 6.1. Aerodynamics and Static Stability The aerodynamic performance and static stability are compared to both Apollo wind tunnel data and Apollo flight test data. There is more certainty in the Apollo wind tunnel data than in the Apollo flight test data, and most of the wind tunnel data is for M? = 6 while the flight test data is for M? = 36. To convert from the listed angle of attack value of the NASA Apollo reports to the angle of attack value used in this work, defined in Figure 3.1(a), subtract 180o from the NASA reported value. This should usually convert the NASA reported value to a negative angle of attack. Note that there is not any truly acceptable experimental data on the rolling moment stability coefficient, but predictions are compared to Whitmore?s recent computational work.28 86 6.1.1. Comparison with Apollo Wind Tunnel Data Results from the code based on modified Newtonian theory, have been compared to wind tunnel8,9 data of the Apollo Command Module (CM). The center of gravity is offset from the central body axis in order to trim the Apollo CM at a specific angle-of-attack during re-entry.10 Different center of gravity locations were considered in the wind tunnel models during the design of the CM. 8,9,11 In Figure 6.1, the center of gravity location is Xcg/l = 2.171, Ycg/l = 0.3158, and Zcg/l = 0.0 according to the body-fixed coordinate system in Figure 3.1(b). -0.08 -0.06 -0.04 -0.02 0 0.02 0.04 -35 -30 -25 -20 -15 -10 -5 0 Angle of Attack (deg) Cm ,cg Modified Newtonian Wind Tunnel Data Apollo Wind Tunnel Data, M = 6 Figure 6.1. Cm,cg comparison between modified Newtonian and wind tunnel data, Ref. [8]. Additionally, because Xcg/l > 1, the center of gravity location of the CM is past the heat shield. The Newtonian results for the pitching moment Cm,cg at M? = 6 in Fig. 5 produce Cm,cg,? = -0.16/rad; the modified Newtonian results follow the behavior and closely agree with the values of the Apollo wind tunnel (WT) data.8 As a result, this is evidence that the modified Newtonian results can match the pitching moment closely and thus predict ?trim, and it is well-known to match the lift-to-drag ratio for a blunt body better than the lift or drag coefficients. 87 The wind tunnel data for the rolling moment Cl was scattered near zero and has values that are two orders of magnitude smaller than those measured for Cm. Although the data accuracy of Cl and Cm is not reported for this wind tunnel data, the scattering and smaller values of the Cl data points in Fig. 6 suggest that the measurement instruments did not have the precision required to obtain a clear data set of the CM?s rolling moment behavior. -1.00E-03 -7.50E-04 -5.00E-04 -2.50E-04 0.00E+00 2.50E-04 -6 -4 -2 0 2 4 6 Sideslip Angle (deg) Cl ,0 M. Newtonian Wind Tunnel Data Apollo Wind Tunnel Data, M = 6 Figure 6.2. Cl,0 comparison between modified Newtonian and wind tunnel data, Ref. [8]. The wind tunnel data suggest a neutrally stable spherical-segment at -20o angle-of- attack, and the modified Newtonian results agree. A mesh with jmax = 203 and kmax = 121 has been chosen based on a grid convergence study. Since the Apollo CM is axisymmetric, the yawing moment coefficient Cn,0 at a given sideslip angle (the condition ?1 ? 0, ?1 = 0) would be equivalent to the pitching moment coefficient Cm,0 at a given angle-of-attack (the condition ?2 = ?1, ?2 = 0). This is one reason that no specific Cn,0 data exists in the references. 88 0 0.1 0.2 0.3 0.4 0.5 0.6 -40 -30 -20 -10 0 Angle of Attack (deg) CL M. Newtonian M = 15.8 WT M = 18.73 WT a) Validation of CL results. 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 -40 -30 -20 -10 0 Angle of Attack (deg) CD M. Newtonian M = 15.8 WT M = 18.73 WT b) Validation of CD results. 0 0.1 0.2 0.3 0.4 0.5 0.6 -40 -30 -20 -10 0 Angle of Attack (deg) L/D M. Newtonian M = 15.8 WT M = 18.73 WT c) Validation of L/D results. Figure 6.3. Aerodynamic force comparisons between modified Newtonian and wind tunnel data, Ref. [8]. 89 The modified Newtonian results in Figure 6.3 were calculated at M? = 18.73, but the difference between these results and those at M? = 15.8 is negligible (0.05% difference at ? = -20o). Modified Newtonian results for the lift and drag coefficients are larger than values from both datasets shown in Figure 6.3(a) and (b). However, the increase in lift and drag with an increase in Mach number in the wind tunnel data is more significant than expected; this may suggest the presence of significant wind tunnel effects. At M?=18.73, CL and CD from Newtonian theory are at most 9.6% and 7.2% larger than the wind tunnel data respectively, and they are within the uncertainty of the wind tunnel data of ?0.114 for CL and ? 0.10 for CD.8 L/D Newtonian results shown in Figure 6.3(c) agree very well with the wind tunnel data (better than for the individual CL and CD as expected). At lower freestream Mach numbers, such as M?=9, the errors are larger than 10% for the lift coefficient as shown in Table 6.1. While the data presented for M?=15.8 and 18.73 are based on Apollo CM models with rc/d of approximately 0.1, the data in Table 6.1 corresponds to rc/d = 0.0. Moseley conducted a survey of the effect of increasing rc/d, and his wind tunnel results for M?=9 at rc/d = 0.1 would increase the errors from those values in Table 6.1, for CL to approximately 22% and CD to approximately 13% while the error in L/D was constant at 8% at ? = -15o. Table 6.1. Percent error of Newtonian computations compared to wind tunnel data, M? = 9, in Ref. [9], Percent error averaged over -30o ? ? ? 0o. Average Percent Error Maximum Percent Error ? of Maximum Percent Error CL 0.45 0.534 18.6% CD 1.25 1.296 3.70% L/D 0.37 0.412 11.3% 90 As the code used in this work does not account for corner radius in determining the surface pressure distribution, this is one reason for the increase in error. The Newtonian surface pressure distribution is known to become more accurate with an increase in Mach number, and the validation results are consistent with this understanding. However, it is shown in the next section that comparisons with the flight test data from Apollo AS-202 result in an amount of error similar to that for M?=9. Overall, the modified Newtonian results are within 10% of the wind tunnel data with corner radius for M? ? 18.73, within 15% of the wind tunnel data without corner radius for M? ? 9, and within 25% of wind tunnel data with corner radius for M? ? 18.73. 6.1.2. Comparison with Apollo Flight Test Data Results from the code have been compared to flight test6,7 data for the Apollo Command Module (CM) for mission AS-202 and Apollo 4 (also known as AS-501). The CM in AS-202 re-entered Earth?s atmosphere at satellite orbit speed 8.23 km/s (27,000 ft/s) while the Apollo 4 CM produced the expected re-entry velocity from lunar return of 10.7 km/s (35,000 ft/s). The uncertainty in the flight data varies throughout the trajectory, and so the more steady aerodynamic data was identified and utilized. Of the two datasets, the flight data from AS-202 had the smaller uncertainty in the flight coefficient data of ?9% at 4900 s into the mission. The coefficients of the normal force, lift, and lift-to- drag ratio have percentage errors around this error. However, the coefficients of the 91 axial force and drag have higher errors around 17%. The Newtonian results are compared to the AS-202 flight data in Table 6.2. Table 6.2. Comparison of Apollo AS-201 Data and Computations, M? = 14, ? = -16.5o at 4900 s. AS-201 [ref. 6] Mod. Newtonian % Error CN -0.05 -0.0454 -9.2% CA 1.34 1.56 16.2% CL 0.37 0.399 7.8% CD 1.28 1.51 17.6% L/D 0.289 0.265 -8.4% The trend in the percentage error being higher for CL than CD seen in the wind tunnel data comparison is the opposite for AS-201. Because the corner radius is not accounted for, it is expected that the error in L/D to stay constant at 8%, for CL, according to wind tunnel results, to have approximately 22% error instead of 7.8% and CD to have approximately 13% instead of 17.6%. Note that these percentage errors are nearly constant, at least over the range of angle of attack values from ?30o to 0o. It is completely feasible for CD to have a difference in error of 4.6% since the uncertainty is a higher percentage, and so the only surprising trend is that the lift coefficient has 14% less error than expected. From the wind tunnel data, it is suggested that the corner radius affects the lift and drag coefficients less at higher freestream Mach numbers, but this is countered with the higher errors present in the AS-201 flight test data. In fact, wind tunnel effects could be changing the trends also, and so it is apparent that there is not consistency throughout this wind tunnel and flight test data to the resolution required to reason for the different percentage errors. Therefore, no conclusions could be made concerning whether the modified Newtonian results are less than 18?9% accurate. 92 Compared to flight data for Apollo 4 at M? = 30, Newtonian theory produces a CD that is 3.7% larger and a CL that is 18.6% larger as shown in Table 2.7 According to Hillje, the best flight-derived data for CN (near maximum freestream dynamic pressure) has an uncertainty of ?0.048.7 Because the normal force coefficient has a small magnitude, small precision errors in CN strongly affect the calculation of CL. The contribution of CN to CL is one order of magnitude less than the contribution of CA to CL. However, the contribution of CN to CD is two orders of magnitude less than the contribution of CA to CD, and so an error in CN will not affect CD as much as CL. This produces significant increase in accuracy of the Newtonian results for CD at 3.7% compared to CL at 18.6%. Table 6.3. Comparison of Apollo 4 Data and Computations, M? = 30, ? = -25o at 30040 s. Apollo 4 [ref. 7] Mod. Newtonian % Error CN -0.11 -0.06387 -41.9% CA 1.32 1.400 6.1% CL 0.45 0.5337 18.6% CD 1.25 1.296 3.7% L/D 0.37 0.4119 11.3% Additionally, Newtonian theory produces results that trim the CM within 1.2o for both Apollo missions AS-202 (? = 17.5o ? 0.5o)6 and Apollo 4 (? = 25.5o ? 3o).7 For all these reasons, it is concluded that the CN flight data is probably inaccurate, rendering the higher percentage errors in CL and L/D. Since the percentage differences between Newtonian theory and the acceptable CM experimental wind tunnel and flight data is less than 15%, and since the theory follows the behavior of the wind tunnel data, modified Newtonian flow is considered acceptable for comparing the basic hypersonic aerodynamic characteristics of the investigated blunt- 93 body heat shield shapes with low computational time. Only the rolling moment values and stability derivatives have not been completely validated since a lack of this data exists, but it is partly validated in the next section. 6.1.3. Comparison with Additional Sources Whitmore28 offers a recent analysis of the Apollo capsule as well as other human-rated lunar return vehicles such as a flattened bi-conic with trim flaps and an HL-20-derived lifting body configuration. His numerical results on the stability characteristics of the Apollo capsule closely match the results of this work?s code. Whitmore also uses a modified Newtonian surface pressure distribution to determine the aerodynamics of each vehicle. Both the results of this work and of Whitmore suggest that the Apollo capsule is slightly statically unstable in the roll direction. In this case, to be statically roll stable, the vehicle would have a negative value of Cl,cg,? since vertical lift is positive at negative angles of attack for the Apollo CM. Both works indicate that the Apollo capsule would have slightly positive values for the Cl,cg,?, if the center of gravity is above the central axis during planetary entry. Since the Apollo CM had a Reaction Control System (RCS) that could control the Command Module?s roll angle, one guess is that the RCS may have been used once in a while to fix the CM?s roll alignment. Another guess is that the Cl,cg,? had a negligible value for the CM. Whitmore reports a value of Cl,cg,? = 0.0065/rad while this work produces a value of Cl,cg,? = 0.00541/rad at ? = -16o to produce L/D = 0.25. Since both of our works concur and Whitmore?s work is the only source in the 94 literature search that offered a value to compare, this is the extent that the Cl,cg,? is validated in this work. Magazu26 investigated the feasibility and aerothermodynamic performance of a 12-sided parashield re-entry vehicle that has a shape similar to a 12-sided umbrella with no more than 7% concavity. The reproduction of this heat shield shape is defined as having a spherical-segment axial shape with ?s ? 45o and a dodecagon cross- section without any concavity. The superformula of the superellipse Eqn. (2.8) can approximate a sharp dodecagon with the following parameters m = 12, n1 = 10.75, n2 = n3 = 1. With these parameters, this work?s code produced a lift-to-drag ratio of 0.19 compared to the reported 0.18 in Ref. [26] at ? = -15o. 6.2. Stagnation-Point Heat Transfer Validating the results of this work?s stagnation-point heat transfer methods against Apollo and FIRE II experimental and flight data is completed in this section. It is shown that the methods produce results with < 15% error. Note that it is not the purpose of this work to imply from these low errors that heat transfer during planetary entry is well understood. CFD would also produce results with errors of approximately 10-15% also. Additionally, although the percentage error is low for the stagnation-point heat transfer methods of this work, the error would probably increase dramatically for entry velocities greater than 12 km/s, in which it is expected that radiation cooling and convection coupling would lower the radiative heat flux. However, it is unknown precisely how much reduction there would be since no instrumented flight tests have been completed on flights with entry speeds greater 95 than 11.4 km/s from the FIRE II. Several questions still exist on laminar, transitional, and turbulent boundary layer heat transfer during planetary entry. As a result, experimental research in this area would be especially worthwhile as future work. 6.2.1. Apollo 4 The peak radiative heat flux for the Apollo 4 mission occurred at an altitude of approximately 200000 ft around 30030 s into the mission at which point the Command Module was moving at a speed of 34000 ft/s. For the portion of the trajectory with high radiative heat flux, Figure 6.4 shows the calculated normal-shock density ratio and corresponding specific heat ratio using Tannehill?s correlation set.54 Figure 6.4. Normal-shock density and specific heat ratios for the high radiative heat flux portion of the Apollo 4 trajectory. The altitudes and velocities during this portion of the Apollo 4 trajectory are also shown in Figure 6.4. The stagnation point on a blunt-body is usually across from the part of the bow shock that is normal to the freestream. As a result, the normal-shock density ratio ?2/?1 and corresponding effective specific heat ratio after the shock can 96 be used to approximate the effective radius-of-curvature at the stagnation point. Kaattari?s method requires ?2/?1 and ?eff,2 to determine reff. To validate the implementation of Kaattari?s method in this work, in Figure 6.5 it is compared to other methods of determining the shock-standoff distance for the case of a sphere. This figure is partially a reproduction of Figure 4.1 in which the empirical curve-fit Eqn. (4.8) is compared to wind tunnel data. As a result, it can be observed that Kaattari?s method in Figure 6.5 follows the experimental data closer than the empirical curve-fit at the lower values of ?2/?1. Rasmussen30 provided the solutions to the Vorticity method and parabolic thin shock layer approximation in his textbook. The solution from the Vorticity method follows the behavior of Eqn. (4.8) almost perfectly while the parabolic thin shock layer approximation produces shock-standoff distances that are at least 25% larger than wind tunnel results. Figure 6.5. Shock-standoff distance method comparison. 97 It is noticed that Kaattari?s method and Eqn. (4.8) bracket most of the wind tunnel results shown in Figure 4.1. After Kaattari?s method determines the shock-standoff distance at zero angle of attack, the modified method for finding the shock-standoff distance at the prescribed angle of attack is accounted for through the effective radius term. For the Apollo 4, Ried48 generated predictions with early 1970 computer technology using CFD. Ried produced an effective radius at the stagnation point that would apply for radiative heat transfer, and it is compared to the results of Kaattari?s modified method in Figure 6.6. 0 5 10 15 20 25 30 35 7 8 9 10 11 12 13 14 15 16 Effective Radius for Radiation (ft) An gle of A ttack (d eg ) Apollo 4 predictions Code results Figure 6.6. Apollo 4 reff for stagnation-point radiative heat transfer. Kaattari?s modified method varies no more than 10% from Ried?s predictions. Then the reff is applied in the radiative heat flux correlation set. To determine which correlations would be best to apply for this work, a plot of the Apollo 4 mission?s radiative heat flux shown in Figure 6.7 is used to compare correlations. Figure 6.7 shows these results for the portion of the Apollo 4 trajectory with high radiative heat flux. Both radiometer and calorimeter measurements were made on the Apollo 4 at 98 the point of maximum heating and the stagnation point, although measurement uncertainties were not recorded. Ried shows that his calculations match the radiometer results that measured only the visible and infrared radiation. He also calculated the UV continuum and UV line radiation. Figure 6.7. Validation of radiative heat flux correlations for Apollo 4. It made the most sense to compare the values of the correlations to the total radiative heat flux. As a result, the total radiative heat transfer that includes the visible, infrared, UV continuum, and UV lines is shown in Figure 6.7 as the Apollo 4 predictions. The most recent correlation from Tauber and Sutton45 matched the Apollo 4 results for most of the region. However, the results of this correlation do not match the predictions for speeds less than 9000 m/s. In fact, both Lovelace41 and Bertin29 provide correlations that produce conservative results that are not far from the results for speeds less than 9000 m/s. Since the correlation from Bertin was originally designed for speeds less than 7620 m/s (25000 ft/s), Lovelace?s correlation is applied for speeds less than 9000 m/s. 99 Along with a method to transition between the two correlations, Lovelace and Tauber?s correlations are used in this code and produce the results shown in Figure 6.8. Together, these correlations produce results that are conservative but close enough for first-order optimization results. Figure 6.8. Apollo 4 radiative heat transfer code validation. Figure 6.9. Apollo 4 Trajectory from Ref. [36]. 100 To validate the convective heat flux, radiative heat flux, and the corresponding heat load values, results have been generated using the Apollo 4 trajectory shown in Figure 6.9. Apollo 4?s maximum Mach number7 during Earth entry was Mach 40, and because it had the highest entry velocity of all the Apollo missions, it also had the largest heat load. The total heat flux and heat loads are calculated using both Lovelace?s Eqn. (4.9) and Tauber?s Eqn. (4.10), and so Table 6.4 includes two columns of results. The equations used to produce each results are listed in the title of each column. These results are within 15% of the reported values. Table 6.4. Apollo 4 Comparison of Total Heat Transfer. Parameter Apollo 4, Ref. [38] Results from [1.6*1.06*Eqn. (4.1)+Eqn. (4.9)] Results from [1.6*1.06*Eqn. (4.1)+Eqn. (4.10)] qmax,tot (W/cm2) 483 542 (+12%) 469 (-2.9%) Qmax,tot (J/cm2) 42600 46200 (+8.5%) 38700 (-9.2%) NASA reported the values of the heat flux and heat load at the point of maximum heating, which in the case of the Apollo CM was not at the stagnation point. Although this work calculates the stagnation-point heating only as explained in Chapter 4, these reported values can still be used for validation. As shown in Figure 6.10, the maximum convective heating for the Apollo CM at ? = -25o was 60% larger than the stagnation-point convective heat flux at zero angle of attack. Maximum heating is located at S/R = 0.9 while the stagnation point at ? = - 25o is located at S/R = 0.74. Since the stagnation point at ? = -25o has a 10% higher heat flux than that at zero angle of attack, the maximum heat flux is 45% larger than the stagnation-point heat flux at ? = -25o. Although angle of attack has been 101 accounted for by this work?s radiative heat flux calculations, it has been assumed that the convective heat flux would be kept constant at the nose. Due to the Apollo CM?s low spherical-segment angle of 25o and corner geometry, the stagnation-point does not have the highest convective heat flux at ? = 25o. Bertin29 notes that a correction factor of 1.06 to the correlation for a sphere can be used to account for the change in the sonic line location from 45o to approximately 25o for the CM. As a result, after multiplying the convective heat flux by 1.06 and then 1.60 to account for the corner radius? effect that produces maximum heating, the convective heat flux can be added to the radiative heat flux to produce maximum heat flux and heat load results within 12% of the reported values. 102 Figure 6.10. Convective heat flux distribution of Apollo Command Module at ? = 25o from Ref. [36]. 6.2.2. FIRE II In the case of the FIRE II flight, the entry vehicle?s stagnation point was equal to the point of maximum heating, and it traveled mainly at zero angle of attack. As a result, it would be expected that this work would match the FIRE II data more closely than the Apollo 4 data. However, the FIRE II had an entry velocity of 11.4 km/s 103 (37400 ft/s), which is slightly faster than the entry velocity of Apollo 4 at 10.7 km/s. Because FIRE II had an entry Mach number greater than forty, it is possible for there to be coupled effects between convection and radiation that would reduce the total heat flux. The FIRE II had three heat shields of different radii placed on top of each other. One heat shield would be jettisoned at a time to acquire heat transfer data for each heat shield. Since the heat shields have different radii, discontinuities in the flight data are expected. As shown in Figure 6.11, flight data from the calorimeter produced a noticeably smaller heat flux value than the theory that does not assume coupling. Figure 6.11. FIRE II Total heat flux comparison with flight data from Ref. [47]. The correlations of this work, which are labeled as code results, also do not assume coupling. The maximum total heat calculated by this work is 9% larger than the flight data. The interesting part is that the convective theory curve that assumes coupling and the code results nearly match perfectly for the first shield and do not vary greatly for the other two. However, it is apparent that the correlations fall approximately 104 halfway in-between the theory that assumes no coupling and the calorimeter data. It is believed that the FIRE II had some coupling, and that this is the reason why the total heat flux theory without coupling and the code results produce a peak at a different time than the FIRE II calorimeter data. As a result, it would be expected that this work?s accuracy would begin to disappear at slightly higher velocities. 105 Chapter 7. Parametric Analysis In order to become familiar with the design space that will be used in optimization, a parametric analysis has been conducted. Familiarity with the design space and previous work allows one to know whether optimization results are reasonable and provides simple test cases for verifying that the optimizer is working properly. Also, better initial designs for optimizing a given objective function may also be discovered throughout the parametric analysis. Most of this parametric analysis is included in Ref. [72]. 7.1. Selecting a Superelliptical Base Aerothermodynamic results were acquired for several axial and base shape combinations with the parameters in Table 2.1. One of the main considerations in choosing a polygon of m-sides is for it to be passively longitudinally stable over a range of cross-sections, and so one of the most longitudinally stable shapes is desirable. In order to compare the value of the pitching moment consistently throughout the given shapes, moments about the tip of the nose are considered. Moments about the shape?s center of gravity are accounted for later in this analysis. The derivative of the pitching moment coefficient Cm,0,? shown in Figure 7.1 varies slightly with the rounded-edge concave m-gon compared to its variance with eccentricity. Because the hexagon has the most stable value for pitching and yawing moments, it was decided that a superellipse with m = 6 would be featured in this 106 analysis. The results in this section focus on heat shield geometries with the rounded- edge and concave hexagonal (m = 6) and elliptical cross-sections. Figure 7.1. Cm,0,? distribution varying m-gon and e with spherical-segment axial shape and rounded-edge concave cross-sections, ?=-20o, ? = 5o. The Cm,0,? distribution also suggests that eccentricity always decreases longitudinal static stability for the shapes considered. Positive values of the eccentricity correspond to the prolate shapes, and negative values to the oblate ones. A prolate eccentricity value of 0.5 was chosen as the constant eccentricity at which to present results because it does not considerably lower vehicle stability and since data on eccentric heat shields is scarce. Note that a particular oblate shape with a larger L/D but smaller CL than the common non-eccentric spherical-segment will be discussed later in this analysis. 7.2. Heat Shield Shapes and Aerodynamic Performance The results are acquired at M? = 36, the re-entry Mach number from lunar return for the trajectory of the Apollo CM. The code was run over several ranges of geometric parameter values and angles-of-attack for each of the axial shapes and 107 cross-sections. The set of superelliptic bases included a rounded-edge hexagon, an ellipse, and a rounded-edge concave hexagon, each with an eccentricity of 0.5 as shown in Figure 7.2, along with examples of axial shapes. (a) n2 = 1.5, Spherically-blunted cone, (b) n2 = 2.0, Spherical-segment, rn/d = 0.25, ?c = 70o. ?s = 25o. (c) n2 = 4.0, Power law shape, A = 2, b = 0.75. Figure 7.2. Chosen heat shield shapes for parametric analysis. The ranges of the geometric variables for the axial shapes are included in Table 7.1; this table has ranges that are applied to most of the analysis, including the results in Table 7.2. The axial shapes shown in Figure 7.2 are those applied when varying ?; of these three axial shapes, the one with the smallest geometric l/r is the spherical- segment, followed by the spherically-blunted cone, and then the power law shape. 108 As used in previous work, a sideslip angle of five degrees has been chosen in calculating the values of Cn,? and Cl,?. Apollo 4 had a maximum sideslip of ? = 2o, but wind tunnel tests have tested the Aeroassist Flight Experiment32,33 (AFE) at sideslip values up to ? = ? 5o.32 Note that it is convention to combine the three normal vectors CA, CN, and CY into two vectors CL and CD; this produces vertical and horizontal (with respect to the body axis) components of lift, represented by LV and LH respectively for cases with ? ? 0.20,21 Even though LH is negligible in this particular analysis since ? is small compared to ?, LV is listed in results with ? ? 0 in order to be consistent with general theory. Table 7.1. Variable ranges and constants for each axial shape. Axial Shape Variable Range Constants -30o ? ? ? 0o ?s = 25 o (Apollo Command Module) Spherical- segment 5o ? ?s ? 90o ? = -20o -30o ? ? ? 0o ?c = 70 o, rn/d = 0.25 (Viking Mars Lander) 30o ? ?c ? 89o ? = -20o, rn/d = 0.25 Spherically- blunted Cone 0.01 ? rn/d ? 1.00 ? = -20o, ?c = 70o -30o ? ? ? 0o A = 2, b = 0.75 1 ? A ? 6 ? = -20o, b = 0.75 Power Law Shape 0.1 ? b ? 0.999 ? = -20o, A = 2 The coordinate system shown in Figure 3.1(a) has the direction of positive sideslip and negative angle-of-attack. The direction of positive moments is shown in Figure 3.1(b) for both positive and negative LV, which only changes the convention of the rolling moment for reasons explained in Chapter 3. Since blunt-bodies produce positive lift at negative angles-of-attack (for ?c > 45o), this analysis mainly focuses on how geometric variables vary with a constant negative angle-of-attack. Since the 109 Apollo CM had trim angles of attack equal to -17.5o and -25.5o during orbital re-entry and lunar return respectively, the effects of the geometric parameters are analyzed at an angle of attack in-between them at -20o. 7.3. Hypersonic Aerodynamic Performance and Stability The effects of the power law?s slenderness ratio, A, and cross-section parameter, n2, on Cm,0,? are shown in Figure 7.3. This plot is typical of the results for all of the aerodynamic parameters in that they are much more sensitive to a change in axial shape than to a change in cross-section. As a result, the effects of varying the cross-section at a fixed eccentricity are not usually as important compared to the effects of changing the axial shape for longitudinal static stability. Figure 7.3. Cm,0,? distribution for power law A and n2, b = 0.75, e = 0.5, ?=-20o, ? = 5o. However, a cross-section?s eccentricity can affect the vehicle?s static roll stability significantly and is discussed later in this analysis. Figure 7.4 shows a similar trend for Cm,cg,? but also that there is a minimum of ?0.22/rad near A = 1.5 and n2 = 2. Both 110 Cm,0,? and Cm,cg,? have maximum absolute values at n2 = 2, and this is also characteristic of the yawing moment stability derivative. The minimum Cm,cg,? may change in value and occur at a different (A, n2) with a base of different eccentricity, or different values of b, ?, or ?. Because there are several combinations of variables that affect it, the process of optimization, which can vary any or all of the variables, will be an effective tool for locating extrema. Figure 7.4. Cm,cg,? distribution for power law A and n2, b = 0.75, e = 0.5, ?=-20o, ? = 5o. Table 7.2 offers a summary of the sensitivity of main aerodynamic parameters (no heat transfer) by arranging the values of percentage difference of the parameter?s minimum and maximum into six groups, labeled 0 through 5, in which coefficients in category five have the largest percentage difference. Each group corresponds to a range of percent difference values. Since the aerodynamic parameters do not vary considerably with a change in cross-section, as discussed earlier and shown in Figure 7.3 and Figure 7.4, the percentage differences as well as the actual values are close to each other and the same in sign when varying the cross-section. As a result, Table 7.2 111 includes one column of data for the set of three base cases instead of three separate columns. Table 7.2. Effects of geometric parameters and ? on aerodynamic performance. Spherical Segment Spherically-blunted Cone Power Law Shape ? ?s ? ?c rn/d ? A b CL,V 5 5 5 4 1 5 5 4 LV/D 5 5 5 3 0 5 4 3 Cm 5 5 5 5 0 5 4 1 Cm,? 2 5 2 3 0 2 3 1 Cn 1 5 2 5 0 1 4 1 Cn,? 1 5 1 5 0 1 4 1 Cl 1 5 1 5 0 3 5 1 Cl,? 0 5 0 5 0 4 5 5 Xcp/l 0 2 0 1 1 0 3 2 Ycp/l 5 3 5 1 1 5 2 1 Zcp/l 0 2 1 1 1 0 1 1 ?v N 4 N 4 1 N 3 1 Note: Ranges of ?, ?s, ?c, rn/d, A, b given in Table 7.1. Percent Difference Key 0: < 14% 1: 15% - 39% 2: 40% - 75% 3: 76% - 400% 4: 401% - 999% 5: 1000% + N: Not applicable. Of the three moment coefficients, only Cm varies over two orders of magnitude with ? while Cm,? only varies by approximately 50%. Cm also varies in two orders of magnitude with ?, ?s, ?c, and A. In general, the moment coefficients and stability derivatives varied strongly with ?s, ?c, and A for the given range. For the 112 spherically-blunted cone, rn/d only had a small effect, by varying the aerodynamic parameters ? 5-10% at most. The exponent b for the power law shape varied them ? 25% except for Cl,? that was affected strongly, although this does not necessarily mean that an extremely high value of Cl,? was acquired; it only means that it varied strongly with b from a possibly negligible to significant value. As a result, a high percentage does not necessarily mean varying strongly from one significant value to another one, and some high percentages were produced since the smaller of the two absolute values was near zero (<10-5). In the least, these results can be compared to more advanced analyses in future investigations. A human planetary entry vehicle may require a reaction control system (RCS) to control the roll angle for human safety and follow the entry trajectory. If the rolling moment stability derivative is unstable but small, a less powerful rolling moment control system would be needed. Also, the units of the stability derivatives are per radian rather than per degree, and so reasonable rolling moment derivative and yawing moment derivative values from the AFE include Cl,?=-0.04584/rad = - 0.0008/o and Cn,? = 0.1318/rad = 0.002300/o.21 The AFE has a circular cross-section with a blunted-nose, raked-cone axial shape that produces values of Cl,? that are within the range of values acquired in this analysis, and the AFE?s values of Cn,? are within the mid-range of values acquired in this analysis. Moment coefficients and stability derivatives shown in Figure 7.5 at ? = -20o, ? = 5o, are affected strongly by varying the geometric parameters. Although the magnitudes are not equal, the plot of Cm,? in Figure 7.5(b) would show the same behavior as that of Cm in Figure 7.5(a) if the data were reflected about the horizontal 113 axis. Figure 7.5(c) and (d) show Cn and Cn,? have the same behavior, although Cn is an order of magnitude smaller. a) Variations in Cm. b) Variations in Cm,?. c) Variations in Cn. d) Variations in Cn,?. Figure 7.5. Effects of ?s, ?c (rn/d = 0.25), A (b = 0.75) on stability coefficients and derivatives, ? = - 20o, ? = 5o. All four variables show that the center of gravity moments and derivatives first increase in magnitude with an increase in the geometric parameter, then produces a minimum or maximum, and then decreases in magnitude, which is a different behavior from that of the moments about the nose that usually have maximum and 114 minimum values near or at the end points of the range. As a result, it is important to note that the values of the moments about the nose may neither be near the values of the moments about the center of gravity nor share the same behavior. It is noticed that Cm,cg, Cm,cg,?, Cn,cg, and Cn,cg,? all have maximum magnitudes near the same value, suggesting that a value of ?0.22/rad for Cm,cg,? for a power law shape with A = 1.5 would also be produced with both a spherically-blunted cone of ?c = 42.5o and a spherical-segment of ?s = 52.5o. Heat shields with equivalent values of Cn,cg,?, which has a maximum magnitude of 0.24/rad, can also be determined. Both the Cl and Cl,? have values within those acquired in wind tunnel for the AFE that are of the order of 0.01/rad for Cl,? and 0.001 for Cl.21 Figure 7.6. Effects of ?s, ?c (rn/d = 0.25), A (b = 0.75), and b (A = 2) on ?v, ? = -20o, ? = 5o. Figure 7.6 shows how all five geometric variables affect the volumetric efficiency of the heat shields. The volumetric efficiency in this case is normalized to a 115 hemisphere in Eqn. (2.15), and this results in the most volumetrically efficient shape being the non-eccentric spherical-segment at ?s = 90o. The volumetric efficiency is varied with eccentricity and ?s for a range of spherical-segments in Figure 7.7. Figure 7.7. ?v distribution for spherical-segment, elliptical base (n2 = 2), varying e and ?s. For ?s = 90o, an increase in eccentricity decreases the volumetric efficiency, but a saddle point exists at ?s = 35o; as a result, below ?s = 35o eccentricity increases the volumetric efficiency by up to 10%. 7.4. Effect of Eccentricity on Aerodynamic Performance The stability derivative of the rolling moment about the center of gravity, in Figure 7.8 does not become significantly affected by eccentricity until ?s > 20o. Beyond this value of ?s, it is observed that the magnitude of Cl,cg,? increases. For clarity purposes, the stable configurations are shown as Cl,cg,? ? 0 in Figure 7.8. While some of the oblate shapes are stable or unstable, the non-eccentric and prolate shapes (e > 0) are statically roll stable. 116 An analysis of the effect of eccentricity on LV/D was conducted to determine if there were any possible shapes that were not completely stable but could give a noticeable increase in LV/D. Figure 7.9 shows the LV/D distribution for varying ?s and eccentricity. Figure 7.8. Cl,cg,? distribution for spherical-segment, elliptical base (n2 = 2), varying e and ?s, ? = 20o, ? = 5o. Shown in Figure 7.10, a positive ? dataset produced the positive LV/D value of 0.584, a 56.1% increase, at ?s = 90o for an oblate shape with e = -0.95, in which b1 = 1.0 and a1 = 0.311 at ? = 20o compared to a less round, more blunt ?s = 5o with e = 0.0 with a positive LV/D value of 0.374 at ? = -20o. However, CL,V drops to 0.282 from 0.56, a 49.6% decrease. Table 7.3 lists the aerodynamic and stability characteristics based on modified Newtonian flow and uniform density heat shield geometries. The characteristics of the following geometries are listed in Table 7.3: ?s = 5o & e=0.0, ?s = 25o & e = 0.0 (similar to the Apollo CM heat shield), and ?s = 90o & e = -0.95. All three have stable 117 yawing moments also, with ?s = 25o, e = 0.0 at the largest value of 0.0138 for Cn,cg, and the other two have smaller yawing moment coefficients on the order of 0.003. Figure 7.9. LV/D distribution for spherical-segment: elliptical base (n2 = 2), varying e and ?s, ? = 20o, ? = 5o. While the yawing moment derivative Cl,0,? for ?s = 5o & e = 0.0 is only 27.7% of the Cl,0,? for the AFE, both the oblate ?s = 90o, e = -0.95 and non-eccentric ?s = 25o have values of the same order as the AFE?s. The rolling moment derivative about the center of gravity for ?s = 5o, e = 0.0 is negligible, but the oblate ?s = 90o, e = -0.95 has a Cl,0,? = -0.0924 that is twice the stability derivative of the AFE. The volumetric efficiency is lower for the blunt shapes ?s = 5o and ?s = 25o with values of 0.204 and 0.583 respectively compared to a value of 0.922 for ?s = 90o, e = -0.95. The two non- eccentric cases have stable pitching moments. a) Front view. b) Side view. Figure 7.10. Spherical-segment ?s = 90o, e = -0.95 with an increase of 56% in LV/D. 118 Table 7.3 Aerodynamic comparison of spherical-segments (? = 5o). e = 0, n2 = 2 e = -0.95 n 2 = 2 ?s = 5o ? = -20o ?s = 25o ? = -20o ?s = 90o ? = 20o CL,V 0.560 0.468 0.282 LV/D 0.374 0.335 0.584 (LV/D)? -1.10 -0.961 0.469 Cm,0 0.0126 0.0613 -0.105 Cm,0,? -0.0299 -0.145 -0.363 Cn,0 0.00302 0.0147 0.0133 Cn,0,? 0.0365 0.177 0.161 Cl,0 0.000 -3.38E-5 -0.00808 Cl,0,? ? -4.06E-5 -0.0924 Cm,cg 0.0126 0.0575 -0.0195 (0.0310) Cm,cg,? (/rad) -0.0299 -0.136 -0.0990 (0.0566) Cn,cg 0.00301 0.0138 0.00785 (0.00488) Cn,cg,? (/rad) 0.0364 0.166 0.0916 (0.0541) Cl,cg 0.000 -3.38E-5 -0.00808 (-0.00808) Cl,cg,? (/rad) ? -4.06E-5 -0.0924 (-0.0924) Xcg/l 0.663 0.662 0.400 (0.635) ?v 0.204 0.583 0.922 With the high eccentricity of e = -0.95 comes the unstable pitching moment derivative Cm,cg,? = 0.0566/rad if a uniform density heat shield is assumed. However, if the uniform density value Xcg/l = 0.635 is switched to Xcg/l = 0.400, then the pitching moment becomes stable with Cm,cg,? = -0.099/rad. In addition to values of aerodynamic moments at Xcg/l = 0.400, Table 7.3 includes moment and derivative values for this geometry with Xcg/l = 0.635 in parentheses. As a result, it may be advantageous to further study oblate geometries that produce higher LV/D since an 119 increase in trim LV/D opens a larger range of entry flight path angles available for planetary entry and significantly increases the range capability of the space capsule.1 7.5. Comparison of Aerothermodynamic Performance on Two Heat Shields After conducting the optimization cases discussed in the next chapter, it was determined that a heat shield with a parallelogram cross-section (m = 4) produces a higher L/D than one with a hexagonal cross-section. As a result, a brief parametric comparison of the m = 6 and the m = 4 shapes based on stagnation-point heating and L/D is conducted. This is completed with a spherically-blunted cone axial shape with a 55o half-cone angle and rn/d = 0.05 at ? = -20o. As noted in the next chapter, the minimum rn/d for this work is 0.05, and the minimum half-cone angle is 55o; this parametric study attempts to show some of the effects of one of the expected worst cases from a stagnation-point heating approach. The total stagnation-point heating varies with n2 and e for m = 6 in Figure 7.11(a). Since the method of determining the shock-standoff distance is a piecewise, the plot of ,totsq& is expected to have discontinuous slopes. This ripple effect is more pronounced in Figure 7.11(b) for m = 4. From an optimization standpoint, this indicates that the optimizer will have to run numerous sets of initial designs to find a set of local minima that may exist in-between the ripples and then determine the global minimum. Note that in these cases, the rn/d solely determines the convective heat transfer while reff and ? determine the radiative heat transfer. As a result, the values for the convective heat transfer are constant for Figure 7.11(a) and (b) at 961 W/cm2. Since the convective heat transfer correlations are accepted as reasonably 120 accurate and since radiation is a current line of research, only the radiative heat transfer correlations were explored further. a) Hexagonal base (m = 6). b) Parallelogram base (m = 4). Figure 7.11. ,totsq& distributions for m = 4 and 6, spherically-blunted cone axial shape, ?c = 55o, rn/d =0.05, varying e and n2 = 1.3 to 2.3, M? = 32.8, ? = -20o. 121 Each of these figures includes a drop of 1-5 W/cm2 in at least the n2 < 2 region, due to using a piecewise method. Since the drop is small compared to the magnitude of the total heat flux, it is not significant in this case. For additional plots, it is shown that this drop becomes larger but does not exceed 20% of the radiative heat flux. a) Hexagonal base (m = 6). a) Parallelogram base (m = 4). Figure 7.12. ,totsq& distributions for m = 4 and 6, spherically-blunted cone axial shape, ?c = 55o, rn/d =0.05, varying e and n2 = 1.3 to 4.0, M? = 32.8, ? = -20o. 122 If the parametric analysis is furthered to n2 = 4, then the ,totsq& varies for m = 6 in Figure 7.12(a) better than it does for m = 4 in Figure 7.12(b) since the method begins to break down around n2 = 3 for the parallelogram. This breakdown is shown in Figure 7.12(b) with the troughs that are seen through the main slope. This is not present in the hexagonal cross-sectional case. a) Hexagonal base (m = 6). a) Parallelogram base (m = 4). Figure 7.13. LV/D distribution for m = 4 and 6, spherically-blunted cone axial shape, ?c = 55o, rn/d =0.05, varying e and n2 = 1.3 to 4.0, M? = 32.8, ? = -20o. 123 LV/D is shown to have a maximum magnitude of 0.61 with an oblate, rounded- edge concave hexagon in Figure 7.13(a). In this case the value is negative, which means that the hexagonal shape could produce a positive LV/D of equal magnitude at positive angle of attack since it is symmetric about the horizontal axis (z-axis). The main result found through optimization is that the magnitude of LV/D as shown in Figure 7.13(b) could be increased past 1.0 for the oblate rounded-edge parallelogram. a) ,convsq& distribution. b) ,radsq& distribution. Figure 7.14. ,convsq& and ,radsq& distributions for parallelogram base (m = 4, n2 = 1.4 ), spherically-blunted cone axial shape, ?c = 55o, varying e and rn/d, M? = 32.8, ? = -20o. 124 For m = 4, the variation in convective heat flux with eccentricity and rn/d is included in Figure 7.14(a). The eccentricity does not modify the nose radius dramatically, and so the convective heat flux does not vary with eccentricity. However, an increase in nose radius alleviates much of the convective heat flux. The radiative heat flux shown in Figure 7.14(b) shows the opposite trend: an increase in nose radius produces more radiative heat flux. However, the prolate cases show a maximum at rn/d = 1.3 while the oblate cases continue to increase. Some uncertainty is present with these results since prolate and oblate heat transfer analyses have not been researched in-depth. This would be a good topic of future research. It is believed that the maximum heat flux of the oblate cases provides a conservative limit on the heat flux expected on an actual heat shield based on the way the eccentricity correction factor is applied in Eqns. (3.52) and (3.53). The trade-off between convection and radiation produce a total heat flux that has a local minimum at rn/d = 0.5 for e = -1 and rn/d = 0.8 for e = 1, as shown in Figure 7.15(a). Figure 7.15(b) provides another view of the total heat flux for clarity. For rn/d > 1, some of the oblate cases increase in total heat flux while all the other cases continue to decrease. However, even with this increase, the overall change in heat flux is small and suggests that heat shields at 200000 ft and Mach number 32.8 should either have an rn/d between 0.5 and 0.8 or greater than 1. The Apollo CM?s design had a rn/d = 1.18 and thus is in the lower region of heat transfer shown in Figure 7.15(a). For an increase in freestream Mach number, the radiative heat transfer becomes greater, and the results of optimizing the total heat transfer throughout the Mach numbers is included in Chapter 8. 125 a) Emphasis on the local minima. b) Emphasis on overall distribution. Figure 7.15. ,totsq& distribution for parallelogram base (m = 4, n2 = 1.4 ), spherically-blunted cone axial shape, ?c = 55o, varying e and rn/d, M? = 32.8, ? = -20o. 126 Chapter 8. Optimal Configurations The optimization results of several objective functions are provided for the geometry whose axial shape produces the most ideal results. The main optimization results are provided as iteration histories of the objective function, design variables, and constraints, a 3D image, and a table of its aerothermodynamic characteristics. The iteration histories are located in the appendix. The objective functions in this analysis consist of maximizing LV/D, ?v(LV/D), LV/D/ ,,totsq& and of minimizing totsq ,& and Cm,cg,?. A separate optimization is run for each of the three axial shapes, and this work provides iteration histories of the design variables in non-dimensionalized form so that all of them can be shown on the same figure. For each axial shape, the design variables with their lower and upper constraint values are given along with their non- dimensional value counterparts in Table 8.1. For the geometries with a spherical segment axial shape, the limit of 5o on ?s was chosen as the lower limit in order to provide a blunt-body that is not completely flat, and 89o was chosen as an upper limit since the code would produce a zero in the denominator in some equations for ?s = 90o and is a close approximation from a numerical standpoint. The n2 variable from Eqn. (2.8) controls whether the cross-section is a polygon, ellipse, or concave polygon. For this analysis, zero radius-of-curvature designs are not considered since they produce high heat concentrations. As a result, the n2 lower limit of 1.3 produces slightly rounded-edge polygons. As n2 approaches 2.0, the polygon transforms into an ellipse, and increasing n2 further transforms the 127 ellipse into a rounded-edge concave polygon. An upper limit of 4.0 on n2 generates shapes that still have a reasonable radius-of-curvature. Table 8.1. Optimization design variables with side constraints. Spherical Segment Dimensional Non-dimensional 5o ? ?s ? 89o 0.0556 ? ?s/90o ? 0.989 1.3 ? n2 ? 4.0 0.325 ? n2/4 ? 1.0 -0.968246 ? e ? 0.968246 -0.968246 ? e ? 0.968246 -30o ? ? ? 30o -1.0 ? ?/30o ? 1.0 Spherically-blunted Cone Dimensional Non-dimensional 55o ? ?c ? 89o 0.611 ? ?c/90o ? 0.989 0.15 ? rn/d ? 2.0 0.075 ? (rn/d)/2 ? 1.0 -0.968246 ? e ? 0.968246 -0.968246 ? e ? 0.968246 1.3 ? n2 ? 4.0 0.325 ? n2/4 ? 1.0 -30o ? ? ? 30o -1.0 ? ?/30o ? 1.0 Power law Dimensional Non-dimensional 0.2 ? b ? 0.9999 0.2 ? b ? 0.9999 0.9 ? A ? 10.0 0.09 ? A/10 ? 1.0 -0.968246 ? e ? 0.968246 -0.968246 ? e ? 0.968246 1.3 ? n2 ? 4.0 0.325 ? n2/4 ? 1.0 -30o ? ? ? 30o -1.0 ? ?/30o ? 1.0 The eccentricity limits of ?0.968246 were chosen to limit the ratio of the semi-major axis? length to the semi-minor axis? to 4-to-1. This was decided from inspection, by what appeared to be a liberal choice of a reasonable shape by intuition. 128 The angle of attack is limited to ?30o since human space capsules usually enter at or below 25o and since the heat shield may be only half of the main vehicle?s shape depending on the value of ?s. If ?s is large, then it is possible that the entire space capsule could fit within the heat shield or in the case of a ballute-type heat shield. These limits could be modified easily for future work. A non-eccentric heat shield with ?c ? 45o is the interface at which the spherically-blunted cone begins to produce positive LV at negative ?. If ?c is less than this value, then negative LV at negative ?. The term blunt-body for re-entry usually insinuates that the vehicle produces positive LV at negative ? and that the shock- standoff distance is substantial. Since Ried48 approximated that the shock-standoff distance of the Apollo 4 was 14 cm and this work predicts 12.4 cm (for t = 30030 s, M? = 32.8, ? = 25o at h = 200000 ft), it was decided that the order of accuracy of Kaattari?s method is 2.54 cm. As a result, the spherically-blunted cone that has a shock-standoff distance of 2.54 cm would be designated as the lower limit for ?c and rn/d based on these method limitations. For a non-eccentric heat shield, this work predicts a 2.54 cm shock-standoff distance for a spherically blunted cone with ?c = 55o and rn/d = 0.25. Although any solutions that suggest a shock-standoff distance around one to five inches should be reinvestigated, the lower limit on the nose radius-to-diameter ratio does not exceed 0.25 since previous work such as the Mars Viking missions included heat shields with rn/d = 0.25. The chosen lower limit on rn/d is 0.15 to widen the design space. For numerical reasons, ?c is limited to 89o rather than 90o. The upper limit to rn/d is set at two in order to include some shapes that are pure spherical- 129 segments; the Apollo Command Module can be approximated with ?c = 75o, rn/d =1.1831. For the geometries with a power law axial shape, the lower limit value of b is 0.2 since it is both blunt and has a slope change in the shape that is less extreme than that for b = 0.1 or 0.01. Newtonian Impact Theory may have a problem with the quick slope changes shown in Figure 2.3 for b = 0.1 or smaller. The upper limit on b produces a nearly linear line, but the code requires the slope of the power law profile to vary at least slightly for numerical reasons. A value of b greater than one would produce concave axial shapes with infinitely sharp noses, which are not included in this analysis. Since previous work blunt-bodies usually have l ? d (i.e., Apollo CM l/d ? 1/9), it was decided in this work to widen the design space by including A = (l/d)-1 = (10/9)-1. Then the upper limit of A was decided to be ten since the power law shape loses most of its uniqueness at high A, in comparison with the cone or the spherical- segment axial shapes. Note that although ? is listed as one of the design variables, some of the objective functions may be optimized with fixed angle of attack (this is mentioned if applicable). This optimization uses the following constraint vector, :Gr { }654321 ,,,,, GGGGGGG =r (8.1) .30.0/1,30001 ,0,01.01 ,0,01.01 ,001.011001,001.011001,11 , , ,, , ,, ,,,, ??? ??? ? ??? ??? ? ?+? 42, 138 Tannehill?s correlations54 are out of their pressure and density ranges at 200000 ft, producing a limit on this code. The solution for maximizing LV/D is the same throughout the hypersonic freestream Mach number range 30 through 41. The spherically-blunted cone solution has an LV/D = 0.946 at ? = 15.1o and is included in Table 8.3. 8.2. Maximizing (LV/D)/qs,tot Seven optimization runs of the spherical-segment, five of the spherically- blunted cone, and seven of the power law geometries were completed for maximizing (LV/D)/qs,tot. Constraints G1 through G5 have been applied. Although different initial designs were tested in this analysis, the initial designs for the spherical-segment and spherically-blunted cone for this optimization are the same as that required for maximizing LV/D. The aerothermodynamic performance and stability characteristics of the heat shield shapes with maximum (LV/D)/qs,tot are included in Table 8.4, with the initial designs listed at the bottom. The maximized (LV/D)/qs,tot spherical-segment configuration is identical to its maximized (LV/D) configuration. Since the spherical-segment configuration is shown in Figure 8.1(c), the other two configurations are shown in Figure 8.3. The spherically-blunted cone cases have nearly identical LV/D, but the configuration in this optimization has a 27.4% lower qs,tot than the maximized (LV/D) configuration. The optimizer accomplishes this by increasing the nose-radius-to-base-diameter ratio and increasing angle of attack, as shown in the iteration histories included in Figure A.0.4. This configurations rn/d is 145% larger than that of the maximized (LV/D) 139 configuration. The optimizer also found a slighter higher LV/D in this optimization, but they are within 8% of each other. Table 8.4. Aerothermodynamic comparison of (LV/D)/qs,tot results at M? = 32.8255 (m = 4). Maximum (LV/D)/qs,tot SS* ?s = 89o n2 = 1.3 e = -0.968 ? = 17.6o SC ?c = 55o rn/d=0.367 n2 =1.3 e =-0.968 ? = 15.5o PL b = 0.426 A = 0.900 n2=1.3 e =-0.968 ?= 14.3o CL,V 0.262 0.198 0.221 LV/D 1.10 0.942 1.35 (LV/D)? (/rad) -0.0184 -0.118 0.0429 Cm,cg,? (/rad) -0.0806 -0.141 -0.0463 Cn,cg,? (/rad) 0.0302 0.0468 0.00627 Cl,cg,? (/rad) -0.0719 -0.0682 -0.0134 qs,tot (W/cm2) 491 483 916 qs,conv (W/cm2) 304 355 600 qs,rad (W/cm2) 187 129 316 ?so (cm) 11.0 4.6 36.8 Xcp/l 0.423 0.591 0.490 Xcg/l 0.641 0.679 0.630 CG type** X75 X75 X75 ?v 89.0% 86.4% 84.6% Initial designs ?s = 85o n2 = 1.5 e = -0.9 ? = 25o ?c = 60o rn/d=0.25 n2 =1.6 e =-0.9 ? = 20o b = 0.5 A = 1.0 n2=1.4 e =-0.9 ? = 10.0o *Axial shape key: SS: spherical segment, SC: spherically-blunted cone, PL: power law. ** CG type key: UD: uniform density, X75: uniform density except Xcg,75 = 75% Xcg,UD. 140 a) Spherically-blunted cone axial shape with LV/D = 0.942. b) Power law axial shape with LV/D = 1.35. Figure 8.3. Maximized (LV/D)/qs,tot geometries from Table 8.4. The optimum power law geometry produced the largest LV/D of 1.35 and total heat flux of 916 W/cm2. The stagnation-point heat fluxes for these vehicles are within the feasibility range of modern materials such as the Crew Exploration Vehicle, which is being designed for 1000 W/cm2. The variance in shock-standoff distance shows the limitations of the method. It should not be used to compare power law and spherically-blunted cone axial shapes. A short analysis of the objective function (LV/D)/(qs,tot)n was completed with n = 0.25, 0.50, 0.75, 1.0, 2.0, and 3.0 using the spherical segment. The results did not change except at n = 3.0. For this case, the LV/D was reduced from 1.10 to 0.54, and qs,tot was slightly reduced from 493 to 479. Since there is no significant difference between the total heat flux values even though the lift-to-drag ratio was halved, it was decided that the n = 3.0 configuration had lower performance. Overall, the optimization is not sensitive to a change in n < 3.0, and when it is sensitive, there is evidence that it lowers aerodynamic performance. Since the proportions of convective and radiative heat flux to the total heat flux change with velocity, the optimization has been run over a range of Mach numbers to observe how much the configurations change. The spherically-blunted cone axial shape is chosen for this study since it is 141 directly connected to the convective heat flux correlation used in this work. The rn/d generally decreases with an increase in Mach number as shown in Figure 8.4. This is expected since the proportion of radiative heat transfer to the total increases dramatically over this range and surpasses the convective have flux around Mach 40. While the total heat flux steadily increases with Mach number, the optimized configurations have LV/D values that increase and decrease. Table A.0.1 in the appendix provides complete configuration information for this Mach number study. a) Heat transfer flux qs,tot results. b) LV/D results. Figure 8.4. Maximized (LV/D)/qs,tot results for M? = 30 ? 41. 8.3. Minimizing qs,tot Since qs,tot was the first objective function optimized, fifty-two optimization runs were completed of the spherical-segment to minimize qs,tot. Also, twelve runs of the spherically-blunted cone and six runs of the power law geometries were completed. Constraints G1 through G5 were applied. When changing m to vary the number of sides of the cross-section, the minimum qs,tot was nearly constant. For m = 5, 6, and 7, the minimum total heat flux was between 375 and 390 W/cm2. The 142 parallelogram m = 4 cross-section had a slightly lower minimum at 339 W/cm2, but the employed methods should not be taken as accurate to the extent of differentiating between shapes with ?50 W/cm2 of each other. Instead it is concluded that all these cases have approximately the same minimum within 10-15% of each other. Not all of the shapes with local minimum necessarily look similar to each other. As shown in Figure 8.5, the optimal solution for the parallelogram is concave while the hexagonal geometry is not although they both were run at the same initial designs. Still these shapes have similar stagnation-point heat transfer fluxes. For the optimized parallelogram, the radiative heat flux is 180 W/cm2 while the convective heat flux is 160 W/cm2 since the rn/d is much greater than one. a) m = 4, ?s = 16.1o, n2 = 4.0, e = 0.968, ? = -12.6o. b) m = 6, ?s = 15.9o, n2 = 1.67, e = 0.968, ? = -10.9o. Figure 8.5. Minimum qs,tot configurations, spherical-segment axial shape. Table 8.5 provides the optimized results for parallelogram geometries with each of the three axial shapes. While LV/D is approximately the same for each axial 143 shape, the vertical lift coefficient of the power law shape is three times greater than that of the other two. The spherical-segment and spherically-blunted cone results are similar because that they are similar shapes. Table 8.5. Aerothermodynamic comparison of qs,tot results at M? = 32.8255 (m = 4). Minimum qs,tot SS* ?s = 16.1o n2 = 4.0 e = 0.968 ? = -12.6o SC ?c = 55o rn/d=2.0 n2 =4.0 e = 0.968 ? = -12.3o PL b = 0.485 A = 7.71 n2=1.56 e = -0.0771 ? = -12.5o CL,V 0.113 0.117 0.347 LV/D 0.215 0.212 0.211 (LV/D)? (/rad) -1.01 -1.01 -0.998 Cm,cg,? (/rad) -0.0276 -0.0259 -0.103 Cn,cg,? (/rad) 0.0173 0.0178 0.0553 Cl,cg,? (/rad) -0.00264 -0.0021 0.00000235 qs,tot (W/cm2) 339 393 349 qs,conv (W/cm2) 160 152 154 qs,rad (W/cm2) 179 242 195 ?so (cm) 9.90 19.5 12.4 Xcp/l 0.641 0.644 0.661 Xcg/l 0.664 0.596 0.589 CG type** X75 X75 X75 ?v 40.2% 37.6% 44.0% Initial designs ?s = 25o n2 = 1.3 e = -0.8 ? = -10o ?c = 65o rn/d=1.183 n2 =1.8 e =-0.8 ? = -10o b = 0.35 A = 7.0 n2=1.5 e =-0.10 ? = -12.0o *Axial shape key: SS: spherical segment, SC: spherically-blunted cone, PL: power law. ** CG type key: UD: uniform density, X75: uniform density except Xcg,75 = 75% Xcg,UD. 144 The blunted cone has an ? = 14.4o compared to the 16.1o of the spherical-segment. The high value of rn/d indicates that this blunted cone is a disguised spherical- segment. The iteration histories for the optimized spherical-segment are included in Figure A.0.5. The geometries with the spherically-blunted cone and power law axial shapes are shown in Figure 8.6. a) Spherically-blunted cone axial shape with qs,tot = 393 W/cm2. b) Power law axial shape with qs,tot = 349 W/cm2. Figure 8.6. Minimum qs,tot geometries from Table 8.5. The trend that is suggested from this observation is that if a concave rounded-edge polygon and a rounded-edge polygon have the same LV/D, the vertical lift coefficient of the rounded-edge polygon is probably greater than that of its concave counterpart. 145 Because this spherically-blunted cone has an rn/d = 2, it is a spherical-segment. One could approximate the Apollo CM spherical segment with a larger nose-radius-to- diameter ratio rn/d = 1.1831 and a half-cone angle of 65o. The initial designs for the blunted cone are the dimensions of the Apollo CM except for the oblate eccentricity. The spherically-blunted cone axial shape allows the optimization to cover some of the spherical-segment shapes in its own design space. The heat shield with the spherical-segment axial shape has the smallest total heat flux, but as mentioned before, all that can be concluded from these results is that the three axial shapes have approximately the same minimum. It would be expected that the spherical-segment axial shape would produce the smallest total heat flux since it can produce the highest nose radius in a region where convection easily dominates if the nose radius is not large. Since the heat flux increases with an increase in velocity, the optimal geometry may change. To observe any geometric changes to the optimal configurations, optimization throughout the freestream re-entry Mach number range from 30 to 41 has been completed. It is expected for the radiative heat flux to begin to dominate as the freestream Mach number is increased from M? = 30. Because the radiative heat flux for blunt bodies increases with an increase in nose radius, according to the correlations, the nose radius of the optimized vehicle should generally drop when the freestream Mach number is increased. Figure 8.7 shows how the nose-radius-to-diameter radius drops with increasing M?, and complete geometric characteristics of the optimized configurations are listed in Table A.0.2. For this objective function at the given initial designs, the major drop in nose radius occurs 146 between M? = 33 and 34. In this case, it could be that the spherically-blunted cone is a spherical-segment at M? = 33 that changes into a spherically-blunted cone at M? = 34. Figure 8.7. Minimized qs,tot results for M? = 30 ? 41. It can be concluded that the spherically-blunted cone would be the choice for missions with highest heat fluxes present at an altitude of 200000 ft moving at M? ? 34. At this altitude, the Apollo CM was moving at M? = 32.8255, and strictly from a heat transfer standpoint, the results of this optimization are consistent with the decision to use a spherical-segment for Project Apollo. 8.4. Minimizing Cm,cg,? Nineteen optimization runs of the power law, six of the spherical-segment, and three of the spherically-blunted cone were completed for minimizing the pitching moment derivative Cm,cg,?. If the blunt-body is entering an atmosphere at angle of attack, then the magnitude of the pitching moment derivative is probably the largest out of the three stability derivatives. In this case, minimizing Cm,cg,? generates 147 negative values with large magnitudes, and this corresponds to the most statically stable configuration in the longitudinal direction. Constraints G1 through G5 have been applied. Since the pitching moment stability requirement constraint G3 is being used, MMFD requires the initial configuration to be longitudinally stable. As a result, Cm,cg,? is already negative before the optimization begins, and so the optimizer is searching for the stable configuration with a larger |Cm,cg,?|. The three configurations that are the most statically stable longitudinally are shown in Figure 8.8. a) Power law axial shape b) Spherical-segment axial shape c) Spherically-blunted cone axial shape Figure 8.8. Minimum Cm,cg,? geometries (m = 4) in Table 8.6. The optimized power law geometry has a pointed nose, and the heat flux constraint is active. The spherically-blunted cone has a smaller nose radius than the spherical- segment. Neither the blunt cone nor the power law have the eccentricity of the spherical-segment. The aerothermodynamic performance and stability characteristics of these shapes are listed in Table 8.6. All three shapes have a minimum value of 148 approximately ?0.30/rad for the pitching moment stability derivative, and the power law shape has value that is at least 27% larger in magnitude than the other two geometries. Table 8.6. Aerothermodynamic comparison of Cm,cg,? results at M? = 32.8255 (m = 4). Minimum Cm,cg,? SS* ?s = 47.9o n2 = 2.24 e = -0.64655 ? = -2.68o SC ?c = 55o rn/d=0.403 n2 =2.25 e = 0.0149 ? = -0.656o PL b = 0.78 A = 0.90 n2=2.28 e = 0.119 ? = 26.8o CL,V 0.0269 0.00918 0.0139 LV/D 0.0219 0.00705 0.0184 (LV/D)? (/rad) -0.452 -0.474 0.379 Cm,cg,? (/rad) -0.285 -0.276 -0.363 Cn,cg,? (/rad) 0.165 0.138 0.00369 Cl,cg,? (/rad) 0.00170 -1.6E-5 0.0000888 qs,tot (W/cm2) 452 469 3000 qs,conv (W/cm2) 262 338 2890 qs,rad (W/cm2) 190 131 110 ?so (cm) 11.3 4.87 3.56 Xcp/l 0.617 0.622 0.636 Xcg/l 0.656 0.669 0.707 CG type** X75 X75 X75 ?v 85.9% 79.8% 93.2% Initial designs ?s = 85o n2 = 2.0 e = -0.8 ? = 25o ?c = 60o rn/d=0.25 n2 =1.6 e =0.01 ? = -20o b = 0.75 A = 2.0 n2=2.0 e = 0.5 ? = -20o *Axial shape key: SS: spherical segment, SC: spherically-blunted cone, PL: power law. ** CG type key: UD: uniform density, X75: uniform density except Xcg,75 = 75% Xcg,UD. The value of ?0.30/rad is approximately twice the pitching stability derivative of the Apollo Command Module.8 This can also be noticed when comparing the results of 149 this work in Table 7.3. The optimum angle of attack for each is near zero and due to the fact that these shapes are symmetric about the horizontal body axis, the lift-to- drag ratio is nearly zero. Similar to the Apollo Command Module, the spherical-segment has a slightly unstable rolling moment. This is allowed in the constraints on purpose in order to allow the optimizer to choose heat shields similar to the Apollo Command Module?s if desired. The Apollo CM is estimated to have had a Cl,cg,? of 0.005/rad (discussed in Chapter 6). The iteration histories for the optimized power law configuration are included in Figure A.0.6. The optimizer produced a geometry with greater stability by decreasing coefficient A and the eccentricity, and greatly decreasing the magnitude of ? to 0o. The iteration histories for the spherical-segment configuration with maximum longitudinal static stability are included in Figure A.0.7. The optimizer decreased the magnitude of ? and ?s dramatically and originally changed the eccentricity greatly, but then it brought the eccentricity back to nearly its original value. Most of the results from optimizing other objective functions have magnitudes of Cm,cg,? less than 0.10/rad, and only some of the spherically-blunted cone and power law results for other objective functions have magnitudes greater than 0.10/rad. The maximum ?VLV/D blunted cone configuration is neutrally longitudinally stable. As a result, stability has to be traded-off with LV/D and qs,tot to produce an optimal-set geometry. The configurations with optimal sets of aerothermodynamic characteristics have cross-sections that are rounded-edge parallelograms and are generated by 150 maximizing (LV/D)/qs,tot. These configurations have the characteristics listed in Table 8.4. All of them have high lift-to-drag ratios (above 0.5) for space capsules, total heat fluxes less than or at most equal to the design requirement for NASA?s CEV of 1000 W/cm2, and stable stability derivatives. The spherically-blunted cone configuration has a pitching stability derivative value of ?0.14/rad that is near the ?0.16/rad of the Apollo CM, but the required magnitudes for this and the other stability derivatives have yet to be determined. Most of this optimization analysis is included concisely in Ref. [73]. 8.5. Limitations of this Optimization Several optimization runs were completed since different minima were encountered with different initial designs. The design space does not have only one minimum for each objective function. These optimization runs found local minimum, and the one that had the lowest value is identified as the engineering global minimum. The design space has several minima. For example, if the initial design for maximizing LV/D for the spherical segment were changed from ?s = 85o, n2 = 1.5, e = -0.9, and ? = 25o to ?s = 25o, n2 = 1.4, e = -0.01, and ? = -10o, the optimizer finds a local optimum value of 0.320 instead of 1.10 for LV/D. If the optimizer runs without constraint vector Gr , then it finds a value of 0.575 instead of 1.10. It is understandable for the design space to have more than one maximum, but one has to accept that there could be a better optimum in the design space that was not found. There are other optimization methods for finding the global maximum, but it is unknown to the author whether those methods would provide better results. 151 In finding the maximum LV/D, the optimizer had to be given initial designs based on the parametric analysis in order to find the global minimum. The parametric analysis gave the best starting point for the optimizer in maximizing LV/D by setting some of the initial designs equal to the maximum in Figure 7.9. Then the optimizer was able to find the maximum. This exemplifies the importance of a well-constructed parametric analysis. In a few cases, the optimizer did not vary one or two of the design variables. In maximizing ?VLV/D, there was no variance in angle of attack for the spherically- blunted cone case. This work uses a semi-empirical method for varying the radiative heat flux with angle of attack, and this method is modified to account for n2 and eccentricity, as well as the power law and blunted cone axial shapes. It is shown in Figure 7.11 that this modified method produces several ripples in the design space. Aside from the ripples, it is also nearly flat for n2 < 2, and it is believed that these are the reasons that the optimizer does not find an optimum angle of attack far from the initial angle of attack when minimizing qs,tot. Better optima may be found in future work. 152 Chapter 9. Conclusions 9.1. Summary of Results 9.1.1. Parametric Analysis A parametric analysis of candidate blunt-body heat shield shapes for a Crew Exploration Vehicle has been conducted to determine the main effects of several geometric parameters on the aerothermodynamic performance and stability of the vehicle. This analysis is completed by picking a cross-section and an axial shape to generate a heat shield mesh, and then by placing the mesh into an aerodynamics program based on modified Newtonian flow. The results were validated with wind tunnel and flight test data, and Cm,cg and L/D matched the values of the Apollo Command Module (CM) closer than the results of CL and CD. Although the hexagon is the most aerodynamically stable of the polygons (m = 4?10), it did not have the highest LV/D, and LV/D became larger as n2 approaches the elliptical cross-section (n2 = 2). There is a tradeoff between LV/D and the pitching moment stability derivative. Although the increase in LV/D of 56.1% may be beneficial by making the cross-section strongly oblate at e = -0.95, the heat shield would be longitudinally statically unstable assuming uniform density. One way to remove this instability is by moving the center of gravity forward by 23.5% to Xcg/l = 0.400, and moving the x-location of the center of gravity forward by 25% (was applied in some of the optimization runs to further open up the design space). 153 A change in cross-section did not affect the aerodynamic performance of the heat shield as significantly as a change in axial shape. A change in axial shape rendered a larger range of aerodynamic characteristics. It was also observed that the magnitudes of the longitudinal and directional stability derivatives are maximized with an elliptical base as opposed to a rounded-edge hexagonal concave base. Table 7.3 summarized the sensitivities of the aerodynamic parameters to the geometric parameters. Cm varied strongly with ?, ?s, ?c, and A while the other moment coefficients and stability derivatives varied strongly with ?s, ?c, and A. The results of Cl,? are of the same order of magnitude as other blunt-body designs. For ?s < 35o, an increase in eccentricity from 0.0 to 0.95 increases the volumetric efficiency by up to 10%. 9.1.2. Optimization Results Incorporating all of these parameters into an optimization process has assisted in producing heat shield shapes with improved combinations of aerodynamic characteristics. By maximizing LV/D it was noticed that the parallelogram base cross- section (m = 4) provides the highest LV/D. Because this is one of the two most important characteristics, the other being qs,tot, the optimization continued with m = 4 rather than at the m = 6 that produced the most longitudinally stable configurations. Minimizing the heat transfer flux qs,tot produced polygon bases with and without concavity, and the trend was noticed that even though two shapes may have the same LV/D, they do not necessarily have the same CL,V. In this case, the rounded- edge polygon had a greater vertical lift coefficient by 300%. 154 The results of maximizing LV/D or minimizing qs,tot, or Cm,cg,? was not as promising as maximizing a combinations of these parameters. Each of these has trade-offs with the other. The maximum LV/D was usually located between an |?| of 20o and 30o while the minimum Cm,cg,? would be present near zero angle of attack. Most of the optimum heat shields shapes are symmetric about the horizontal axis, and thus produce no lift at zero angle of attack, rendering a low lift-to-drag ratio. The minimum qs,tot configurations all had LV/D ? 0.2, which is lower than the Apollo CM?s 0.34. The maximum LV/D would produce high qs,tot especially for the spherically-blunted cone and power law axial shapes. However, by choosing to maximize (LV/D)/qs,tot, the optimizer was able to produce a better, more optimal set of aerothermodynamic characteristics. In this case, the geometries with rounded-edge parallelogram cross-sections and maximum (LV/D)/qs,tot provide the most desired set of characteristics (listed in Table 8.4) for the design point altitude of 200000 ft and M? = 32.8255. Since the heat transfer increases with freestream Mach number, an analysis was conducted on how the optimum shape changes for M? = 30 ? 41. When minimizing qs,tot by itself, a large drop in the optimum rn/d ratio occurs between Mach 33 and Mach 34. The value of rn/d at Mach 33 generates a spherical-segment while the value at Mach 34 generates a spherically-blunted cone, and this drop shows at which Mach number it would be ideal to switch between the two. Since the Apollo 4 CM was traveling at M? = 32.8255, and the manned Apollo Command Modules traveled slower at this altitude, this research agrees with the choice to use a spherical- segment instead of a spherically-blunted cone for Project Apollo from a heat transfer 155 standpoint. However, when maximizing (LV/D)/qs,tot over this range of freestream Mach numbers, all the optimum results suggest a spherically-blunted cone over the spherical-segment. This renders a higher qs,tot than produced during the Apollo 4 trajectory and may have created a technology difficulty at the time. Due to the fact that the design space had several local minima, perhaps another optimization method would have been better suited for locating a global minimum. Since several optimization runs have been completed, it is certain that these results are near the value of the global minimum, but there is the possibility that the true global minimum has not been found. However, several optimal heat shield designs with improved characteristics over previous work have been discovered. 9.2. Suggestions for Future Work A substantial amount of future work in planetary entry vehicles can be completed to improve upon both this work and the general understanding of the field. To increase the accuracy of the aerothermodynamics code, the following additions could be made: ? Account for corner radius. The work of Zoby44 may also assist in distinguishing heat shields of the same axial shape and cross-section but different corner radii. The corner radius geometry can also be added to the 3D mesh so that the surface pressure distribution accounts for it. ? Improve the method for estimating the shock-standoff distance for angles of attack, especially for the power law axial shape and in accounting for base eccentricity. 156 ? Use a more accurate method to determine the surface pressure distribution. For this work Newtonian Impact Theory was validated, but if the scope of the project were to include analyzing the boundary layer, advanced CFD would need to be utilized. To increase the scope of the aerothermodynamics code, the following additions could be made: ? Include a second-order trajectory for determining non-oscillatory trajectories. Loh74 offers a way to modify second-order trajectory theory to approximate oscillatory trajectories. A second-order trajectory code does not require the computational time of full trajectory packages such as POST or OTIS. As a result, the heat transfer correlations can be applied at each point in the trajectory to approximate the heat transfer load on the vehicle. ? Incorporate more axial shapes: the raked, biconic, and bent-biconic cones. ? Include thermal material properties and temperature constraints. ? Include a model for high temperature gas properties at 200000 ft, M? > 42. The Tannehill correlations are outside their range for these freestream Mach numbers. ? Develop a method of determining the point of maximum heating for a general 3D body. The velocity gradient could be modeled to determine the point of maximum convective heating for a general 3D body. Zoby44 provides some results based on the change in the velocity gradient in order to calculate the convection for values of rn/d > 2 more accurately than using the inverse square-root of the nose radius. 157 ? Validation of the stagnation-point radiative heat transfer curve-fits of Suttles75 for hyperbolic earth entry with velocities from 11 to 16 km/s. Future work concerning planetary entry vehicles outside this computational code that would benefit the field: ? Study laminar, transition, and turbulent boundary layer heat transfer on blunt bodies for M? > 25. Wind tunnel analysis of rounded-edge concave heat shields would help in investigating these phenomena. The Apollo Command Module?s heat shield experienced laminar heat transfer. Turbulent heat transfer is unknown at M? > 40, especially the effects of radiation cooling and convective-radiative coupling that reduce the total heat transfer flux. For a phenomena that increases exponentially with Mach number, the radiative heat transfer can easily be miscalculated for M? > 40. ? Static and dynamic stability guidelines for human space capsules. ? Flight tests and wind tunnel experiments for M? > 40 ranging up to M? = 55. This could provide arguably the most useful results concerning planetary entry at M? > 40. Current aerothermodynamic understanding of this region of freestream Mach numbers is modest. Since rolling moment experimental and flight data is almost nonexistent, measuring the rolling moment on both axisymmetric and non-axisymmetric heat shields would be beneficial. High temperature correlations, radiation and general heat transfer models could be produced for the first time. Hypersonic aerothermodynamic models can be improved. Some models do exist, but they do not apply well to M? > 40. 158 Appendix A: Optimization Iteration Histories A.1 Maximizing LV/D and ?VLV/D a) Objective function iteration history. b) Design variable iteration history c) Constraints iteration history. Figure A.0.1. Iteration history for maximum LV/D hexagonal shape (m = 6) in Table 8.2. 159 a) Objective function iteration history. b) Design variable iteration history c) Constraints iteration history. Figure A.0.2. Iteration history for maximum LV/D power law/parallelogram (m = 4) in Table 8.3. 160 a) Objective function iteration history. b) Design variable iteration history c) Constraints iteration history. Figure A.0.3. Iteration history for maximum ?VLV/D spherically-blunted cone/parallelogram (m = 4) in Table 8.3. 161 A.2 Maximizing (LV/D)/qs,tot a) Objective function iteration history. b) Design variable iteration history. c) Constraints iteration history. Figure A.0.4. Iteration history for maximum (LV/D)/qs,tot spherically-blunted cone axial shape (m = 4) in Table 8.4. 162 Table A.0.1. Optimized (LV/D)/qs,tot for M? from 30 to 41, m = 4. Spherically-blunted Cone Axial Shape Initial Design: ?c = 60o, rn/d=0.25, n2 =1.6, e =-0.9, ? = 20o Optimal Design (all cases have ?c = 55o, e = -0.968, n2 = 1.3) Split Objective Function Objective Function M? rn/d ? LV/D qs,tot (W/cm 2) (qs,rad, qs,conv ) (LV/D)/qs,tot (cm2/W) 30 0.379 20.5o 0.872 280 (17.0, 263) 0.00311 31 0.327 14.8o 0.986 359 (44.9, 314) 0.00275 32 0.292 15.2o 1.02 452 (85.4, 367) 0.00226 33 0.316 16.8o 0.984 543 (154, 389) 0.00181 34 0.184 16.1o 1.10 738 (179, 559) 0.00149 35 0.150 13.6o 1.14 911 (232, 679) 0.00125 36 0.206 20.2o 0.998 1015 (381, 633) 0.000983 37 0.188 20.1o 1.01 1200 (480, 720) 0.000842 38 0.169 13.5o 1.13 1430 (600, 830) 0.000790 39 0.150 13.8o 1.14 1670 (710, 960) 0.000683 40 0.150 13.6o 1.14 1910 (880, 1030) 0.000597 41 0.150 13.5o 1.14 2170 (1050, 1120) 0.000525 163 A.3 Minimizing qs,tot a) Objective function iteration history. b) Design variable iteration history c) Constraints iteration history. Figure A.0.5. Iteration history for minimum qs,tot spherical-segment axial shape (m = 4) in Table 8.5. 164 Table A.0.2. Optimized qs,tot for M? from 30 to 41, m = 4. Spherically-blunted Cone Axial Shape Initial Design: ?c = 65o, rn/d=1.1831, n2 =1.8, e =-0.8, ? = -10o Optimal Design Objective Function M? ?c rn/d n2 e ? LV/D qs,tot (W/cm 2) (qs,rad, qs,conv ) 30 55o 2.00 4.00 0.968 -11.7o 0.201 149 (35.1, 114) 31 55o 2.00 4.00 0.968 -12.4o 0.213 207 (80.2, 127) 32 55o 2.00 4.00 0.968 -12.4o 0.213 298 (158, 140) 33 75.6o 1.80 4.00 0.968 -11.9o 0.204 326 (163, 163) 34 55o 0.593 2.06 -0.171 -10.5o 0.122 596 (285, 312) 35 55o 0.615 2.81 0.356 -10.3o 0.129 735 (400, 335) 36 55o 0.384 1.98 -0.223 -10.2o 0.0992 896 (432, 464) 37 55o 0.368 1.83 -0.013 -10.3o 0.0978 1073 (556, 517) 38 55o 0.332 1.84 -0.009 -10.3o 0.0956 1279 (688, 592) 39 55o 0.313 2.65 0.041 -10.6o 0.115 1456 (795, 661) 40 55o 0.344 2.61 0.156 -10.3o 0.112 1680 (997, 683) 41 55o 0.292 2.74 0.073 -12.0o 0.130 1909 (1108, 801) 165 A.4 Minimizing Cm,cg,? a) Objective function iteration history. b) Design variable iteration history c) Constraints iteration history. Figure A.0.6. 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