Jul 21, 2014 - Data to improve CFD fluid slosh model predictions, benefiting spacecraft .... Hard Drives manufactured identically as VERTIGO. Hard Drives ...
Liquid Sloshing Behavior in Microgravity with Application to Spacecraft Propulsion Systems
Florida Institute of Technology Department of Mechanical and Aerospace Engineering Gabriel Lapilli Richard Schulman Charles Holicker Brian Wise Sunil Chintalapati Hector Gutierrez Daniel Kirk
NASA Kennedy Space Center Launch Services Program Paul Schallhorn Brandon Marsell Jacob Roth
Massachusetts Institute of Technology Space Systems Laboratory
Dustin Hayhurst David Miller Alvar Saenz-Otero
Overview: Introduction
• Introduction – Why Study Liquid Propellant Slosh? – Sample Results – Goal and Objectives – ISS Slosh Experiment • Slosh Experiment on the International Space Station • Conclusions
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Upper-Stage Propellant Modeling Lockheed Martin Atlas V 401 Boeing Delta IV Heavy
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http://www.boeing.com/defense-space/space/delta/delta4/d4h_demo/book04.html AAS 3rd ISS Research and Development Conference - Chicago, IL
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http://www.osd.noaa.gov/GOES/ULA_GOES-P_Mission_Book.pdf 7/21/2014
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Why Study Liquid Propellant Slosh?
• Delta IV launch postponed because of CFD – Left: Original prediction of LH2 slosh – Middle: Independent prediction of LH2 slosh – Right: Redo of original prediction of LH2 slosh
• Two users get same result using same code, but is it true? • How to validate models? What experimental data is there? 7/21/2014
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Value • NASA KSC LSP must ensure safety and performance of launch vehicles • Current CFD slosh models lack benchmarking data and limited in predictive abilities
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Sample Results • Data to improve CFD fluid slosh model predictions, benefiting spacecraft and launch vehicle design and operations
Experiment
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CFD Model
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Rationale for ISS Slosh Research
• ISS offers opportunity to acquire low-gravity slosh data • Leverage proven SPHERES hardware on ISS • World’s first long duration liquid slosh database 7/21/2014
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Goal and Objectives • Goal – Acquire long-duration, low-gravity slosh data for calibration of detailed Computational Fluid Dynamics (CFD) models of coupled fluid-vehicle behavior • Objectives – Utilize existing SPHERES satellites to propel transparent liquidfilled tank – Acquire system and liquid position data for known applied forces using IMU and imaging systems – Benchmark CFD model predictions
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SPHERES Slosh Experiment (SSE)
• Picture above shows assembled SPHERES Slosh Experiment (SSE) • SPHERES (x2) and VERTIGO (x2) already on ISS – items sent to ISS referred to as ‘Slosh Payload’ 7/21/2014
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Slosh Payload • Designed by Florida Tech in collaboration with NASA KSC LSP
• Slosh Payload manufactured by Florida Tech with exception of – 3D printed plastic – Liquid Slosh tank – Electronics
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3D Printed Parts •
First SPHERES experiment to use 3D printed Ultem parts
3D printed tanks, optical polish, pressure tested to 1.5 atmospheres 7/21/2014
3D printed backdrop, hood, saddles and avionics boxes
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SPHERES Slosh Experiment (SSE)
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Overview: Slosh Experiment
• Introduction • Slosh Experiment on the International Space Station – Hydrodynamic Regimes – Simulating Maneuvers on ISS – Space to Ground interaction – Test Sessions – Initial Conditions – Execution • Conclusion 7/21/2014
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Application of Non-dimensional Parameters • Impossible to match all numbers simultaneously • Flow regimes and individual nondimensional numbers can be matched • Settling Thrust maneuver: By Froude number matching • Pitch to Reorient maneuver: By matching rotation rates for each individual upperstage non-dimensional number
• Passive Thermal Control maneuver: By matching scaled rotation rate 7/21/2014
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Hydrodynamic Regimes Froude=1
• Ratio of Weber to Bond provides insight to either inertial dominated regime or a gravitational dominated regime • Ratio of Reynolds to Froude provides insight to either gravitational dominated regime or a viscous dominated regime
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Example Maneuver: BBQ Roll • BBQ roll performed for an upper-stage propellant tank to ensure even solar heating • What are impacts of BBQ roll on liquid distribution inside a tank?
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Example Maneuver: Turn to Attitude
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Maneuvers on ISS •
Maneuver 1: Simulate an Engine shut down – Accelerate system along major axis of tank for a fixed duration – Apply reverse thrust to accelerate system in opposite direction for a fixed duration
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Maneuver 2: Simulate a turn to attitude – Spin tank about a minor axis to settle all propellants – Make sharp 45 degree turn out of spin plane to 2nd burn attitude
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Maneuver 3: Simulate a thermal roll – Slowly spin tank about minor axis to attain constant spin rate and settle fluid – Thermal roll about major axis while maintaining constant major axis spin rate
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Control Room •
Purposely-setup control room at Florida Tech to support live ISS operations
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•
Test Sessions Checkout Session: Jan 22nd, 2014 – Test Systems – Execute first set of tests: • Translation (engine shut down) • Rotation (thermal roll) • Turn to Attitude
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•
Results showed: – Sensitivity to initial conditions – Bubble count reduction required
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Initial Conditions • Initial distribution of liquid in slosh tank unknown before experimentation • Modeling feasibility is critical Attempted Initial Conditions Option 1: Abrupt acceleration and braking Not effective at reducing bubble count
Option 3: Spinning about major axis Effective at reducing bubbles, easy to execute.
Option 2: Spinning about offset axis Effective at reducing bubbles, hard to achieve (large experiment, small space to move)
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• •
Test Sessions Science 1 Session: Feb 28th, 2014 Executed with 40% fill level tank – Crewmembers found best way to create bubble-free initial condition with cover off
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– Executed tests • Translation (engine shut down) • Rotation (thermal roll) • Turn to Attitude
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Overview: Conclusion
• Introduction • Slosh Experiment on the International Space Station • Conclusion – Conclusions – Summary – Future Research
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Conclusions • Slosh Experiment launched in January 2014 • Two Tanks (20% fill level, 40% fill level) • Three test sessions • Slosh Experiment testbed ultimately handed over to SPHERES Program office at NASA AMES for continuing research
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Summary Testing Platform
Experiment
Simulation
Comparison Agreement ± 3%
Agreement ± 8%
Agreement Being determined
Slosh experiment on ISS fills a gap in available data to benchmark models 7/21/2014
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Future Research Possibilities •
Create and improve control algorithms that include sloshing liquid behavior control and prediction for trajectory optimization
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Study Propellant Management Devices
Courtesy of ATK – Alliant Techsystems
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Study cryogenic propellants
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Acknowledgements NASA KSC – Launch Services Program NASA Game Changing Development Program
NASA AMES NASA Johnson Space Center NASA Marshall Space Flight Center MIT – Space Systems Laboratory Florida Tech team – Aerospace Systems And Propulsion (ASAP) laboratory Crewmembers in the ISS
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Supplemental Slides
Flammability/Off-gassing •
Flammability and Off-gassing analysis/assessment performed on all components of Slosh OpNom Material Flammability Assessment Status Aluminum 2024 T351 On MAPTIS list of approved material payload Frame Arm Center Hub
ULTEM 9085 Aluminum 2024 T351 IDS UI-5580CP-C GigE camera
Camera Stainless-steel Aluminum 2024 T351 ULTEM 9085
NASA WSTF flammability and offgassing test results of 3D printed plastic
LED light panel Hood Lexan sheet Bellow Aluminum 2024 T351 ULTEM 9085 Backdrop
LED light panel Lexan sheet
L20 Tank
3D printed Lexan
L40 Tank
3D printed Lexan
S40 Mass
ULTEM 9085
Internal electronic components Slosh Avionics Box ULTEM 9085
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Small printed circuit board carrying the circuit elements and a USB Slosh Flash Drive connector, insulated electrically and protected inside a plastic, metal, or rubberized case Flash Hard Disk is manufactured by InnoDisk, contains no magnets, (this Slosh Hard Drive is similar to a USB thumb drive, except uses-the SATA port) Development Conference Chicago, IL
Passed flammability and offgassing test, reference: Slosh_ULTEM_Flammability Assessment On MAPTIS list of approved material Acceptable by analysis (reference: discussion at flammability and offgassing meeting via teleconference on March 29, 2013) On MAPTIS list of approved material On MAPTIS list of approved material Passed flammability and offgassing test, reference: Slosh_ULTEM_Flammability Assessment Acceptable by analysis (reference: discussion at flammability and offgassing meeting via teleconference on March 29, 2013) On MAPTIS list of approved material Acceptable by analysis (reference: email from Dr. Mike Pedley on May 8, 2013) On MAPTIS list of approved material Passed flammability and offgassing test, reference: Slosh_ULTEM_Flammability Assessment Acceptable by analysis (reference: discussion at flammability and offgassing meeting via teleconference on March 29, 2013) On MAPTIS list of approved material Acceptable by analysis (reference: email from Dr. Mike Pedley on February 12, 2013) Acceptable by analysis (reference: email from Dr. Mike Pedley on February 12, 2013) Passed flammability and offgassing test, reference: Slosh_ULTEM_Flammability Assessment Acceptable by analysis(reference: discussion at flammability and offgassing meeting via teleconference on March 29, 2013) Passed flammability and offgassing test, reference: Slosh_ULTEM_Flammability Assessment
Passed Passed
Passed
Passed
Passed
Passed Passed Passed
Passed
Acceptable by analysis (reference: SSE_Flammability_Offgassing_Summary.pdf)
Passed
Hard Drives manufactured identically as VERTIGO Hard Drives, Acceptable by analysis (reference: SSE_Flammability_Offgassing_Summary.pdf)
Passed
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Tank Pressure • •
•
Requirement from Safety Data Package, standard hazard form are: – Have a maximum delta pressure of 1.5 atmospheres (22 psia, 1.5 bars) Four different pressure tests performed – Gradual increase of pressure within Wet Slosh tank (full of water) – Rapid increase of pressure within the Wet Slosh tank (full of water) – Gradual increase of pressure within Dry Slosh tank (no water) – Rapid increase of pressure within the Dry Slosh tank (no water) Leak check performed with dry towel (for Wet tank test) and soap solution (for Dry tank test)
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Touch Temperature Test • • •
Requirements for touch temperature are based of SSP 50005, section 6.5.3 Minimum temperature of 4 ºC (39 ºF) and a maximum temperature of 45 ºC (113 ºF) Touch Temperature testing was performed at NASA MSFC, EMC/EMI facility for Slosh hardware articles in the ISS configuration – Temperature readings were taken at pre-defined locations on surface of the SSE – Temperature readings were taken every five minutes after SSE startup for a total duration of 60 minutes.
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Vibration Test •
Slosh hardware vibration tested in its stowage configuration (bubble wrapped and packed in class III triple CTB)
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Maximum flight random vibration envelope as specified in SSP 50835
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Post-vibration analysis, inspection, and verification performed – Functioning of Slosh Avionics Box – Structural integrity of the Slosh tank – Camera lens (shatter) – Slosh hardware (fit check) – LED panels (shatter) in Hood and Backdrop
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EMI/EMC Test •
• •
EMI testing is required to verify that the SSE meets EMI requirements set forth in SSP 30237 SSE did not pass the RE02 test, but waiver has been issued for flight certification Two tests performed for entire SSE – Radiated Emissions – Radiated Susceptibility
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Clamp Functionality •
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• •
A frame arm consisting of a directional positioning system (saddle) and a sliding screw clamping mechanism is utilized for attachment of SPHERES to the Slosh Experiment frame. Two types of buffer materials are used on either side of clamp mechanism. – An Ultem buffer that is part of saddle extends into clamping region from top. – A thick rubber buffer is used on sliding portion of clamp to ensure a spread contact force. SPHERES is positioned into saddle with tank protruding through clamp mechanism. Thumbscrew is tightened to a high finger tight torque securing SPHERES unit to Slosh Experiment.
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Clamp Over Tightening •
•
Multiple methods to prevent over-torquing are implemented: – Small knob size reduces amount of torque an astronaut can apply – Mechanical stop ramps ensure that tank cannot be deflected by more than 0.072” – Rubber buffer can compress by more than 0.072” – Carrier mount screws sized shear/deform prior to thumbscrew pull out DOT-SP 10776 Rev. 10 §178.42 (f) (2) states tank certification hydrostatic test: – Conducted at 3000 psi and flattened with 60° wedges containing a 1/2” radii nose. Must not rupture under six times the seam thickness of deformation. – Tank seam of 1/8” allows for 3/4” of deflection. Far less than 0.072” maximum mechanically allowed by system
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NASA-STD-3000 207 lists maximum torque applied by an astronauts hands. Design numbers used worst case hand torque over lesser finger torque.
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Structural Failure of CO2 Tank due to Clamp Mechanism Cause 1 •
Over torqueing of tank clamp thumbscrew has potential to damage SPHERES CO2 tank
Control 2.A: Tank must not Must not rupture under six times the seam thickness of deformation per DOTSP 10776 Rev. 10 §178.42 (f) (2). SPHERES CO2 tank has 0.125” seam therefore allowing 0.750” deflection. Test/Verification 1: • Verification 1.1 Micrometer 4 CO2 tanks diameter, two empty and two full, in three different orientations each to take average. Secure CO2 tank in clamp, tighten thumbscrew to maximum supination torque as define by NASA-STD-3000 207 and micrometer diameter in three different areas. Verify no value exceeding maximum deflection criteria. • Verification 1.2 Leave CO2 tank clamped for 3 hours and recheck tank diameter dimensions. Verify no value above the maximum deflection. Free Spinning End
Cross-Sectional View 7/21/2014
Retaining Pin
Bottom View AAS 3rd ISS Research and Development Conference - Chicago, IL
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Experimental Validation Overview • •
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Two tanks and two SPHERES units used in MSVP experimental validation. CO2 tanks are flight size, but do not include thermal coating used on ISS flight tanks.
• •
Tank diameters measured at three different stations from the non-threaded end of the tank: 1.75 inches, 3.50 inches and 5.00 inches on each tank. Tank 1 diameter: 2.01 – 2.013 inches Tank 2 diameter: 2.008 – 2.0195 inches
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BLUE sleeve diameter: 2.055 inches ORANGE sleeve diameter: 2.065 inches
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Nominal gap on radius: 0.021 inches (0.53 mm) between tank wall and sleeve
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CO2 Tank – Sleeve Contact Metal sleeve
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CO2 tank
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CO2 tank (tank 2) threaded into blue SPHERE Zoom-in picture shows nominal gap between CO2 tank and metal sleeve Nominal gap on radius: 0.021 inches (0.53 mm)
Pushing in any orientation (left, right, up, down) it is ‘easy’ to push the CO2 tank into the wall of the SPHERES metal sleeve using just finger pressure. It is easy to push either CO2 tank into the sleeve of either SPHERES. No change to operation (no damage) occurs when the CO2 tank is pushed into the sleeve.
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Example of Clamp Mechanism Holding CO2 Tank •
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Completed: Verification 1.1 and Verification 1.2
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Upper Left: photo of underside of clamp assembly. No CO2 tank inserted. Clamp is fully retracted. Upper Right: photo of underside of clamp assembly with CO2 tank fully clamped into place. Thumb screw is finger tightened. Notice compression of orange rubber pad, no compression of ULTEM sleeve occurs. Lower Left: Example of measurement of tank diameter with thumb screw tightened. Lower Right: Example of CO2 tank clamped in one of three positions used to measure possible deflection of CO2 tank diameter Conclusion: with tank clamped under thumb screw torque no tank deformation measured. Conclusion: using maximum finger tightening, clamp can not be overtorqued – stop works as intended.
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Structural Failure of Frame arm due to Collision Cause 2 •
Collision of SPHERES Slosh Experiment has potential to damage frame arm and tank clamp mechanism.
Control 2: Frame arm and tank clamp must not yield and maintain functionality under loading conditions defined in section 7.18 of SLOSH FSDP Phase-I-II . Test/Verification 2.A: • Verification 2.A.1 Clamp SPHERES in with nominal finger torque. Mount frame arm vertically so that the CO2 tank axis is parallel with the floor. Apply a total static load of 36.6 N to the end of spheres. Verify no yielding by dimensional and visual inspection. • Verification 2.A.2 Clamp the SPHERES in with nominal finger torque. Mount frame arm horizontally with CO2 tank axis parallel with the floor. Apply an incremental static load of 50 N up to a maximum load of 227 N to the upward facing side of SPHERES. Verify no yielding by dimensional and visual inspection after each load increment.
V 2.2
V 2.1 7/21/2014
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Examples of Clamp Holding SPHERES in Various Orientations
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Maximum Loading Summary • • • •
• • • •
• •
Completed: Verification 2.A.1 and Verification 2.A.2 7/21/2014
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Upper: Blue SPHERES with CO2 tank (tank 2) loaded into cantilevered test fixture. Note that blue SPHERE with CO2 tank is about 4.2 kg (9.2 lb). Force transmitted to CO2 tank and saddle is about 40 N Visual inspection indicates that CO2 tank contacts wall sleeve Lower: Blue SPHERES with CO2 tank (tank 2) loaded into cantilevered test fixture. Additional weight: 25.4 kg (56 lb). Force transmitted to CO2 tank and saddle is about 250 N Visual inspection indicates that CO2 tank contacts wall sleeve Test repeated on three sides of SPHERES unit (not repeated on side that holds VERTIGO). Test repeated by placing weight on top of SPHERES with saddle on bottom Conclusion: no loss of functionality or damage to SPHERES, CO2 tank, saddle, clamp, etc.
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Testing of Both Clamps
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Notes/Observations/Comments •
Orientation saddle performs as intended – Alignments of SPHERES with frame axis arm is better than 2 degrees (note cosine 2 degrees = 0.99939) – Clamp mechanism/grip itself prevents rotation of the CO2 tank once clamped down
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With thumb screw tightened down using nominal finger torque, I was not able to pull CO2 tank out of clamping mechanism
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With thumb screw tightened down using nominal finger torque, placing 250 N (56 lb) on top of SPHERES did not cause tank to slide or move within clamping mechanism or create any measureable deflection of saddles (indicated good base contact).
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Shaking frame arm with SPHERES unit attached did not result in any movement of clamp relative to CO2 tank. Works exactly as anticipated.
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Tests repeated multiple times – no instances of clamp not working as intended.
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•
• •
Liquid Slosh Tank Design Bo can be maximized for given fill level (balance between r2 and m) – Approaching peak from small radius, acceleration ↓, and Bo ↑ – Past peak, radius ↑, acceleration ↓, and Bo ↓ Purpose: Bond analysis not sufficient – how much impact does fill level have on creating a slosh event that alters system trajectory Liquid impacts tank and entire system is ‘pushed’ to a new velocity, given by conservation of momentum
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Surrogate Fluid Options • • • •
Surrogate fluid options Novec Fluid and Silicone Fluid (vs. water) Both fluid have low viscosity, surface tension and contact angle Non-dimensional numbers reflect Novec fluid has high Bond number and Weber number ranges High Bond and Weber numbers would favor slosh as fluid tends to be in gravity or inertia dominated regime Water Novec Silicone Bond Number
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1.62
12.95
5.61
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PTC Maneuver: Non-dimensional Mapping Results • • •
For a specified rotation rate (deg/s) for an rocket upper-stage, can the non-dimensional number suggest rotation rates for ISS slosh experiment? Table below shows expected rotation rate (in deg/s) for slosh experiment to match non-dimensional numbers for typical rocket upper-stage Bond, Weber and Reynolds numbers from upper-stage are used to derive individual rotation rates for specified fluid and slosh experiment dimensions (tank radius) and each non-dimensional number provides a unique rotation rate Water Rotation Rate (Deg/s) Velocity (m/s) Acceleration (m/s2) Bond Number Weber Number Reynolds Number Froude Number Rocket Upper-Stage Rotation Rate (Deg/s) Rotation Rate (Deg/s) Rotation Rate (Deg/s) Bond Number Weber Number Bond Matching Froude Number Reynolds Number Bond Number Weber Number Tank Slosh Experiment Weber Matching Froude Number Reynolds Number Bond Number Weber Number Reynolds Matching Froude Number Reynolds Number
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0.1 4.36E-03 7.62E-06 1.29E+00 1.29E+00 5.65E+04 1.00E+00 27.1 27.1 515.8 1.29E+00 4.24E+03 3.28E+03 1.70E+05 4.24E+03 1.29E+00 3.05E-04 2.97E+03 1.53E+06 4.67E+02 3.05E-04 5.65E+04
LH2 0.1 3.49E-03 6.09E-06 6.61E-01 6.61E-01 3.62E+04 1.00E+00 19.4 19.4 330.1 6.61E-01 2.17E+03 3.28E+03 1.22E+05 2.17E+03 6.61E-01 3.05E-04 2.13E+03 6.28E+05 1.91E+02 3.05E-04 3.62E+04
0.1 2.66E-03 4.65E-06 2.93E-01 2.93E-01 2.10E+04 1.00E+00 12.9 12.9 191.9 2.93E-01 9.62E+02 3.28E+03 8.11E+04 9.62E+02 2.93E-01 3.05E-04 1.42E+03 2.12E+05 6.47E+01 3.05E-04 2.10E+04
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0.1 4.36E-03 7.62E-06 4.12E+00 4.12E+00 6.34E+04 1.00E+00 48.4 48.4 578.8 4.12E+00 1.35E+04 3.28E+03 3.04E+05 1.35E+04 4.12E+00 3.05E-04 5.31E+03 1.93E+06 5.88E+02 3.05E-04 6.34E+04
LOX 0.1 3.49E-03 6.09E-06 2.11E+00 2.11E+00 4.06E+04 1.00E+00 34.7 34.7 370.4 2.11E+00 6.92E+03 3.28E+03 2.18E+05 6.92E+03 2.11E+00 3.05E-04 3.80E+03 7.91E+05 2.41E+02 3.05E-04 4.06E+04
0.1 2.66E-03 4.65E-06 9.35E-01 9.35E-01 2.36E+04 1.00E+00 23.1 23.1 215.4 9.35E-01 3.07E+03 3.28E+03 1.45E+05 3.07E+03 9.35E-01 3.05E-04 2.53E+03 2.67E+05 8.14E+01 3.05E-04 2.36E+04 49
Surrogate Fluid •
Deviation in displacement between frozen solid and liquid is: – CG Displacement: 100 mm – Velocity: 2 mm/s – No rotations induced in this case
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Deviation in displacement between frozen solid and liquid is: – CG Displacement: 38 mm – Velocity: 2 mm/s – No rotations induced in this case
POSITION (mm) VELOCITY (mm/s) ROTATION (Deg/s) LIQ SOL LIQ SOL LIQ SOL LIQ SOL LIQ SOL LIQ SOL LIQ SOL LIQ SOL LIQ SOL Man Fill Vol X X Δ Y Y Δ Z Z Δ X X Δ Y Y Δ Z Z Δ X X Δ Y Y Δ Z Z Δ 1 20 -1 0 1 813 713 100 -14 -13 2 0 0 0 143 145 2 0 0 0 0 0 0 0 0 0 0 0 0 1 20 -1 0 1 725 686 38 -24 -12 12 -1 0 1 142 140 2 -1 0 1 0 0 0 0 0 0 0 0 0 7/21/2014
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