CFD Analysis of CUBRC Base Flow Experiments
CFD Analysis of CUBRC Base Flow Experiments
CFD Analysis of CUBRC Base Flow Experiments
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This paper presents results from a computational analysis of a series of experiments con-
ducted in the CUBRC 48” reflected shock tunnel for the purpose of studying the transition
of afterbody wake flows. The experiments examined the flow over a spherically-blunted
capsule, roughly chosen to be a scale representation of the new Orion crew module cur-
rently being designed by NASA. In this study, we have focused on three test runs for
analysis, corresponding to low, medium, and high Reynolds number conditions. Each case
has been examined with the intent of understanding the influence of turbulence modeling,
time accuracy, and flux discretization on solution accuracy. Numerically, we find a stan-
dard first order in time, second order in space (with modified Steger-Warming fluxes) to
be adequate for the external, reentry type flows of interest. For the low Reynolds number
case (ReD ≤ 106 ), a laminar Navier-Stokes simulation is sufficient to accurately capture the
statistical character of the flowfield. At the medium Reynolds number (ReD = 6.3×106 ), the
analysis indicates a possibly transitional wake where heat transfer predictions are bounded
by laminar and turbulent simulations. At the high Reynolds number (ReD = 10.8 × 106 ), the
experimental data are best matched by a fully turbulent calculation using the Detached
Eddy Simulation (DES) form of the Spalart-Allmaras turbulence model. Additionally,
comparisons between Reynolds-averaged Navier-Stokes (RANS) and DES calculations re-
veal the inability of RANS models to correctly capture either the rapidly fluctuating flow
transients or mean field. Repeating the DES calculation with an alternative second order
in time, low-dissipation flux scheme shows a substantial improvement in the simulation’s
ability to capture flow transients and may prove crucial for applications in which this is
a priority. It is observed that the improvements seen in moving from RANS to DES and
from Steger-Warming to the low-dissipation scheme are related in that both ultimately
reduce the level of unnecessary dissipation present in the simulation.
I. Introduction
espite nearly 50 years of research, analysis of high-speed, unsteady wake flows remains a challenging and
D unsolved problem. Yet as hypersonic applications become increasingly complex, so too increases the
demand for computational tools capable of accurately predicting unsteady, separated flows. We know from
experience that the effects of turbulent heating can be a significant contributor to overall vehicle heating. In
practice, when any appreciable amount of flow unsteadiness is present, whether laminar or turbulent, it is
most often offset by design margins which try to compensate for the unknown accuracy of the computational
results. The practice of applying design margins is severely limiting, especially in the tight budget climate
of today’s space industry. A prime example is thermal protection system (TPS) design for space vehicles.
The launch cost of a space vehicle is predominantly a function of its mass: more mass requires more fuel
and potentially greater vehicle complexity. In the context of the Space Shuttle, the average $500 Million
launch cost results in a net payload cost of approximately $20,000 per kilogram. It is critically important to
a program budget that payload mass be minimized to the extent possible in order to increase the trade space
when choosing a launch vehicle. One must also consider that, in the event that a particular launch vehicle’s
∗ Research Scientist (currently with ELORET Corp., Sunnyvale, CA), AIAA Member; michael.d.barnhardt@nasa.gov
† Professor,Department of Aerospace Engineering and Mechanics, AIAA Fellow; candler@aem.umn.edu
‡ Senior Research Scientist, AIAA Senior Member; maclean@cubrc.org
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B. Capsule Configuration
As stated earlier, the nominal model configuration used in this study is an Apollo-style spherical capsule
chosen to closely resemble the proposed Orion spacecraft being designed by NASA as a replacement for the
soon-to-retire Space Shuttle fleet. A detailed schematic is shown in Figure 1. All dimensions shown in the
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figure are given in inches. The scale of the model was chosen after carefully considering the test core diameter
of the 48” tunnel as well as the time necessary for the model’s wake to fully establish. The model is fixed with
a 28◦ angle of attack, which is near the peak L/D for this configuration. Four sting mount configurations
were used during the course of testing: (1) round center mounted sting, (2) diamond cross-section center
mounted sting, (3) a split sting attached to the capsule at two lateral points, and (4) an aerodynamic blade
sting attached to the windward backshell. Of these, only the round center mounted sting was considered in
this study.
The topologies and sizing used in this work are developed from experience with the simulations presented
in Ref. [13]. While not shown here, the sizing was further refined through a preliminary grid resolution
study of the most turbulent case and a single grid was used for all simulations. To the extent possible, grid
refinement was localized to the wake region of the leeside aftbody so that unnecessary refinement of the far
field was minimized. The final result is a mesh comprised of 9.7 million cells. The cell width in the wake is
nominally 2.5 mm, or approximately 1% of the model diameter. Figure 2 depicts the surface and symmetry
planes of the mesh.
The capsule model is instrumented with a total of 85 sensors, including all inserts and optional mea-
surements. Of these, 38 are piezoelectric pressure gauges and 47 are heat transfer gauges. With the round
center-mounted sting in place, the number of gauges was reduced to 35 and 39, respectively. The complete
instrumentation map is shown in Figure 3. The forebody instrumentation is relatively sparse and is meant
only for basic confirmation of test conditions. Four coaxial thermocouple gauges are placed on the capsule
centerline, with two additional thin-film gauges at each shoulder. The pressure gauges are located along two
orthogonal rays. It is important to note that the limited amount of forebody instrumentation also limits
our knowledge of boundary layer transition, a fact which affects some of our subsequent modeling choices,
as will be seen.
The remaining gauges are distributed in rays along the aftbody. In this study, because the number of
gauges is quite large, proper identification of each component is a critical task in order to coherently break
down the presentation of results. To this end, we have chosen to label the instrument rays according to a
clockwise angular naming convention, where the angle is denoted by φ. At 28◦ angle of attack, the φ = 0◦
ray corresponds to the most leeward side of the capsule while φ = 180◦ is most windward. The individual
gauges are identified using a consecutive numbering scheme. Thus, accounting for missing and inoperable
gauges, the pressure gauges are simply labeled [1 - 35] and the heat transfer gauges [36 - 74]. Note that this
numbering scheme differs somewhat from that seen in Ref. 18. For detailed comparison to that study, refer
to Table 1 for a complete transposition of the two labeling schemes. Throughout the remaining text, we
have made an effort to further identify the gauges descriptively so that the spatial relationships among the
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C. Test Conditions
Numerous datasets are available from this series of experiments, representing runs using the various sting
configurations across a range of Reynolds numbers and freestream enthalpies. For simplicity, we have chosen
to limit our analysis to the runs which used the round center mounted sting. Five runs were made in this
configuration, spanning a range of Reynolds numbers from 2.6 × 106 to 8.5 × 107 per meter. The relevant
freestream conditions are given in Table 2. Of these cases, Run 5 exhibited peculiarities during the data
reduction process and so it was rejected for inclusion in this study. We also determined that Runs 1 and 3
were redundant because their respective Reynolds numbers placed them both in the transitional regime and
our primary interest is to assess turbulence modeling, not enthalpy effects. Our final analysis is therefore
concerned with Runs 4, 3, and 2, representing nominally low, medium, and high Reynolds number wake
flows, respectively.
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Current Ref. 18
Pressure 1 - 35 P1 - P7, P10 - P37
Heat Transfer 36 - 74 T1 - T11, T13 - T17, T21 - T43
Forebody
1 - 3, 12 - 15 P1 - P3, P14 - P17
36 - 41 T1 - T6
φ = 0◦
4-7 P4 - P7
42 - 46 T7 - T11
φ = 13◦
16 - 18 P18 - P20
52 - 55 T21 - T24
φ = 26◦
19 - 21 P21 - P23
56 - 59 T25 - T28
φ = 38◦
22 - 24 P24 - P26
60 - 63 T29 - T32
φ = 64◦
25 - 27 P27 - P29
64 - 66 T33 - T35
φ = 90◦
28 - 30 P30 - P32
67 - 69 T36 - T38
φ = 135◦
31 - 33 P33 - P35
70 - 72 T39 - T41
φ = 150◦
34, 35 P36, P37
73, 74 T42, T43
φ = 180◦
8 - 11 P10 - P13
47 - 51 T13 - T17
Table 2. Test conditions for the spherical capsule with round center mounted sting.
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scheme of Subbareddy and Candler.22 Time integration of the scheme is second order by way of a dual-time
sub-iterative technique.
As noted in Table 2, the flows of interest all have a Mach number near 6.5. At this Mach number,
there is insufficient energy to cause dissociation of the gas - a perfect gas model is therefore employed for
all simulations. Similarly, simple transport models are assumed to be adequate: Blottner curve fits and
an Eucken relation are used for species viscosity and thermal conductivity, respectively, along with Wilke’s
mixing rule to obtain mixture values, and a constant Lewis number assumption (equal to 1.4) is used to
calculate diffusion coefficients.
A variety of turbulence models are tested, although our primary focus is on the application of DES with
the Spalart-Allmaras (S-A) one-equation model.23, 24 The DES model available in US3D was previously
shown in Reference [13] to accurately model the turbulent Reentry-F base flow (ReD > 107 ). To understand
how the DES formulation functions in a separated flow, consider first the Spalart-Allmaras RANS model
(including the compressibility corrections of Catris and Aupoix25 ):
2
Dρν̃ 1 √ √ √ ν̃
= ∇ · (µ∇ν̃ + ρν̃∇ ρν̃) + cb2 (∇ ρν̃)2 + cb1 ρS̃ ν̃ − cw1 fw ρ (1)
Dt σ d
where ρ is the local fluid density, ν̃ is related to the eddy viscosity, S̃ is a measure of vorticity, and d is
the distance to the nearest wall. Definitions for the remaining variables can be found in the previously
cited references. Note that the destruction term scales as d−2 . Therefore, with the model active far from
solid surfaces, there is very little destruction of turbulent viscosity, and high levels of ν̃ persist. The DES
formulation replaces the length scale of a RANS model with a new one, such that the model behaves as
a Smagorinsky-like subgrid scale model in regions where the flow is separated. Thus the new length scale
acts as a filter, allowing the simulation to resolve eddies down to the grid scale while modeling those that
are smaller. For the particular case of the S-A model, this is accomplished in a straightforward manner by
replacing d with a new variable that depends on some measure of the local grid cell size, ∆:
With this definition, the modified equation is equivalent to the unchanged S-A RANS model near walls.
Away from walls, if the filter width (i.e. cell size) is chosen to lie in the inertial subrange, then turbulent
production and destruction should roughly balance each other. Under this assumption, it is easy to show
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Figure 6. Comparison of experimental and numerical measurements for Run 4. (a) Pressure, (b) Heat transfer
rate.
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80000 15
60000
10
40000
20000 5
0
0
0 10 20 30 40 50 60 70
Gauge Number Gauge Number
(a) (b)
Figure 7. Comparison of experimental and numerical measurements for Run 3. (a) Pressure, (b) Heat transfer
rate.
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20
100000
15
10
50000
0
0
0 10 20 30 40 50 60 70
Gauge Number Gauge Number
(a) (b)
Figure 8. Comparison of experimental and numerical measurements for Run 2. (a) Pressure, (b) Heat transfer
rate.
from the windside to the leeside, see for instance the φ = 90◦ ray. This seems to indicate an inability
of the computational models to accommodate a rapid expansion of the flowfield, not unlike the frequently
seen heat transfer spikes at the shoulders of capsule geometries. It is also indicative of the grid possibly
being under-resolved near the separation points. Again, we note that this phenomenon is almost completely
localized such that it has little or no impact on the gas subsequent to separation.
Finally, we may gain further insight into our numerical performance for this particular case by looking
closer at the detailed transients of a few selected gauges. While we cannot expect to perfectly replicate
transient phenomena in our simulations, we can reasonably compare frequencies and amplitudes of oscillation.
For this purpose, we have run our simulations over a time period comparable to the flow time achieved in
the experiment and extracted transient data along the φ = 0◦ ray.
The resulting comparisons for gauges [42 - 46] are shown in Figure 11. Note that increasing gauge number
indicates movement from the shoulder toward the base of the capsule. Gauge 42 therefore reflects the state of
the flow just subsequent to the strong expansion off the leeside shoulder. Here we see that the ability of the
computation to correctly capture the amplitude and frequency of the flow is severely degraded. Interestingly,
this does not detrimentally affect the time-averaged result, although this is perhaps only a fortuitous result.
As we move away from the shoulder toward the base, we see a steady improvement in the simulation’s
prediction of oscillation frequencies and amplitudes. There is however a slight bias toward overprediction
near the base, a fact which is apparent in the time-averaged results of Figure 10. These results suggest
that an additional local refinement of the computational mesh near the shoulder separation and wake/sting
interaction may be necessary in order to accurately capture transient behavior in these regions.
E. DES v. RANS
Comparisons are shown in Figure 12 of DES and RANS simulations for the Run 2 condition. We’ve restricted
the plots to show only afterbody gauges in order to draw out differences between models more clearly. As
noted earlier, there is relatively small variation in computed pressure profiles - for this case, the largest
difference occurs near gauges 26 and 27 and amounts to approximately 0.5% of the forebody stagnation
pressure. SST-RANS and SA-DES produce the best results, while Baldwin-Lomax and SA-RANS tend
to over- and under-predict the experiment, respectively. Nevertheless, relative to the dominant forebody
pressure, each model produces fair or better results. Differences in predicted heat transfer between the
models are more pronounced, with variations as large as 7% (gauge 45) of the experimentally measured
stagnation value. One can actually deduce from Figure 12(b) whether the gauges are located in attached
or separated flow regions by comparing the S-A DES and S-A RANS curves. In attached regions, S-A DES
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Figure 9. Comparison of experimental and numerical pressure measurements along instrument rays for Run
2. Symbols denote experiment, solid lines denote simulation (SA-DES).
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Figure 10. Comparison of experimental and numerical heat transfer rates along instrument rays for Run 2.
Symbols denote experiment, solid lines denote simulation (SA-DES).
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42
44
46
45
Figure 11. Comparison of CFD to experimental transient heat transfer along φ = 0◦ ray for Run 2.
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Figure 12. Comparison of numerical measurements along the afterbody for Run 2. (a) Pressure, (b) Heat
flux.
and S-A RANS give nearly identical results, a consequence of the RANS formulation being a limiting case
of DES under such conditions. For gauges located in separation regions, however, the two models diverge.
Significantly, we see that the predictive accuracy of the S-A RANS model is degraded relative to S-A DES,
even on an identical, highly-refined mesh.
On a per-gauge basis, there is no discernible pattern of over- or under-prediction in the S-A RANS
model. On the other hand, SST-RANS almost uniformly under-predicts the heat transfer rate. In both
cases, the excessive dissipation introduced by the RANS model essentially creates an ‘alternative’ flow
structure. Separation and reattachment lines are moved, and convection streamlines are dramatically altered
to accommodate the more ‘viscous’ flow. For the capsule case (and indeed for all cases investigated during the
course of our research), the result is that the RANS models tend to produce a much smoother flowfield with
little local fluctuation, while the DES model exhibits a much greater degree of disorder and unsteadiness.
Analytically, this is precisely what we expect to occur because, for a sufficiently refined grid, the DES
simulation essentially amounts to transferring the bulk of modeling work from the approximate turbulence
model to the exact Navier-Stokes equations. In other words, the success of DES in our simulations stems
not so much from the model producing a more ‘correct’ value of eddy viscosity, but merely by the fact that
it interferes minimally with the fidelity that Navier-Stokes already provides. (This is not to suggest that the
particulars of the subgrid model are trivial; they certainly are not.)
Interestingly, the heat transfer results from the Baldwin-Lomax model would appear to contradict our
generalization of RANS models. With the obvious exception of gauge 45, the Baldwin-Lomax model does
a surprisingly good job of reproducing the experiment. This is puzzling because the model is generally
regarded as appropriate only for attached boundary layers. To understand our result, in Figure 13 we have
plotted the ratio of eddy viscosity to molecular viscosity found in the symmetry planes of the SST and
Baldwin-Lomax simulations. Here we see that the SST model is working as described: an enormous amount
of dissipation is being added throughout the wake. In contrast, the dissipation of the Baldwin-Lomax model
is rather small - more importantly, dissipation is clearly confined to the grid blocks attached to the surface.
In fact, Figure 13 demonstrates that the seemingly good performance of the Baldwin-Lomax model is simply
a result of the DPLR implementation which, for this specific block topology, prevents the model from being
active except in very limited regions near the body. A different block topology in DPLR would conceivably
result in a very different answer. The model is therefore artificially behaving as a sort of wall model, not
unlike the function of the DES formulation, which reinforces our previous assertion that excessive values of
eddy viscosity are the largest obstacle to overcome in a simulation when the grid is sufficiently refined. We
emphasize again that this behavior should not be considered a general feature of the Baldwin-Lomax model,
but is particular to its implementation in DPLR.
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Thus, the capsule surface is subjected to different levels and distribution of heating depending on which
model one chooses. This observation is quantitatively verified in Figure 14 which depicts the simulated
transient heat fluxes at gauge 45. In this figure, we have started the SA-DES and SA-RANS simulations
from an identical initial condition and allowed them to evolve over a period of time while keeping the CFL
number fixed. Note that the time scale has been truncated relative to Figure 11 in order to draw out
distinctions in the resolved heat flux measurements.
First, after the initial ∼0.5 ms transient has passed, during which time the flow is adjusting to the models
being switched on, it is apparent that the SA-RANS simulation has a greatly diminished ability to resolve
flow unsteadiness. Looking at the standard deviation (using the full time trace data as shown in Figure 11),
we find that the magnitude relative to the experimentally measured mean is 52% for SA-DES and only
0.64% for SA-RANS. Thus the amplitude of fluctuation is reduced by nearly two orders of magnitude. The
SA-DES simulation, on the other hand, compares quite favorably to the experiment.
Second, the SA-RANS simulation greatly overpredicts the experiment across nearly the entire flow time
and so it fails to achieve even the correct mean heat flux. We compute the relative error of the mean heat
flux for this case to be 30% and 156% for SA-DES and SA-RANS, respectively. The computed statistics for
the experiment and both simulations at gauge 45 are summarized in Table 3. By integrating over all of the
gauges located in the wake, we obtain total error estimates of 36% and 57% for SA-DES and SA-RANS,
respectively. The reduction in total error for the SA-RANS case is chiefly due to the inclusion of gauges
located near the shoulder separation (like gauges 42 and 43 in Figure 11) where flow unsteadiness is fairly
weak. In light of RANS being the most favored modeling approach employed in today’s production CFD
codes, we can surmise that the use of more sophisticated methods like DES, if applied during the design
phase of an actual flight vehicle, could crucially impact development of an afterbody thermal protection
system.
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Figure 14. Heat flux transients from gauge 45 of Run 2 simulated with SA-RANS and SA-DES.
µ σ µ/µexp σ/µexp
2
(W/cm )
Experiment 1.1178 0.5962 1.0000 0.5334
SA-DES 1.4509 0.5855 1.2980 0.5238
SA-RANS 2.8601 0.0072 2.5587 0.0064
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0.5
0
0 0.5 1 1.5 2 2.5
Time (ms)
Figure 15. Heat flux transients from gauge 42 of Run 2 simulated with the original Steger-Warming scheme
and the low-dissipation scheme of Subbareddy and Candler.
V. Conclusions
In this paper, we examined the spherical capsule experiments of Ref. [18] in order to (1) obviate concerns
that were raised concerning ambiguity of the Reentry-F flight data, and (2) extend our analysis to realistic
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Acknowledgments
This research is supported by the NASA Fundamental Aeronautics Program under grant NNX07AC28A
with Dr. Seokkwan Yoon as Program Manager. This research is also supported by the Air Force Office
of Scientific Research (AFOSR) under Grant No. FA9550-04-1-0341. The views and conclusions contained
herein are those of the authors and should not be interpreted as necessarily representing the official policies
or endorsements, either expressed or implied, of the AFOSR or the U.S. Government. Computer time was
provided by the University of Minnesota Supercomputing Institute.
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