Thermal-structural analysis of regenerativelycooled thrust chamber wall in reusable LOX/Methane rocket engines

To predict the thermal and structural responses of the thrust chamber wall under cyclic work,a 3-D fluid-structural coupling computational methodology is developed.The thermal and mechanical loads are determined by a validated 3-D finite volume fluid-thermal coupling computational method.With the specified loads,the nonlinear thermal-structural finite element analysis is applied to obtaining the 3-D thermal and structural responses.The Chaboche nonlinear kinematic hardening model calibrated by experimental data is adopted to predict the cyclic plastic behavior of the inner wall.The methodology is further applied to the thrust chamber of LOX/Methane rocket engines.The results show that both the maximum temperature at hot run phase and the maximum circumferential residual strain of the inner wall appear at the convergent part of the chamber.Struc tural analysis for multiple work cycles reveals that the failure of the inner wall may be controlled by the low-cycle fatigue when the Chaboche model parameter γ3 =0,and the damage caused by the thermal-mechanical ratcheting of the inner wall cannot be ignored when γ3 ＞ 0.The results of sen sitivity analysis indicate that mechanical loads have a strong influence on the strains in the inner wall.     

液氧/甲烷发动机推力室多循环热-结构分析

为了研究一款液氧/甲烷发动机推力室多循环工作状态下的结构变形,拓展并验证了一种包括流动-传热分析和非线性有限元分析的热-结构分析方法。通过该方法得到了推力室热载荷与压力载荷分布,并分析了推力室在这些载荷下的应力应变响应。研究表明：推力室整体结构变形并非主要取决于热载荷,压力载荷引起的冷却通道底面弯曲在喷管扩张段尤其明显;后冷阶段产生的弹塑性拉伸应变大于热试阶段产生的压缩应变是导致每次循环结束后结构产生残余应变的直接原因;随着工作循环次数的增加,扩张段的冷却通道底角位置残余应变累积速率最快,该部位被确定为结构失效的潜在位置;增加冷却剂入口附近的通道底面厚度、减小后冷阶段与热试阶段的温差以及将冷却通道的尖锐底角设计为圆角可以成为抑制变形和减缓应变累积的备选措施。     

液体火箭发动机推力室可重复使用技术

为了验证液体火箭发动机推力室可重复使用技术,采用流-固耦合方法对推力室内壁材料、外壁厚度、冷却通道高宽比等影响推力室内壁寿命的因素进行了数值模拟.通过计算,得到了推力室内壁在不同内壁材料、不同外套厚度、不同冷却通道高宽比下单循环各阶段的应力、应变分布,对计算结果进行后处理,得到了内壁损伤.结果表明,采用高强度及延展性内壁材料、低刚性外套、大冷却通道高宽比可以减小推力室内壁损伤,延长推力室内壁使用寿命.      

Thermo-structural analysis of regenerative cooling thrust chamber cylinder segment based on experimental data

To evaluate the structural failure risk of the regenerative cooling thrust chamber cylinder segment, a Finite Element Method (FEM) based on experimental data was developed. The methodology was validated and utilized to reveal the thermal response and the nonlinear deformation behavior of the cylinder segment phase by phase. The conclusions of the research are as follows: The 2D heat flux distribution caused by the injector determines the uneven temperature distribution on the gas-side wall and leads to the temperature disparity between various cooling channels; The reason for the accumulation of residual strain is that the tensile strain generated in the post-cooling phase is greater than the compressive strain produced in the hot run phase; Through the single-cycle simulation, two potential failure locations with conspicuous deformations were found, but it is difficult to determine which point is more dangerous. However, the multi-cycle thermo-structural analysis gives the evolution of the stress-strain curve and gradually discloses that the low-temperature corner of a particular channel is the most likely location to fail, rather than the maximum residual strain point of the gas-side wall. The damage analysis for dangerous point indicates that the quasi-static damage accounts for the majority of the total damage and is the main factor limiting the service life.     

液体火箭发动机推力室内壁寿命预估

为了分析推力室内壁失效机理及准确预估推力室内壁寿命,对推力室进行流-热-固耦合计算.流-热耦合为热-固耦合提供准确的热和机械载荷,热-固耦合模型对推力室内壁在循环加载下的变形进行非线性平面应变有限元分析.通过计算,得到了推力室内壁在单循环各阶段的应力-应变分布和循环加载下的变形过程,并进行了寿命预估.结果表明:采用的流-固耦合策略能准确地实现流-热耦合模块向热-固耦合模块的载荷传递,能为结构分析提供准确的边界条件.在预冷、后冷和松弛阶段,内壁承受拉应力;在工作阶段,内壁承受压应力.随着循环次数的增加,内壁残余应力和应变不断增大,内壁向燃烧室内鼓起和不断变薄,冷却通道中心最先失效.所采用的分析模型能够模拟内壁在循环热和机械载荷下的变形过程,用于预估推力室内壁的循环寿命.      

Numerical analysis of regenerative cooling in liquid propellant rocket engines

High combustion temperatures and long operation durations require the use of cooling techniques in liquid propellant rocket engines (LPRE). For high-pressure and high-thrust rocket engines, regenerative cooling is the most preferred cooling method. Traditionally, approximately square cross sectional cooling channels have been used. However, recent studies have shown that by increasing the coolant channel height-to-width aspect ratio and changing the cross sectional area in non-critical regions for heat flux, the rocket combustion chamber gas-side wall temperature can be reduced significantly without an increase in the coolant pressure drop. In this study, the regenerative cooling of a liquid propellant rocket engine has been numerically simulated. The engine has been modeled to operate on a LOX/kerosene mixture at a chamber pressure of 60 bar with 300 kN thrust and kerosene is considered as the coolant. A numerical investigation was performed to determine the effect of different aspect ratio and number of cooling channels on gas-side wall and coolant temperatures and pressure drop in cooling channels.     

冷却剂不同流动方式对膨胀循环推力室再生冷却换热的影响

为了解液体火箭发动机膨胀循环推力室再生冷却换热特性,对某一参考发动机推力室和另外两种面积比的膨胀循环推力室建立三维计算模型,采用数值模拟的方法,考察冷却剂的温升、冷却通道压降以及推力室内壁面温度和热流密度的分布情况.重点比较了不同燃烧室圆柱段长度、冷却剂不同流动方式以及不同面积比对以上结果的影响.计算过程中采用二阶迎风格式离散控制方程.计算结果表明:采用逆流冷却时,通过加长推力室圆柱段长度使推力室受热面积增加70%后,冷却剂温升提高了一倍左右;对膨胀循环推力室进行再生冷却时,采用顺流冷却要比逆流冷却的冷却通道压降低,但同时冷却剂温升也较低,并且对喉部壁面的冷却效果较差.     

层板推力室发汗冷却壁温特性的初步研究

对液体火箭发动机发汗冷却层板推力室的壁温特性进行了初步研究,通过建立一维固液耦合温差模型,利用有限体积法,计算得到沿推力室径向层板固体和冷却剂的温度分布,并对影响壁温特性的各种因素进行了计算分析,包括冷却剂流量、层板导热系数和冷却通道尺寸等.结果表明:冷却剂流量是控制层板结构温度的重要参数;层板应该采用一种导热系数适中的材料,过大或过小导热系数的材料都不利于推力室的整体性能;较大的冷却通道宽高比有利于层板向冷却剂导热;冷却通道内的换热效率与冷却剂流量和层板导热系数有关.      

复合材料主动冷却薄壁燃烧室设计分析

通过建立流固耦合传热模型,对不同尺寸冷却通道的主动冷却薄壁燃烧室结构瞬态传热特性进行数值模拟,给出了主动冷却燃烧室的瞬态温度场分布及其演化.再采用有限元法计算燃烧室的热应力和应变,从而揭示了冷却通道几何参数及内部煤油体积流量对燃烧室薄壁结构最高温度和热应力的影响规律.计算结果表明:在充分发挥煤油冷却效果前提下,冷却通道距离燃烧室内壁距离越近,所需煤油体积流量越大,而燃烧室结构热应力在10s左右达到最大值,设计时应着重考虑这段时间内的材料性能.      

液氧甲烷发动机台阶型冷却通道的耦合传热特性

为了研究液氧甲烷发动机再生冷却通道中跨临界甲烷的流动和传热特性,以及冷却通道较大幅度的突扩突缩对冷却效果的影响,采用整场直接耦合的方法对推力室三维耦合传热进行了数值模拟,考虑了燃气的非平衡流动.通过计算得到了推力室三维温度场和流场.计算结果表明：由于喉部截面附近存在较强的二次流,燃气侧壁面温度的最大值出现在喉部上游.由于突扩突缩处存在较强的旋涡运动,冷却剂的湍流强度增强,冷却剂侧表面传热系数显著提高,燃气侧壁面温度出现局部极小值,同时也产生了较大的局部损失.由于铜内衬热阻比镍外套热阻小得多,从燃烧室进入的大部分热量在冷却通道底面和侧面被冷却剂吸收.冷却通道底面的温度和热流密度沿程变化比顶面更剧烈.     

液体火箭发动机推力室复合冷却流动与传热研究

为了预测液体火箭发动机推力室的复合冷却性能,建立了推力室再生冷却通道和超临界氢的三维仿真模型以及推力室内燃气和超临界氢膜的轴对称二维仿真模型。通过边界耦合发展了液体火箭发动机推力室复合冷却流动与传热的数值仿真方法。对航天飞机主发动机推力室内部燃气、超临界冷却膜、室壁和再生冷却剂进行了流动与传热耦合计算仿真研究。研究表明,仿真方法可较好地预测推力室燃气及再生冷却剂的流动和传热,计算得到航天飞机主发动机的燃气侧壁面最高热流密度为129MW/m2,最高壁温为885K,冷却剂温升为192K,压降为8.8MPa,结果与已有数据吻合较好。模型和仿真方法可用于液体火箭发动机推力室冷却系统传热计算和冷却结构的优化设计。     

全流量补燃循环发动机推力室再生冷却技术研究

将层板式大高宽比、薄壁、弹性冷却内衬等新技术采用到全流量补燃循环发动机推力室再生冷却设计上,结合全流量发动机工作特点,建立了冷却通道准一维换热和二维数学模型,得到了推力室轴向热参数分布和危险截面冷却通道的温度场和应力场,得出了采用推力室再生冷却新技术相对于传统模式可以较大地降低推力室喉部内壁温、内衬最大等效应力和冷却压降,从而提高推力室寿命及发动机性能的结论,并初步设计出大推力全流量补燃循环发动机推力室再生冷却结构.      

一种计算再生冷却推力室温度场的方法

为了能够快速而准确地得到再生冷却推力室的温度分布,建立了一种计算再生冷却推力室温度场的方法。首先建立了轴对称推力室的一维冷却模型,并使用换热经验公式,得到了推力室壁面在轴线方向上的温度分布;其次建立了推力室的冷却套二维导热模型,使用数值模拟的方法和一维计算的结果,得到了冷却套的温度场。然后使用这种方法研究了气壁材料、气壁厚度和冷却液流量对推力室再生冷却的影响,获得了比较满意的结果。从计算时间和准确性来说,这种方法能够为推力室的优化设计和性能估算提供参考。      

膨胀循环推力室再生冷却换热的数值模拟

为了解液体火箭发动机膨胀循环推力室再生冷却换热特性,采用数值模拟方法,研究了冷却剂流动方式、推力室圆柱段长度、圆柱段室壁加肋和气壁面粗糙度等因素对冷却通道压降、冷却剂温升、壁面热流密度和温度分布等换热特性的影响.计算过程中采用k-ε双方程湍流模型.计算结果表明:采取顺流冷却要比逆流冷却的冷却通道压降低,但同时冷却剂温升也低;对于室壁加肋结构,在肋个数相同而只改变肋高度的情况下,总换热量正比于总换热面积.      

液氧/丙烷推力室试验研究

1987～1989年间进行的液氧/丙烷推力室试验研究内容主要涉及点火和启动、燃烧、传热等。目的在于探索液氧/丙烷推进剂的技术关键,为新型液氧/烃发动机论证提供必要依据。使用了两种结构状态的推力室。试验室压2.5～7.8MPa。推力8～25kN(真空)。通过试验,考核了液氧/丙烷推进剂的点火和燃烧性能,验证了丙烷再生冷却的可行性;并与四氧化二氮/偏二甲肼自燃推进剂、液氧/煤油推进剂的试验情况进行了比较。     

冷却环带喷注结构对煤油超临界液膜的影响研究

针对液氧/煤油补燃发动机液膜冷却过程,建立了超临界条件下的液膜冷却模型,分析了冷却环带喷注结构对局部流动和冷却效果的影响.在超临界条件下,煤油和周围燃气为同种流体,用同一组方程来描述其流动与传热过程,对3种典型冷却环喷注结构的流动进行了数值模拟.结果表明:冷却环带的出口角度、台阶结构和喷射角对局部流动和传热有显著影响,出口角度小于90°的台阶式结构可减小局部回流从而有利于推力室的热防护.      

Thermal-structural response and low-cycle fatigue damage of channel wall nozzle

To investigate the thermo-mechanical response of channel wall nozzle under cyclic working loads,the fnite volume fluid-thermal coupling calculation method and the fnite element thermal-structural coupling analysis technique are applied.In combination with the material lowcycle fatigue behavior,the modifed continuous damage model on the basics of local strain approach is adopted to analyze the fatigue damage distribution and accumulation with increasing nozzle work cycles.Simulation results have shown that the variation of the non-uniform temperature distribution of channel wall nozzle during cyclic work plays a signifcant role in the thermal-structural response by altering the material properties;the thermal-mechanical loads interaction results in serious deformation mainly in the front region of slotted liner.In particular,the maximal cyclic strains appear in the intersecting regions of liner gas side wall and symmetric planes of channel and rib,where the fatigue failure takes place initially;with the increase in nozzle work cycles,the residual plastic strain accumulates linearly,and the strain amplitude and increment in each work cycle are separately equal,but the fatigue damage grows up nonlinearly.As a result,a simplifed nonlinear damage accumulation approach has been suggested to estimate the fatigue service life of channel wall nozzle.The predicted node life is obviously conservative to the Miner＇s life.In addition,several workable methods have also been proposed to improve the channel wall nozzle durability.     

Preliminary experiment on spontaneous ignition performances of cavity-based strut flameholder

The thermal-structural response and low cycle fatigue life of a three-dimensional (3D) channel wall nozzle with regenerative cooling were numerically investigated by coupling the finite volume fluid-thermal method, nonlinear finite element thermal-structural analysis and local strain methods. The nozzle had a high area ratio (nozzle exit area divided by throat area) under cyclic working loads. Parametric studies were carried out to evaluate the effects of channel structural parameters such as channel width, channel height, liner thickness and rib width. Results showed that the integrated effects of three-dimensional channel structure and load distribution caused serious strain, which mainly occurred at the intersectant regions of liner wall on the gas side and the symmetric planes of channel and rib. The cooling effect and channel structural strength were significantly improved as the channel width and height decreased, leading to substantial extension of the nozzle service life. On the other hand, the successive decrease in liner thickness and rib width apparently increased the strain amplitude and residual strain of channel wall nozzle during cyclic work, significantly shortening the service life. The present work is of value for design of the channel wall nozzle to prolong its cyclic service life.      

推力室槽道式冷却通道尺寸优化设计方法

新一代液氧 /烃类推进剂液体火箭发动机将采用高燃烧室压力方案 ,这时推力室冷却成为一项关键技术问题。本文构造了一个槽道式再生冷却通道几何尺寸的优化设计方法 ,其优化目标是使通过冷却通道的冷却剂的压力损失最小。典型的计算、实验表明 ,采用优化设计方法可使冷却压力损失减少 50 % ,即采用优化设计有利于高室压推力室冷却问题的解决。     

液体火箭发动机不同室压下冷却方案适用范围

为了精准评估不同冷却方案对高压液氧烃火箭发动机推力室传热特性的影响,建立了一套再生通道-液膜屏蔽-隔热镀层-辐射换热的整机模型,采用Ievlev半经验模型计算燃气侧壁面的对流换热过程,引入Shruvik安全裕度评估准则,计算推力室径向的分区温度和热流密度。基于某型大推力液氧煤油火箭发动机,研究了不同冷却结构组合的换热能力上限,分析了不同推力室压力对冷却设计方案的影响。结果表明:推力室压力在12 MPa及以下时,可主要依靠再生冷却技术满足冷却需求;在16 MPa及以下时需要配合内冷却环带满足冷却需求;在18 MPa及以下时需进一步设置隔热镀层提高热防护能力;室压在20 MPa甚至更高时,必须采用其他强化换热措施。