Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Agenda Background/Motivation ARISP Rotor Icing Model - - PowerPoint PPT Presentation
Agenda Background/Motivation ARISP Rotor Icing Model - - PowerPoint PPT Presentation
T HE E XPERIMENTAL I NVESTIGATION OF A R OTOR I CING M ODEL WITH S HEDDING Presentation to NASA Icing Branch April 8, 2010 Edward Brouwers Graduate Research Assistant The Vertical Lift Research Center of Excellence Adverse Environment Rotor
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Agenda
- Background/Motivation
- ARISP Rotor Icing Model
- Understanding AERTS
- ARISP Correlations to AERTS Experiments
- Conclusions & Recommendations for Future Work
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Motivation
- Flight into Icing Conditions is Dangerous
– Reduced vehicle performance
- Torque Rise
- Stability & Control Issues
- Excessive Vibration
- Operational Limitations
– Simply avoid ice – Few aircraft have limited icing clearances – Fewer have IPS
- Rotorcraft Compounding Factors
– Mission Urgency – Mission Profile – Vehicle Sensitivity to Ice – Shedding
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Rotor Icing Analysis
- Test Facilities
– NRC Helicopter Spray Rig – McKinley Climatic Chamber – NASA IRT – Army HISS
NASA Photo C-1993-3962
- Open Issues
– Oscillatory Airfoils – Tip Shape Effects
- Modeling
– Complex problem – No comprehensive model – Lack of validation data
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Research Objectives
- Develop Rotor Icing Model (ARISP)
- Develop Icing Test Facility (AERTS)
- Correlate ARISP Model to Experiments in AERTS Facility
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Agenda
- Background/Motivation
- ARISP Rotor Icing Model
– Program Design – Shedding/Performance Implementation – Validation
- Understanding AERTS
- ARISP Correlations to AERTS Experiments
- Conclusions &
Recommendations for Future Work
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
AERTS Rotor Icing, Shedding and Performance (ARISP) Model
- Objectives
– Aid AERTS Calibration – Uncover Icing Trends – Supplement NRA Activity
- Simplified version of icing analysis effort
- Primary Features
– Prediction of ice accretion on rotor systems – Predict performance degradation – Evaluates effects of ice shedding – Provide interface for ice protection system evaluation
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Program Setup
- Overall Setup
– Analysis centered on the LEWis ICE Accretion Program (LEWICE)
- Industry standard icing modeling software – extensively validated in IRT
- ARISP uses LEWICE 3.0 – 2D version
– Pre and post processing written in MATLAB – Generally similar to work by:
- Britton, “Development of an Analytical Method to Predict Helicopter Main Rotor
Performance in Icing Conditions, AIAA 92-0418
- Miller et al, “Analytical Determination of Propeller Performance Degradation Due to Ice
Accretion” J. Aircraft Vol. 24 No. 11
- Fortin and Perron, “Spinning Rotor Blade Tests in Icing Wind Tunnel” AIAA 2009-4260
- Concept
– Quasi-2D Analysis
- Rotor performance calculated in BEMT
- Ice accretions calculated at each station
– Focused on hover due to AERTS Facility limitations
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Overall Program Flow
Loop Until Analysis Complete
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LEWICE Interface
- Program Inputs
– Rotor Geometry
- Blade profile
- Station properties (airfoil, material)
- Analysis stations
– Icing Conditions
- LWC function of rotor radius
- Mono-dispersed droplet distribution assumed
- Ramping of temperature/LWC
- Software Coupling
– LEWICE time stepping logic is used to size number of analysis steps – Inputs for each station/timestep are created automatically
- Airfoil Geometry – clean/iced airfoil
- Icing Conditions – spanwise gradients in LWC etc
– Series of batch files connect MATLAB and LEWICE
- LEWICE runs “inside” of MATLAB script
- ~0.5 seconds per LEWICE run
- High fidelity test run requires about 10 minutes
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ARISP BEMT Validation
Dry BEMT Module Comparison vs NASA CR 2275 Dry BEMT Module Comparison vs Prouty Tail Rotor
- BEMT currently corrected for AERTS Chamber per NASA TM 86754
- C81 Performance tables for NACA 0012, NACA 0015 included in ARISP
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
ARISP Ice Accretion Comparisons Model Scale
- Model Scale – NASA TM 103712
- Tests conducted in NASA IRT (1989)
– 6’ diameter NACA 0012 generic rotor – Ice tracings published at various rotor stations for many icing conditions – Rotor trimmed in ARISP model to match average station AoA
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Full Scale ARISP Ice Shape Validation
- Full Scale – NASA CR 168332
– Tests conducted at Canadian NRC Helicopter Spray Rig with UH-1H – Results from Flight E Documented – Conditions
- Temperature corrected from -19°C to -14°C
- LWC = 0.7 gr/m3
- MVD = 30 µm
- Time = 3 min
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Ice Extent Calculations
- Method of determining spanwise ice accretion
– Based upon static temperature and ram temperature rise – Assumes thermodynamic recovery factor per NASA CR 3910 – Model validated to CR 3910 and UH-1H HIFT Data Validation
) , ( M LWC f
Current Research
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Ice Accretion Comments
- Overprediction of Ice at Rotor Tips
– Opposite of expectations – Seen in previous research
- NASA TM 107312
- Gent, “Further Studies of Helicopter Rotor Ice
Protection Accretion and Protection” Vertica Vol 11 Issue 3, 1987
– May be related to droplet bounce, centrifugal effects and LWC gradients – Shedding
- 2D nature of shedding analysis may miss shedding
- f glaze ice horns
NASA TM 103712
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Performance Degradation
- Modeling
– Primary metric is rotor torque
- Dependent on sectional drag coefficients
- Lift degradation small
– Empirically modeled based upon published correlations
- Bragg’s and Flemming’s Correlations
currently included in ARISP
- Implementation
– Dynamic database of sectional drag coefficients
- Updated after each time step with ΔCd
- If shedding occurs, clean airfoil
performance is used
Gray Bragg Flemming Temperature (°C) min
- 17.7
- 17.7
- 20.0
max
- 3.8
- 12.2
7.7 MVD (µm) min 11.3 7.0 11.0 max 19.0 19.0 50.0 LWC (gr/m3) min 0.39 0.50 0.24 max 2.00 1.86 3.80 Velocity (ft/sec) min 183.3 256.6 287.7 max 403.3 403.3 745.1 Icing Time (min) min 3.0 1.0 0.3 max 17.7 27.0 5.0
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Shedding Implementation
Centrifugal Force Net Aerodynamic Force (negligible) Ice Forces Section A-A
X Y Z
Shear Adhesion Force Cohesion Force Analysis Direction Ω A A Differential Ice Element
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Shedding Progression
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Ice Details
X Y Z
Centrifugal Force Ice Adhesion Area Impingement Limits Calculated from LEWICE Typical Ice Shape, assumed quasi 2D Ice Cross Sectional Area shi slow
- Impingement Limit Tracker
– Furthest aft impingement limits selected for each station (updated each time step, reset after shedding event) – Glaze ice feathers
- Cross Ice Area Summation
– Area calculated by LEWICE (integration of thickness) – Summed for each timestep, reset after shedding event
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ARISP Model
Loop Until Analysis Complete
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Ice Properties
- Ice Cohesive (Tensile) Strength
– Uses results from the work of Chu and Scavuzzo: “Tensile Properties of Impact Ices,” AIAA 92-0883
- Ice Shear Adhesion Strength
– Currently taken from variety of sources:
- Stallabrass and Price: “On the Adhesion of Ice
to Various Materials,” NRC Canada LR-350
- Scavuzzo and Chu: “Structural Properties of
Impact Ices Accreted on Aircraft Structures,” NASA CR 179580
- Reich: “Interface Influences Upon Ice
Adhesion to Airfoil Materials,” AIAA 94-0714
– Eventually calculated in the AERTS for each icing condition
- Ice Density
– Macklin and Jones model included in ARISP model – All analysis presented uses Jones Model
Author Ice Density (kg/m3) Ashton 918 Macklin 900 Stallabrass 884 Jones 910 LEWICE 917
Ice Density T = -10°C, LWC = 1.5 gr/m3, MVD = 20 µm
Author/Date Method Aluminum Shear Adhesion Strength psi kPa Loughborough* 1946 Pull 81 558 Stallabrass and Price† 1962 Rotating Instrumented Beam 14 97 Itagaki† 1983 Rotating Rotor 4 - 23 27 - 157 Scavuzzo and Chu† 1987 Shear Window 13 - 42 90 - 290 Reich* 1994 Pull 130 896 PSU AERTS* Pull 76 526
Shear Adhesion Strength for Aluminum T = -11˚C
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Shear Adhesion Strength Calculation
- Problem
– Shear adhesion strength is a function of icing condition – Data is characterized by significant scatter (± 35 %)
- Variation due to test method – various mechanical methods
- Variation due to test facility – limited velocity, ice transport
- Approach
– Based upon work of Stallabrass and Price (NRC Canada LR-350, 1962)
- Mount test coupons on instrumented beam at rotor tip
- Monitor strain on beam to calculate shear adhesion strength
– Key Benefits
- Test realistic icing conditions
- Approach realistic rotorcraft tip speeds
- Accrete ice and test in one facility
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Shedding Fixture Concept
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Implementation
Test Coupon Rotor (9’ diameter) Instrumented Beam Heated Fairing (shown transparent) Coupon Mounting Block Tailored strain field for instrumentation
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Implementation
Model of Instrumented Beam at Design Point 1200 rpm (565 ft/sec) Provision for de-ice heaters
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Beam Load (N) Voltage (V) Vo Lo LRPM VRPM LICE
Loading Line Equation determined by points (Vo,Lo) and (VRPM, LRPM)
VICE
Loading due to RPM Loading due to ice Extrapolated Loading Line Calculation Goal
Test Fixture Logic
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence 3.7 3.8 3.9 4 4.1 4.2 4.3 4.4 4.5 50 100 150 200 250 300 350 400 450
Voltage
RPM
400 Gain 500 Gain 400 Gain, + Mass 500 Gain, + Mass
500 gain 400 gain ΔV
y = -0.0003x2 + 0.0111x - 0.0003 R² = 0.9979
0.005 0.01 0.015 0.02 0.025 0.03 0.035 0.04 0.045 0.05 0.00 1.00 2.00 3.00 4.00 5.00 6.00
Delta Voltage (V) Beam Load (kg)
500 Gain
- Poly. (500 Gain)
Shedding Fixture
Shedding fixture is capable of sensing small ice accretions – good SNR
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Icing Shakedown Testing
Blade Anti-Ice Heater Locations Heated Side Fairings Previous testing ice bridging
Problem: Ice Bridging Solution: Heater Fairings Problem: Blade Icing Solution: Anti-Ice Heaters
5 W/in2 Heater (20 per blade)
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Icing Shakedown Tests (con’t)
Notch Ice Accretions Runback Ice Problem: Notch Icing Solution: Additional Heater 10 W/in2 heater
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Icing Shakedown Tests (con’t)
Notch Ice Accretions Runback Ice Problem: Notch Icing Solution: Additional Heater 10 W/in2 heater
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Sample Shear Adhesion Test Fixture Raw Data
Loading due to accreted ice VRPM Shedding Event @ t = 403 s Rotor Spool Down Icing cloud on
Note long test time. Chamber temperature may increase significantly
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Shedding Fixture Test Results
0.00 100.00 200.00 300.00 400.00 500.00 600.00 700.00 800.00 900.00 1000.00
- 30
- 25
- 20
- 15
- 10
- 5
Shear Adhesion Strength (kPa) Temperature ( C)
AERTS (Current Research) Loughenborough (1946) Stallabrass and Price (1962) Itagaki (1983) Scavuzzo and Chu (1987) Reich (1994)
LWC = 10 gr/m3 MVD = 40 µm
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T = -10.0 °C LWC = 3.0 gr/m3 MVD = 40 µm t = 300 sec RPM = 800 Θ0 = 5°
Sample ARISP Outputs
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
T = -5.0 °C LWC = 3.0 gr/m3 MVD = 40 µm t = 300 sec RPM = 800 Θ0 = 5°
Sample ARISP Outputs
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Agenda
- Background/Motivation
- ARISP Rotor Icing Model
- Understanding AERTS
– CFD Modeling – Sensitivity Studies
- ARISP Correlations to AERTS Experiments
- Conclusions & Recommendations for Future Work
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
CFD Modeling
- Objective
– Understand complex flowfield in chamber (rotor in box) – Assist in particle trajectory analysis
- Software: Solidworks Flow Simulation
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600 RPM Velocity Contours
NACA 0015 Rotor 7.75’ diameter 600 RPM Θo = 2.5°
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600 RPM Nozzle Flow Tubes
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600 RPM 20 µm Trajectories
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Sensitivity Studies
Tip Vortex Effect
- AERTS is a unique facility
- Series of tests were run to explore
AERTS icing envelope
– Temperature – Droplet Size – Nozzle Settings – Rotor RPM – Collective Pitch
- Limits established for facility
- Crystalization
– Erosion of ice shapes significant issue – Problem corrected with ice screens and corrected nozzle settings T ≈ -10°C, LWC ≈ 1.3 – 1.6 gr/m3
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Agenda
- Background/Motivation
- ARISP Rotor Icing Model
- Understanding AERTS
- ARISP Correlations to AERTS Experiments
– General Observations – Ice Shape/Torque/Shedding Correlations
- Conclusions & Recommendations for Future Work
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Test Rotor
Parameter Schweizer 269C Application PSU AERTS Application Units Radius 13.42 3.87 ft Chord 6.8 in Solidity 0.040 0.092
- Tip Speed
662 200 – 608 ft/sec RPM 471 500 - 1500
- Twist (linear)
- 8.7
- 2.1
degrees Airfoil NACA 0015
- LE Material
2024-T3 Aluminum
- Weight
~1.33 lb/ft
- Painted stripes provide consistent measuring points. Each
stripe is 0.05R wide.
- The blade leading edge is not painted to allow for shedding
- analysis. Ice accretes directly to an 2024-T3 aluminum
surface. Blades donated by Schweizer Aircraft Blade grips donated by Olympic Tool and Machine Corporation
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Test Cases
Case Temperature MVD Corrected LWC Nozzle Config RPM Collective Time Shedding Shedding Station °C µm gr/m3 deg sec ? 24
- 10.75
25 2.0 5 Outer 500 2.5 180 N 25
- 10.50
25 1.6 5 Outer 600 2.5 180 N 26
- 10.85
35 1.2 5 Outer 600 2.5 180 N 27
- 10.50
35 2.3 5 Outer 600 2.5 180 N 28
- 15.60
15 2.0 5 Outer 600 2.5 180 N 29
- 5.10
35 6.6 5 Outer 180 2.5 180 N 31
- 5.80
35 3.0 5 Outer 600 2.5 215 Y 0.83 32
- 9.90
35 2.8 5 Outer 600 2.5 300 N 33
- 4.70
20 6.9 5 Outer 600 2.5 352 Y
0.77
34
- 6.50
35 3.7 5 Outer 600 2.5 272 Y
0.87
35
- 8.00
25 1.2 4 Outer 600 2.5 320 Y
0.83
36
- 5.00
25 1.3 4 Outer 600 2.5 427 Y
0.81
37
- 5.00
15 2.2 4 Outer 600 2.5 313 Y
0.75
38
- 3.00
25 1.3 4 Outer 600 2.5 304 Y
0.79
39
- 3.00
15 2.2 4 Outer 600 2.5 391 Y
0.82
40
- 14.20
15 1.2 3 Outer 600 2.5 180 N 41
- 12.00
15 0.9 3 Outer 600 2.5 180 N 43
- 8.60
15 1.2 3 Outer 600 2.5 144 Y 0.72 44
- 10.05
15 1.3 3 Outer 600 2.5 180 N Parameter Minimum Maximum Temperature (°C)
- 15.6
- 3.1
MVD (µm) 15 35 LWC (gr/m3) 0.9 6.5 Icing Time (s) 144 427
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Test Case Correlation to FAR Part 25/29 Appendix C Icing Envelope
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Typical Test Video
(.mov)
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Ice Accretion Results
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LWC Calculation
- Calculated Experimentally
– No dedicated sensor, calculation based upon stagnation ice thickness – Significant errors may be generated – ARISP Model must be run after experiment
- Results
– General root to tip gradient due to CF and flowfield effects
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Case 44 Shapes
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Qualitative Shape Correlation
Case Station 0.6r 0.7r 0.8r 0.9r
24
- Y
Y G
25
- Y
G Y
26
- Y
Y R
27
- Y
Y Y
28
- R
R R
29
- Y
R R
31
- G
G G
32
- G
G G
33
- R
R Y
34
- Y
G G
35
G G Y Y
36
R R R R
37
G G Y Y
38
G G Y Y
39
G G G G
40
G G G G
41
G G Y Y
43
G G
- 44
G G G G
Red Case 29, 0.9r Yellow Case 24 0.9r Green Case 25, 0.8r
Best correlations at small particle size, low LWC
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Impingement Limits
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Torque Correlations
Torque Offset Calculation Case 31 Torque
- Torque calibration runs were made to isolate rotor performance
– Removes influence of bearings and seals
- Torque Correlations
– Shaft torque was monitored during all testing – Bragg’s correlations were used in all correlations
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Torque Correlations
Highest Temperatures
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Shedding
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Shedding Event Correlation
Shedding Station
LWC (gr/m3) indicated by each point
Shedding Time
LWC (gr/m3) indicated by each point
- 9 Test Cases Involved Shedding Events
– Most events involved a single blade – All shedding occurred as a single event – Significant imbalance required test stand to be shut down immediately due to high 1/rev loads
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Shedding Correlations
- Ice Properties
– Cohesive Strength: Chu and Scavuzzo: “Tensile Properties of Impact Ices,” AIAA 92-0883 – Shear Adhesion: Reich “Interface Influences Upon Ice Adhesion to Airfoil Materials,” AIAA 94-0714
- Correction Factor
– ARISP generally overpredicted accreted ice shapes
- Ice mass was therefore lower, generating
errors in the shedding analysis
- Tip runback unpredicted
– Uncorrected, the ARISP model predicted multiple shedding events,
- ccurring earlier
– Correction factor derived from ice areas
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Shedding Corrections
Case Shedding Event AERTS ARISP No Corrections C ARISP
- rrections
Time (s) %R Time (s) %R Time (s) %R 31 1 215 0.82 130 0.82 160 0.81 33 1 352 0.77 100 0.93 150 0.92 2 210 0.64 300 0.72 3 320 0.93 34 1 272 0.87 70 0.97 120 0.90 2 150 0.73 220 0.71 3 210 0.97 35 1 320 0.83 85 0.99 123 0.99 2 107 0.92 151 0.84 3 160 0.76 268 0.69 4 245 0.99 5 266 0.92 6 309 0.61 36 1 427 0.81 170 0.91 2 270 0.68 37 1 313 0.75 94 0.88 135 0.94 2 167 0.69 188 0.72 3 261 0.88 38 1 304 0.79 91 0.95 101 0.97 2 132 0.76 132 0.88 3 203 0.95 203 0.73 4 243 0.66 39 1 391 0.82 183 0.95 248 0.97 2 261 0.80 300 0.84 43 1 144 0.72 125 0.96 2 3 4
Case 31, Corrected Case 31, Uncorrected
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Agenda
- Background/Motivation
- ARISP Rotor Icing Model
- Understanding AERTS
- ARISP Correlations to AERTS Experiments
- Conclusions & Recommendations for Future Work
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Conclusions
- ARISP Model
– Demonstrated the ability of model based upon LEWICE to predict ice accretions
- n rotor blades
– Additional features integrated into model include torque degradation and shedding – Model compared to published ice shapes, model scale & full scale
- AERTS Facility
– Basic understanding of the chamber flowfield and particle trajectories
– Limitations established, especially for airfoil shapes
- Experimental Correlations
– Shape: Generally good, overpredicted accretions at tip – Impingement Limits: Within 20% of predicted values – Torque: Using Bragg’s correlations, most test cases were within 20% of predicted values – Shedding: Further work required – Test conditions need to be better quantified for proper modeling
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence
Future Work
- ARISP
– Ice Accretion
- CF effects on ice accretion - LWC variation
- Tip flowfield quantification
– Shedding
- Shear adhesion strength test points
- Tensile strength validation
- More shedding test points
- Non-square tip shapes
- Trajectory analysis of shed ice
- AERTS
– Icing Condition Monitoring
- Temperature Control – current system limited
- MVD Sensor – currently not measured
- LWC Sensor – currently calculated experimentally
– Blades
- Improved blade tracking/balance system
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Thank You Sponsors/Donors Questions?
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Backup
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800 RPM Velocity Contours
Nozzle Rings
NACA 0015 Rotor 7.75’ diameter 800 RPM Θo = 2.5°
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1000 RPM Velocity Contours
Nozzle Rings
NACA 0015 Rotor 7.75’ diameter 1000 RPM Θo = 2.5°
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800 RPM 20 µm Trajectories
Adverse Environment Rotor Test Stand The Vertical Lift Research Center of Excellence