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BOEING is a trademark of Boeing Management Company.
Copyright © 2012 Boeing. All rights reserved. CFD -- Anderson | 6-8 Aug 2012 1
CFD: An Industry Perspective
Future Directions in CFD Research: A Modeling and Simulation Conference
06 August 2012
Hampton, Virginia
Mark Anderson Director - Flight Sciences Technology
Boeing Research & Technology
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
NASA’s Role in Development of CFD
Technical workshops have been critical in focusing academia, industry, and government resources to enhance understanding of flow physics, evaluation of CFD methods, and development of CFD best practices
CFD -- Anderson | 6-8 Aug 2012 2
Source: https://info.aiaa.org/tac/ASG/FDTC/DG/BECAN_files_/BANCII.htm
NASA has been an important organizational member of all international workshops and has provided key expertise in developing workshop CFD validation test cases (DPW, HiLiftPW, Benchmark for Airframe Noise Components, etc.)
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
NASA’s Role in Development of CFD
Experimental test data for CFD validation is critical to the understanding of complex flow physics for a wide array of flow environments and aerospace vehicles, and enables the continued development of more accurate and effective CFD methods and tools
NASA has been very active in creating experiments to collect building-block CFD validation data (30p30n slat noise, tandem cylinders, Trap Wing, CRM, FAITH hill, etc.)
CFD -- Anderson | 6-8 Aug 2012 3
FAITH hill Trap Wing Common Research Model
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Presentation Outline
Role of a prime aerospace manufacturer in use and development of current practice, and emphasis for future direction, in Computational Fluid Dynamics
State of the art, current challenges
Transport aircraft
Other configurations
MDAO
Common Research Model
Where we believe CFD should go (Vision 2030)
CFD -- Anderson | 6-8 Aug 2012 4
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Introduction
Role of a Prime Aerospace Manufacturer
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
6
787 Design Features
Composite primary
structure
Advanced engines & nacelles
Innovative passenger cabin
Enhanced flight deck
Advanced
aerodynamic
design
Innovative
systems
technologies
Large cargo
capacity
Overhead crew rests
Mission Requirements • Extremely long range
• Unprecedented efficiency
• Very low community & cabin noise
• Very low emissions
CFD -- Anderson | 6-8 Aug 2012 6 Copyright © 2012 Boeing. All rights reserved.
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
CFD Application In Tactical Aircraft Design
• Background: Initial F/A-18E/F flight testing revealed uncommanded
rolling motion while maneuvering at transonic flight due to asymmetric
flow separation on the wing upper surface.
• CFD Study: Undertaken to determine whether CFD could predict the lift
curve break seen in wind tunnel tests and obtain detailed flowfield
description of the phenomena.
• Results: Confirmation that CFD could help identify characteristics
associated with cause of abrupt wing stall.
Contours of
Surface Pressure and
Particle Traces
Lift
0.60
0.80
1.00
1.20
4 6 8 10 12 14
AOA - deg
CL
AOA - Deg
CL
Lift Curve
CFD -- Anderson | 6-8 Aug 2012 7
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Animation of Iso-Vorticity Surface
Streamlines in Mean Flow Solution
Unsteady Analyses of Hemispherical Turret for Aero-Optic Performance
Locations of Hotwire
Measurements
CFD -- Anderson | 6-8 Aug 2012 8
Unable to discuss details of military applications due to ITAR and Export Control restrictions
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Background
State of the Art – Current Challenges
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Today’s Situation
Routine
Steady-State Navier-Stokes in all programs
Assess flowfields, conduct trade studies, identify options
Diverse applications
Design confirmation (not design development) through wind tunnel testing
Emerging
Multi-disciplinary
Aeroelasticity
– Simple modal analysis
– Coupled to NASTRAN
Aero-acoustics
Aero-optics
Automated Optimization
Unsteady flow
Routine for rotary wing applications
Use as appropriate for fixed-wing aircraft
CFD -- Anderson | 6-8 Aug 2012 10
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
High-Speed Wing
Design Cab Design
Engine/Airframe
Integration
Inlet Design
Inlet Certification
Exhaust-
System Design
Cabin
Noise
Community Noise
Wing-Body
Fairing Design
Vertical Tail and
Aft Body Design
Design For
Stability &
Control
High-Lift Wing
Design
APU Inlet
And Ducting
ECS Inlet
Design APU and Propulsion
Fire Suppression
Nacelle Design
Thrust-Reverser
Design Design for FOD
Prevention
Aeroelastics
Substantial CFD Utilization Some CFD Utilization
Icing
Air-Data
System
Location
Vortex Generators
Planform
Design
Buffet
Boundary
Reynolds-Number Corrections
Flutter
Control-Surface
Failure Analysis
Wind-Tunnel Corrections Wing-Tip Design
Wing
Controls
Avionics Cooling
Interior
Air
Quality
Engine-Bay Thermal
Analysis
Limited CFD Utilization
Key Enablers Include High Performance Computing and
Physics-based Design/Analysis/Optimization CFD -- Anderson | 6-8 Aug 2012 11
CFD Contributions to Aircraft Design
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Advanced Technology Contributions to Aircraft Efficiency Improvement
Systems
Materials
Aerodynamics
Engines
Improvements relative to 767-300ER
Aerodynamics and
Propulsion are main
contributors
CFD -- Anderson | 6-8 Aug 2012 12
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Lessons learned from existing products
CFD design, analysis,
and optimization tools
Extensive wind- tunnel
test program
CFD -- Anderson | 6-8 Aug 2012 13
Sources of Aerodynamic Design Expertise
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Minneapolis, MN
Farnborough, UK
Cologne, Germany
Hampton, VA Gifu, Japan
Mountain View, CA
Seattle, WA Philadelphia, PA
Le Fauga, France
Copyright © 2005 The Boeing Company. All rights reserved. CFD -- Anderson | 6-8 Aug 2012 14
Global Wind Tunnels Used for Development
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Boeing
Products
Multi-fidelity CFD code are essential for industrial design
CFD
Tools
1 9 8 0 1 9 8 5 1 9 9 0 1 9 9 5 2 0 0 0 2 0 0 5
7 6 7 7 3 7 - 3 0 0 7 7 7 7 3 7 N G 7 5 7 7 8 7
P A N A I R
A 5 0 2 A 4 8 8
F L O 2 2
A 4 1 1
T R A N A I R
C a r t e s i a n
G r i d T e c h .
T R A N A I R
O p t i m i z a t i o n T L N S 3 D -
M B / Z E U S
T L N S 3 D - M B
O V E R F L O W T L N S 3 D
1 9 8 0 s t a t e o f t h e a r t M o d e r n c l o s e c o u p l e d n a c e l l e i n s t a l l a t i o n , 0 . 0 2 M a c h f a s t e r t h a n 7 3 7 - 2 0 0
Th i c k e r f a s t e r w i n g t h a n 7 5 7 , 7 6 7 t e c h n o l o g y
H i g h l y c o n s t r a i n e d w i n g d e s i g n
F a s t e r w i n g t h a n 7 3 7 - 3 0 0
C F D f o r L o a d s a n d
S t a b i l i t y a n d C o n t r o l
U n s t r u c t u r e d
A d a p t i v e G r i d
3 - D N - S
C F L 3 D / Z E U S
O V E R F L O W
C F L 3 D
O V E R F L O W
Multi-point
viscous
optimization
Full Potential Structured
Navier-Stokes
Unstructured
Navier-Stokes
CFD -- Anderson | 6-8 Aug 2012 15
CFD Maturity and Application Chronology (1980-2010)
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
767
(1980)
777-200
(1990)
787
(2005)
Oc
cu
pa
nc
y H
ou
rs
Significant decrease in wind-tunnel testing time since 1980’s reduces cost and enables faster market readiness
Reduction in testing time largely enabled by availability of mature and ‘calibrated’ advanced CFD
How to realize the next major cost reduction?
-25 %
-30 %
X%?
(2020)
XX
CFD -- Anderson | 6-8 Aug 2012 16
Wind Tunnel Test Time Reduction
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Aerodynamic Optimization
Navier Stokes based CFD Methods widely used on past and current Aerodynamic Optimization/Design efforts
BCA: Wing body fairing (787), winglets (787), flap support fairings (747), nacelle fan cowl.
BR&T: AFRL Joined Wing concept development and optimization, NASA N+2 Supersonic Low Boom effort
Developing adjoint capabilities for gradient based optimization using Overflow and internal unstructured grid solver BCFD
Continuing development of MDOPT optimization method
Global surrogate model based optimization using Boeing-developed Design Explorer software
Multi-fidelity flow solver option using Boeing-developed Tranair (full potential/integral boundary layer), NASA-developed Overflow (overset structured), Boeing-developed BCFD (unstructured)
CFD -- Anderson | 6-8 Aug 2012 17
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
M=0.85, Alt=55kft
CL = 0.61
CD = 0.03002
CM = 0.0003
CL = 0.61
CD = 0.03515
CM = 0.0042
•Performed MDOPT Optimization
•Used new Design Explorer tools reducing
Drag while trimming configuration
•Used 60 solid design variables shaping wing
and aft wing, inlet, and body upper surface
•Constrained CL and CM (trimmed),
thickness constraints for antenna
•Optimization concept tested and validated at
NASA Ames 11ft Wind Tunnel
600+ Overflow
solutions
seed optimized
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
CL
CD
Main06-Strut06 MDOPT-OPT2-1237
100 counts
optimized
seed
Body upper
Nose
Chord Locations 16% 41% 80%
Nose droop
Delta z
AIAA-2008-7180
14% improvement
CFD -- Anderson | 6-8 Aug 2012 18
Aerodynamic Optimization Tools for AFRL Aerodynamic Efficiency Improvement (AEI)
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Navier-Stokes Based Winglet Optimization
Overflow-MDOPT design space with a wide range of junction geometries (56 Design variables)
N-S based design able to approach theoretical aero optimum tight juncture
CFD -- Anderson | 6-8 Aug 2012 19
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Common Research Model (CRM)
WBH Configuration
WBNPH Configuration
CFD -- Anderson | 6-8 Aug 2012 20
• A generic geometry,
developed with contributions
from Boeing, NASA and other
industry
• Representative of modern
transport state of the art
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Common Research Model (CRM) Interest
Groups Interested in a CRM
Drag Prediction Workshop
– Subject Geometry for DPW-IV
Computational Methods for Stabilitly and Control (COMSAC)
Various Wind Tunnel Facilities
– NTF
– Ames 11 Foot
Cross-section of Government and Industry
Air Force, Boeing, Cessna, Gulfstream, Hawker-Beechcraft, Lockheed Martin, NASA, Navy, Northrop Grumman, Pratt & Whitney
CFD -- Anderson | 6-8 Aug 2012 21
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
The CRM has been offered as a generic testbed for validation of emerging prediction methods
CFD -- Anderson | 6-8 Aug 2012 22
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Future
Where We Believe CFD Should Go
(Vision 2030)
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
CFD Challenges
Accurate prediction of boundary layer transition
Improved RANS model for efficient complex flow analysis
Accurate prediction recovery, dynamic distortion, and swirl patterns at the Aerodynamic Interface Plane (AIP) for propulsion integration
Accurate prediction of shock-boundary layer in presence of corner flows
An advanced turbulence model within a single framework for accurate unsteady flow phenomena
Efficient and robust mesh adaptation for complex configurations
Error estimation and uncertainty predictions
Multidisciplinary analysis (aeroelasticity, etc.)
CFD -- Anderson | 6-8 Aug 2012 24
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Throughput : End-to-end cycle time must be faster than
process based on wind tunnel testing
Consistent quick turnaround essential in a schedule-driven
development program
Engineering development consists of development of large
databases for loads, stability and control, and flight simulation
Cost: Database creation using CFD must be cheaper than using
wind tunnels
Accuracy : Must be superior to wind-tunnel
Error / Uncertainty Quantifications: Must be able to quantify
the error and uncertainty associated with results
Expertise : Must be automated and operational using project
engineers, not just CFD experts
CFD -- Anderson | 6-8 Aug 2012 25
Important Factors for Industry Regarding 2030 CFD
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
‘Vision 2030’ CFD Code Request for Proposals
Many CFD codes are currently available (e.g. NASA / other government labs, external vendors, academia, etc.) based on structured, unstructured and hybrid-grid technology and low fidelity turbulence models, which are adequate for a limited subset of turbulent flow applications of immediate interest. If computations of complex, unsteady, turbulent flows are to become routine, however, it is likely that computational technology will need to evolve to readily embrace new ideas and developments in turbulence modeling, high-order numerical methods, fast solvers, grid adaptation, etc., in addition to exploiting the current and future developments in computer
Answer the following 5 questions: 1. What hardware requirements and software attributes will characterize an advanced ‘Vision 2030’
CFD code that is used routinely to compute complex turbulent flows, involving flow separation, at subsonic and supersonic/hypersonic speeds, and exhibits greater robustness than current technology?
2. How many orders of magnitude faster (time-to-solution), as compared with current capabilities, will 2030 CFD technology be?
3. What will be the fundamental elements of 2030 turbulence models, and for what classes of problems will they be reliable?
4. What are the principle impediments, both modeling and algorithmic, that must be overcome to achieve the 2030 CFD vision outlined above?
5. What high-risk/high-yield obstacles remain as enduring and daunting challenges that should be the focus of long range efforts by NASA?
CFD -- Anderson | 6-8 Aug 2012 26
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Boeing has assembled a Team to help answer the Vision 2030 CFD code challenge questions
Task 1: Develop
2030 Vision
Requirements
and Identify Gaps
& impediments
Task 2: Refine Vision
Requirements, and develop
initial research approach
Task 3: Develop Integrated Plans
and Vision 2030 CFD Roadmap
Q1 Q2 Q3 Q4
Final Roadmap
Final Report
Mid-Term Review
Vision 2030
CFD Workshop
Task 4: Program Management
Final Oral
Review
Kick-Off
Meeting
Refine Community InputInitial
Community
feedback on
gaps &
impediments
Team Input
ATP
1. What hardware requirements and software attributes will
characterize an advanced “Vision 2030” CFD code that is
used to routinely compute complex turbulent flows,
involving flow separation, at subsonic and
supersonic/hypersonic speeds, and exhibits greater
robustness than current technology?
2. How many orders of magnitude faster (time-to-solution),
as compared with current capabilities, will 2030 CFD
technology be?
3. What will be the fundamental elements of 2030 turbulence
models, and for what classes of problems will they be
reliable?
4. What are the principle impediments, both modeling and
algorithmic, that must be overcome to achieve the 2030
CFD vision outlined above?
5. What high-risk/high-yield obstacles remain as enduring
and daunting challenges that should be the focus of long
range efforts by NASA?
Boeing Research & Technology
Matt Ganz, VP/GM
High performance Computing
NCSA
William Gropp
Focal
Propulsion
Pratt & Whitney
Elizabeth Lurie
Focal
Airframe
Boeing
Abdi Khodadoust
Focal
Flight Sciences Technology
Mark Anderson, Director
Program Manager and Chief Integrator
Abdi Khodadoust
Academia
Research Team
David Darmofal, MIT
Focal
• Juan Alonso, Stanford
• Dimitri Mavriplis, Wyoming
• Dan Dominik
• Paul Fussell
• Joerg Gablonsky
• Robert Bush, P&W
• John Croxford
• Wesley Lord, P&W
• Rich Shaw
• Nagendra Somanath, P&W
• Tony Antani
• Kevin Bowcutt
• Mori Mani
• Robert Narducci
• Jeff Slotnick• Philippe Spalart
• Venkat Venkatakrishnan
• John Vassberg
NASA COTR
Boeing Business Team
Contracts, Supplier Mgt , Financial Mgt
NASA and
Government Lab
Researchers
Technical Advisory Team
Mark Anderson, Leader
CFD -- Anderson | 6-8 Aug 2012 27
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Conclusion
Final Observations
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
What’s Holding Us Back?
Throughput and end-to-end cycle time
Consistent quick turnaround essential in a schedule-driven
development program
Engineering development culminates in large databases for loads,
stability and control, flight simulation
Consistency (quality control)
Cannot tolerate intermittent process failures
CFD is still a specialist tool to a remarkable degree
User skill is often a key factor in obtaining consistent high quality
results for frontline projects
Skill mixes in research groups do not reflect those of frontline project
groups
CFD -- Anderson | 6-8 Aug 2012 29
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Summary
CFD capabilities have brought forth tremendous capabiltiies over 3+ decades of production use
Significant opportunities remain for further advances
Boeing has ideas about appropriate areas for focused effort
Thank you for opportunity to share ideas with you today
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Backup
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
The CRM Wing is Representative of Modern Transport Aircraft
CFD -- Anderson | 6-8 Aug 2012 32
Wing Pressures, M=0.86
Copyright © 2012 Boeing. All rights reserved.
Engineering, Operations & Technology | Boeing Research & Technology
Nacelle/Pylon Effect
CFD -- Anderson | 6-8 Aug 2012 33