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Manufacturing process simulation enables the evaluation and improvement of autoclave mold concepts early in the design phase. To achieve a high part quality at low cycle times, the thermal behavior of the autoclave mold can be investigated by means of simulations. Most challenging for such a simulation is the generation of necessary boundary conditions. Heat-up and temperature distribution in an autoclave mold are governed by flow phenomena, tooling material and shape, position within the autoclave, and the chosen autoclave cycle. This paper identifies and summarizes the most important factors influencing mold heat-up and how they can be introduced into a thermal simulation. Thermal measurements are used to quantify the impact of the various parameters. Finally, the gained knowledge is applied to develop a semi-empirical approach for boundary condition estimation that enables a simple and fast thermal simulation of the autoclave curing process with reasonably high accuracy for tooling optimization.
Manufacturing Process Simulation for the Prediction of Tool-Part-Interaction and Ply Wrinkling
(2019)
Manufacturing Process Simulation for the Prediction of Tool-Part-Interaction and Ply Wrinkling
(2015)
Flow separation is a phenomenon that occurs in all kinds of supersonic nozzles sometimes during run-up and shut-down operations. Especially in expansion nozzles of rocket engines with large area ratio, flow separation can trigger strong side loads that can damage the structure of the nozzle. The investigation presented in this paper seeks to establish measures that may be applied to alter the point of flow separation. In order to achieve this, a supersonic nozzle was placed at the exit plane of the conical nozzle. This resulted in the generation of cross flow surrounding the core jet flow from the conical nozzle. Due to the entrainment of the gas stream from the conical nozzle the pressure in its exit plane was found to be lower than that of the ambient. A Cold gas instead of hot combustion gases was used as the working fluid. A mathematical simulation of the concept was validated by experiment. Measurements confirmed the simulation results that due to the introduction of a second nozzle the pressure in the separated region of the conical nozzle was significantly reduced. It was also established that the boundary layer separation inside the conical nozzle was delayed thus allowing an increased degree of overexpansion. The condition established by the pressure measurements was also demonstrated qualitatively using transparent nozzle configurations.