Update – March 1, 2023: AxSTREAM NET is our legacy software replaced by AxSTREAM System Simulation. System Simulation was born out of the union of the legacy AxCYCLE and AxSTREAM NET software packages.
It is impossible to imagine the design of any rocket engine without a nozzle – a technical device that serves to accelerate gas flow passing through it to speeds exceeding the speed of sound. The main types of nozzle profiles are shown in Figure 1.
The most widely used are Laval nozzles due to their high efficiency in accelerating gas flow. Read More
Suppose you want to build a turbopump to increase the pressure of your working fluid. However, you find that the fluid that you are working with keeps vaporizing in the impellers you design, causing all sorts of performance issues. What can you do in this case? One solution is to design an inducer for your turbopump.
Axial inducers are used in turbopumps upstream of the impeller to avoid cavitation, reduce the inlet pressure requirement, and/or allow for operation at higher turbopump rotational speeds for a given inlet pressure . For a turbopump to function properly, the inlet pressure of the pump must be high enough to avoid cavitation. Cavitation is a phenomenon where vapor bubbles which form in the flowing fluid collapse suddenly – potentially causing surface damage of the impeller, performance degradation, as well as catastrophic failure.
The cavitation phenomenon can be visualized in the below image. The inlet flow (flowing from the left side of the image) hits a blunt body in the fluid channel. This causes the pressure to locally drop and vapor bubbles to form. As the fluid continues to flow (towards the right side of the image), the vapor bubbles collapse once the fluid pressure has sufficiently increased.
Now that we understand the problem, how can we make sure these cavitation effects won’t happen in our pump? To predict when cavitation will occur, two parameters are commonly used. The available net positive suction head (NPSHa) describes how much greater the local inlet static pressure is relative to the local inlet vapor pressure. Essentially, NPSHa indicates whether the conditions for cavitation to occur are met. The required net positive suction head (NPSHr) describes the inlet head corresponding to a certain drop in performance capability. A typical NPSHr parameter is the standard 3% NPSH (NPSH3) which describes the inlet pressure corresponding to a 3% drop in head rise capability of the pump at a particular flow rate. Generally, NPSHr is measuring whether there is enough cavitation present to cause a noticeable decrease in the pump’s performance. If the NPSHr is much greater than NPSHa, then significant performance decreases due to cavitation may occur. That is to say, when the available net positive suction head is insufficient, bad things can happen, ranging from performance degradation to outright damage and failure.
Rocket engines are the perfect creation of the human mind, incorporating our existing knowledge in aerodynamics, thermodynamics, solid and fluid mechanics, and rotor dynamics. Believe it or not, rocket engines designs contain turbopumps that move fuel and the oxidizer into a combustion chamber creating the perfect conditions for their burning and high-efficiency rocket motion. The word “turbopump” means that the pump is driven by the turbine installed on the same shaft or connected to it through a gearbox. This thrilling tandem results in a bunch of rotor dynamics effects inherent in pumps, turbines, high-speed rotors, cryogenic temperature materials, etc. And all these effects must be carefully taken into account during rotor dynamics studies.
A standard schematic of an internally geared turbopump consists of the liquid hydrogen (LH2, fuel) and liquid oxygen (LO2, oxidizer) rotors.
Although the rotor dynamics model is usually simpler than the CAD models, it looks quite complicated in the case of the turbopump. The rotors contain sections that are hollow and sections with some elements inside the hollow space. Read More
Update – February 28, 2023: AxCYCLE and AxSTREAM NET are our legacy software packages replaced by AxSTREAM System Simulation. System Simulation was born out of the union of the legacy AxCYCLE and AxSTREAM NET.
There’s nothing quite like rocket science, is there? It’s as fascinating as it is complicated. It’s not enough to just get a design right anymore – you have to get it right on the first go-around or very soon thereafter. Enter AxSTREAM.SPACE and all the functionality upgrades introduced in 2021.
AxSTREAM.SPACE was created by experienced mechanical and turbomachinery engineers to level the playing field when it comes to turbomachine-based liquid rocket engine design. By giving propulsion and system engineers a comprehensive tool that can connect with other proprietary or commercial software packages, the sky is, in fact, not the limit for innovation. It covers everything from flow path aerodynamic and hydrodynamic design to rotor dynamics, secondary flow/thermal network simulation, and system power balance calculations. This year, we are proud to unveil some new features that enhance each of these capabilities, which were developed at the request of our customers.
A critical part of any rocket engine development, as pointed out in a NASA blog, is engine power balance, also known as thermodynamic cycle simulation. AxCYCLE, SoftInWay’s own thermodynamic cycle solver that has been widely used in power generation and aviation is now helping companies build rocket engines from scratch, as well as expand their engine lineup based on an existing system. There are some goodies, however, which make it the perfect tool for power balance, and an asset of AxSTREAM.SPACE.
Update – February 28, 2023: AxCYCLE and AxSTREAM NET are our legacy software packages, replaced by AxSTREAM System Simulation. System Simulation was born out of the union of the legacy AxCYCLE and AxSTREAM NET.
Corresponding with the development of industrial technology in the middle of the nineteenth century, people dealt with multiphase flows but the decision to describe them in a rigorous mathematical form was first made only 70 years ago. As the years progressed, development of computers and computation technologies led to the revolution in mathematical modeling of mixing and multiphase flows. There are a few periods, which could describe the development of this computation:
«Empirical Period» (1950-1975)
There were a lot of experiments that were done during this period. All models were obtained from experimental or industrial facilities which is why using them was difficult for different cases.
«Awakening Period» (1975-1985)
Because of sophisticated, expensive, and not universal experiments, the researchers’ attention was directed to the physical processes in multiphase flows.
«Modeling Period» (1985-Present)
Today, the models for multi-flow calculation using the equations of continuity together with equations of energy conservation are obtained, which allow describing phase’s interaction for different flow regimes. (A.V. Babenko, L. B. Korelshtein – Hydraulic calculation two-phase gas-liquid course: modern approach // Calculations and modeling journal. – 2016. – TPА 2 (83) 2016. – P.38-42.)
Since the time of industrial development, installation designs have undergone great changes. For example, there are shell and tube evaporators for freeze systems where the heat transfer coefficient has increased 10 times over during the last 50 years. These results are a consequence of different innovation decisions. Developments led to research into mini-channels systems, which is the one of the methods to increase intensification of phase transition. Research has shown that heat exchange systems with micro and nano dimensions have a much greater effect than the macrosystems with channels dimensions ≤3-200 mm.
In order to organize fundamental research, it is very important to understand hydro, gas dynamics, and heat changes in two-phase systems with the phase transition. At present, the number of researchers using advanced CFD programs has increased. Our team is one of the lead developers of these program complexes.
Mathematical modeling of compressible multiphase fluid flows is interesting with a lot of scientific directions and has big potential for practical use in many different engineering fields. Today it is no secret that environmental issues are some of the most commonly discussed questions in the world. People are trying to reduce the emissions of combustion products. One of the methods to decrease emissions is the organization of an environmentally acceptable process of fuel-burning with reduced yields of nitrogen and sulfur. The last blog (https://blog.softinway.com/en/modern-approach-to-liquid-rocket-engine-development-for-microsatellite-launchers/) discussed numerical methods, which can calculate these tasks with minimal time and cost in CFD applications.
For more effective use of energy resources and low-potential heat utilization, the choice of the Organic Rankine Cycle (ORC) is justified. Due to the fact that heat is used and converted to mechanical work, it is important to use a fluid with a boiling temperature lower than the boiling temperature of water at atmospheric pressure (with working flow-boiling temperature about 100⁰C). The usage of freons and hydrocarbons in these systems makes a solution impossible without taking into account the changes of working fluid phases. Read More
Quite surprisingly, rockets in their primal form were invented before turbomachinery, even though turbines and pumps are both present in modern launcher engines. However, it is interesting to note that both can be traced to the same ancestor. In this post we will discuss some of the history and technical evolution of rockets and turbomachinery – and this all starts with an old pigeon.
Circa 400BCE, a Greek philosopher and mathematician named Archytas designed a pigeon-like shape made out of wood that was suspended with wires and propelled along these guides using steam demonstrating the action-reaction principle long before Newton formalized it as a rule in Physics. As we know today, the faster and the more steam escapes the pigeon, the faster it goes. Turn this 90 degrees to have the bird face upward, and you have a very basic rocket concept. However, rockets are a lot more complex than this, and do not typically use steam (except in the case of liquid hydrogen + liquid oxygen propellants) as the propelling fluid. Read More
Rockets have always fascinated us and to this day a rocket launch is still a global news event worth watching. The sheer noise, power and sight after you hear that “…3-2-1, Lift off!” leave us in awe. A masterpiece of engineering, the recent historic manned SpaceX Falcon 9 launch was no exception. Or was it?
From the outside, a rocket does not look especially advanced – a mere ‘stick’ with a big flame shooting out at one end. The principal concept is simple, too, but the inner workings of a modern liquid-fuel rocket are highly complex.
The first rockets are believed to have existed in China, around 1200. The invention of gunpowder was crucial to the development of these primitive rockets, which were fireworks initially and then weapons. Multistage so-called ‘fire arrows’ were documented during the early Ming Dynasty (Figure 1). The designs were based on bamboo sticks – still a little way off a Falcon 9.
With the rise of gunpowder, this crude rocket technology spread throughout the Middle East and Europe.
The next rocketry milestone came in the 1780s, when the Indian military developed Mysorean rockets with iron castings and successfully deployed them against the British East India Company. Read More
Update – February 28, 2023: AxCYCLE and AxSTREAM NET are our legacy software packages depreciated by AxSTREAM System Simulation. System Simulation was born out of the union of the legacy AxCYCLE and AxSTREAM NET.
Mechanical engineering is an ever-changing field, and we want to be there to help engineers stay ahead of the curve, even while they are flattening it. In that spirit, we wanted to share with you our different training options that are available now. Whether you are looking to brush up on the fundamentals, or evaluate a software platform, this is a great time to train and explore the latest and greatest in turbomachinery engineering.
Without further ado, let’s get into it!
Private Corporate Trainings Online
First and foremost, the best most comprehensive training you can get from SoftInWay is a private session with one of SoftInWay’s lead engineers and your team. Why is this the best training option? A couple of reasons:
Courses are entirely customizable: The scope of these private training courses is tailored to your specific needs. Are you looking to learn the fundamentals? Or perhaps you want to expand your team’s R&D capabilities when it comes to turbomachinery, rotor dynamics, and 1D thermal systems? Whatever the application, we’ll work with you to develop a course curriculum which brings the most value to you and your team.
One-on-one consultation with our expert engineers on individual projects and challenges. Our engineering expertise ranges from flowpath design on a turbomachine, to rotor dynamics, as well as secondary flows/multiphase flows, and other all-encompassing projects such as liquid rocket engine design.
ll registrants get a 1-month license of the relevant AxSTREAM modules. During the class, users will be familiarized with the ins and outs of AxSTREAM, and be able to make use of AxSTREAM’s capabilities for 1 month afterwards.
The class can be as long or as short as you need and scheduled around you and your team. Read More
Microsatellites have been carried to space as secondary payloads aboard larger launchers for many years. However, this secondary payload method does not offer the specificity required for modern day demands of increasingly sophisticated small satellites which have unique orbital and launch-time requirements. Furthermore, to remain competitive the launch cost must be as low as $7000/kg. The question of paramount importance today is how to design both the liquid rocket engine turbopump and the entire engine to reduce the duration and cost of development.
The system design approach applied to rocket engine design is one of the potential ways for development duration reduction. The development of the design system which reduces the duration of development along with performance optimization is described herein.
The engineering system for preliminary engine design needs to integrate a variety of tools for design/simulation of each specific component or subsystem of the turbopump including thermodynamic simulation of the engine in a single iterative process.
The process flowchart, developed by SoftInWay, Inc., integrates all design and analysis processes and is presented in the picture below.
The preliminary layout of the turbopump was automatically generated in CAD tool (Block 11). The developed sketch was utilized in the algorithm for mass/inertia parameters determination, secondary flow system dimensions generations, and for the visualization of the turbopump configuration. The layout was automatically refined at every iteration. Read More
Operation of most liquid-propellant rocket engines, first introduced by Robert Goddard in 1926- is simple. Initially, a fuel and an oxidizer are pumped into a combustion chamber, where they burn to create hot gases of high pressure and high speed. Next, the gases are further accelerated through a nozzle before leaving the engine. Nowadays, liquid propellant propulsion systems still form the back-bone of the majority of space rockets allowing humanity to expand its presence into space. However, one of the big problems in a liquid-propellant rocket engine is cooling the combustion chamber and nozzle, so the cryogenic liquids are first circulated around the super-heated parts to bring the temperature down.