Aerodynamics and Thermal Physics of Helicopter Ice Accretion
Open Access
- Author:
- Han, Yiqiang
- Graduate Program:
- Aerospace Engineering
- Degree:
- Doctor of Philosophy
- Document Type:
- Dissertation
- Date of Defense:
- December 16, 2015
- Committee Members:
- Jose Palacios, Dissertation Advisor/Co-Advisor
Jose Palacios, Committee Chair/Co-Chair
Kenneth Steven Brentner, Committee Member
Robert Francis Kunz, Committee Member
Namiko Yamamoto, Committee Member
John Michael Cimbala, Committee Member - Keywords:
- Aircraft Icing
Ice Accretion Modelling
Helicopter
Aerodynamics
Heat Transfer
Surface Roughness
Performance Degradation - Abstract:
- Ice accretion on aircraft introduces significant loss in airfoil performance. Reduced lift-to-drag ratio reduces the vehicle capability to maintain altitude and also limits its maneuverability. Current ice accretion performance degradation modeling approaches are calibrated only to a limited envelope of liquid water content, impact velocity, temperature, and water droplet size; consequently inaccurate aerodynamic performance degradations are estimated. The reduced ice accretion prediction capabilities in the glaze ice regime are primarily due to a lack of knowledge of surface roughness induced by ice accretion. A comprehensive understanding of the ice roughness effects on airfoil heat transfer, ice accretion shapes, and ultimately aerodynamics performance is critical for the design of ice protection systems. Surface roughness effects on both heat transfer and aerodynamic performance degradation on airfoils have been experimentally evaluated. Novel techniques, such as ice molding and casting methods and transient heat transfer measurement using non-intrusive thermal imaging methods, were developed at the Adverse Environment Rotor Test Stand (AERTS) facility at Penn State. A novel heat transfer scaling method specifically for turbulent flow regime was also conceived. A heat transfer scaling parameter, labeled as Coefficient of Stanton and Reynolds Number (CSR=St_x⁄(Re_x^(-0.2) )), has been validated against reference data found in the literature for rough flat plates with Reynolds number (Re) up to 1×107, for rough cylinders with Re ranging from 3×104 to 4×106, and for turbine blades with Re from 7.5×105 to 7×106. This is the first time that the effect of Reynolds number is shown to be successfully eliminated on heat transfer magnitudes measured on rough surfaces. Analytical models for ice roughness distribution, heat transfer prediction, and aerodynamics performance degradation due to ice accretion have also been developed. The ice roughness prediction model was developed based on a set of 82 experimental measurements and also compared to existing predictions tools. Two reference predictions found in the literature yielded 76% and 54% discrepancy with respect to experimental testing, whereas the proposed ice roughness prediction model resulted in a 31% minimum accuracy in prediction. It must be noted that the accuracy of the proposed model is within the ice shape reproduction uncertainty of icing facilities. Based on the new ice roughness prediction model and the CSR heat transfer scaling method, an icing heat transfer model was developed. The approach achieved high accuracy in heat transfer prediction compared to experiments conducted at the AERTS facility. The discrepancy between predictions and experimental results was within ±15%, which was within the measurement uncertainty range of the facility. By combining both the ice roughness and heat transfer predictions, and incorporating the modules into an existing ice prediction tool (LEWICE), improved prediction capability was obtained, especially for the glaze regime. With the available ice shapes accreted at the AERTS facility and additional experiments found in the literature, 490 sets of experimental ice shapes and corresponding aerodynamics testing data were available. A physics-based performance degradation empirical tool was developed and achieved a mean absolute deviation of 33% when compared to the entire experimental dataset, whereas 60% to 243% discrepancies were observed using legacy drag penalty prediction tools. Rotor torque predictions coupling Blade Element Momentum Theory and the proposed drag performance degradation tool was conducted on a total of 17 validation cases. The coupled prediction tool achieved a 10% predicting error for clean rotor conditions, and 16% error for iced rotor conditions. It was shown that additional roughness element could affect the measured drag by up to 25% during experimental testing, emphasizing the need of realistic ice structures during aerodynamics modeling and testing for ice accretion.