Automated Full Trajectory Aero-Thermo-Mechanical Simulation Coupling for Hypersonic Flight

Accurate prediction of the operating environment to design robust aero-thermo-mechanical loading capabilities of aeroshell materials will enable a better understanding of vehicle capabilities over Navy hypersonic flight trajectories.Ā Spectral Sciences, Inc., in collaboration with GoHypersonic Inc., has developed a detailed software plan that links high-fidelity aerothermal gas flow simulations using US3D and nonlinear thermomechanical finite element analysis (FEA) using ABAQUS for aero-thermo-mechanical simulations of hypersonic vehicle aeroshells along a flight trajectory. Phase I included development and demonstration of key components of this software, including automated mapping of thermal results between the two existing tools and development of an effective time discretization and coupling scheme. The initial prototype capability was demonstrated for select conditions. Phase II will develop the full prototype of the automated coupling software, which will include US3D plugin development, expanded capabilities for the existing Trajectory, Ablation, and Shape Change plugin, full workflow automation, and implementation of advanced aerodynamic and thermomechanical behaviors like transition to turbulence and thermostructural failure analysis. The prototype will then be tested against benchmark tests and with real Navy flight cases as part of an overall validation and verification effort. The proposed work will greatly simplify and streamline the simulation process, reducing the labor required to run a coupled aero-thermo-mechanical simulation over a full hypersonic flight trajectory.