摘要
飞机在含有过冷水滴的云层中飞行时将会发生结冰现象，飞机结冰对其安全飞行带来严重威胁，近年来因为飞机结冰引发的航空事故并不少见。目前，国内由于缺乏支撑试验的大型结冰风洞(正在建设中)，因此本文研究重点研究了结冰数值模拟计算方法，兼有结冰风洞部件的设计方法。论文在参考和学习大量国内外结冰文献的基础上，基于VC/FORTRAN混合编程方法和动态链接库DLL技术，将飞机结冰数值计算模块化编程并集成于MFC软件计算平台中，开发了面向用户的飞机结冰计算软件NUAA-ICE3D，在开发软件的环节中提出了一系列新的研究思路和方法。本文具体的研究工作和取得有价值的成果主要体现在以下几个方面：
首先研究了二维圆柱、单段翼型、多段翼等模型的网格生成和重构方法，发现采用基于求解椭圆型偏微分方程方法生成的结构化网格最为高效可行。通过对椭圆型微分方程的离散推导，分析了模型表面附近网格质量的控制方式和控制效果。在生成等截面机翼、变截面机翼、翼身组合体的结构化网格时，引入两种适用于结冰计算的网格重构方法，即端面表面O网格法和整体H型网格法；考虑到结冰总是发生在部件迎风部位，为了提高网格重构的效率和稳定性，引入两种辅助性的网格分区方法：椭圆形分区和扇形分区。
开发了基于密度求解方式的Euler/Navier-Stokes流场求解代码。在离散求解控制方程时，时间上采用了显式四步/五步龙哥库塔、空间上采用了中心差分格式离散了控制方程。为了抑制奇偶失联造成的高频振荡和激波前后的数值波动，引入了人工耗散项，编程中还采用了当地时间步长和隐式残值光顺技术。在计算湍流粘性系数时，采用了三种湍流模型：零方程B-L模型、一方程S-A模型及两方程k-ε模型。随后，对所编的流场求解器进行了验证和分析。
在过冷水滴撞击特性计算中，分别研究了拉格朗日法和欧拉法两种算法。在拉格朗日法中，将网格拓扑结构应用到了寻找水滴空间位置过程中，同时引入了根据网格分区设置时间步长的方法，解决了拉格朗日法计算水滴轨迹耗时长的问题。在水滴运动方程的时间项离散中，分别采用了欧拉法、预估-校正法、四步龙哥库塔法。在欧拉法计算中，基于FLUENT软件的用户自定义标量功能，编写了用于计算任意几何体表面水滴撞击特性的UDF代码。通过对二维翼型、三维球体、DLR-F6翼身组合体、DLR-F6翼身架舱组合体的水滴撞击计算，验证了所开发代码的正确性。最后，采用FLUENT特有的日志运行功能，基于MFC界面对动态加载UDF、设置来流计算条件、监视收集系数收敛等一系列操作进行了封装。
研究了冰层增长中的复杂传热传质过程，将网格单元作为控制体，使得冰层增长计算与其它模块共用同一套网格。从热边界层和动量边界层理论出发，推导和讨论了空气、水膜、冰层三者之间的换热机理，完成了水滴发生冻结并转化冰层的模拟，将所开发的代码模块命名为ICEC。通过对对流换热系数曲线和结冰冰形的计算，验证了代码的可靠性。以圆柱结冰为研究对象，分析了冰层表面粗糙度对空气、水膜、冰三相间传热传质及结冰冰形的影响，提出了一种全新的几何粗糙度修正模型，它是通过冰形边界的曲折程度来衡量表面粗糙程度的。以集成的结冰软件为计算平台，模拟并研究了结冰参数对对流换热系数和冰形的影响。最后在三维结冰数值计算方面，将二维中的计算方法进行了三维空间的拓展。
在计算代码的高度集成性和面向用户性方面作了深入的研究工作。首先将结冰计算分为网格生成与重构模块GRID、空气流场计算FLOW、水滴撞击计算模块DROP、结冰冰形计算ICEC，将结冰边界修复并入GRID程序模块中，然后基于动态链接库技术把每个模块代码转为化编译的DLL文件。从软件开发的角度出发，还研究了各个模块数据存储、数据通信、用户界面、结果显示、文件管理及软件模块更新等方面的内容。基于MFC框架编写了控制模块计算和反复内部调用模块的多线程仿真平台，同时软件中引入了两种执行方式以适应多步长冰层增长的模拟。最后，书写了软件用户手册，将所开发的结冰软件打包为setup.exe，即可交付用户使用。在结冰数值软件NUAA-ICE3D中，除了集成了自编的各个模块程序及其计算功能外，还内嵌了通过MFC界面启动的FLUENT流场计算和UDF水滴撞击计算功能，所有初始计算工况均由用户界面输入，然后软件自动查找并替换FLUENT日志文件和UDF程序中的参数，以实现模块程序的无缝封装和数值计算的自动化。
对冰风洞的关键部件进行了阐述，然后重点展开了两个方面的研究工作，即冰风洞洞体和四大拐角导流叶片的设计。根据风洞设计理论，设计了某型回流结冰风洞，计算了风洞各段截面上的总压、静压、速度等参数的分布。在确定风洞各段尺寸之后建立了三维几何模型，依次设计了剖面形状为翼剖面型、圆弧直线型、圆弧形的导流叶片，给出了各个拐角处的叶片形式和叶片数目，并绘制了可用于加工的CAD图。随后，以扩散段、第一拐角段(含导流叶片9片)、出口过渡段为计算模型，在进口参数分别为V=80、100、120m/s、静温为t=-30℃的工况下，数值模拟了扩散段、导流叶片附件的流场分布。因此，在结冰数值模拟和冰风洞设计方面，本文的研究成果具有很好的参考价值。
When the aircraft is flying in the clouds containing supercooled water droplets, these dropletsimpinge on the surfaces of the lift components and then freeze. The ice accretion on these componentsis one of the potential hazards in flight, and can lead to air crash. Icing research tunnel is not availablein China now, so the major focus of current research is numerical simulation of aircraft icing. Afterreferring and studying many domestic and foreign literatures, modular icing codes have beenestablished using VC/FORTRAN mixed programming and DLL technology, and the software packagecalled NUAA-ICE3D is well developed to perform normal functions of these modules based on MFCframework. In addition, some ideas and new methods are also presented. The main research andachievements of this thesis are as follows:
At first, grid generation and reconstruction for calculation of airfoil ice accretion on cylinder,single and multi airfoils are studied carefully, and it is a very efficient and feasible way to generate thegrid by solving the elliptic PDEs. The forcing terms are automatically chosen in the manner ofHilgenstock method such that orthogonality and spacing control on the icing smoothed boundary areachieved. In order to obtain the appropriate structured grid for the wings and wingbody models, twokinds of grid reconstruction method are introduced; they are H-type grid around the wing and O-typegrid on the end face of the wing tip. Taking account of ice accretion on the upwind surfaces of the liftcomponents such as wings, in order to improve the efficiency, quality and reliability of grid,ellipse-shaped and fan-shaped partition methods have been introduced and validated. Finally, the gridgeneration and reconstruction can be carried out successfully during the calculations of ice accretionbased on these new techniques.
The flow field solver based on the density pattern is developed in this thesis which can be used tosolve the Euler/Navier-Stokes controlled equations. In this code, the modified central differencemethod with artificial viscosity by Jameson scheme is applied for spacial discretization and an explicitfour/five stages Runge-Kutta seheme is used for temporal discretization. The convergence procedure isaccelerated by using local time step and implicit residual smooth technology. In order to calculate theturbulence viscosity coefficient, three turbulence models, zero-equation B-L model, one-equationSpalart-Allmaras model and two-equation k-ε model, are employed in this thesis. After this, thevalidation and analysis of the developed solver are carried out.
Two classes of methods for supercooled water droplet impinging calculation are adopted in thisthesis; they are Lagrangian and Eulerian methods. In the Lagrangean formulation, the grid topologicalrelation is employed to seek the spatial location of water droplet and the grid partition method is usedto set the time step for discretizing the governing equations of droplet, which has resolved thetime-consuming problem. In addition, three discretization approaches including Euler method, estimatealong with adjustment method, and four stages Runge-Kutta time stepping scheme are employed todiscretize the time term of the momentum equations. In Eulerian approach, the UDF codes for solvingtransport equations for momentum and phase volume fraction are developed by integrating the UserDefined Scalar. For the sake of the UDF codes, some classic models are tested here such as airfoils,sphere, DLR-F6wing/body model, DLR-F6wing/body/pylon/nacelle model. Based on the automatic script function of FLUENT software, a series of encapsulation for loading the UDF codes, setting theinitial conditions, monitoring the iteration residual value are completed by using the MFC framework.
This thesis gives systematic study on the process of ice layer accretion, especially the mass andenergy transfer between two-phase distribution (air and water droplet) and icing build-up region alongthe surface of airfoil. Based on the theory of momentum and thermal boundary layer, the governingequations are established by considering the conservation of mass and energy in each control volume.The developed code for calculating the ice-layer accretion is called ICEC module. Taking the cylinderas the example, this thesis also studies the effects of roughness height on the heat and mass transferamong the air, water film and ice, together with the final ice shape in the ice-layer accretion module. Anew correction model for roughness height is given to measure the rough characteristics of roughnessalong the iced surface more accurately. In this model, the roughness height is regarded as a function oficing condition, spatial coordinate, and icing time step by considering the local curvature of icedsurface. Based on the icing software developed, the effects of several key parameters on heat transfercoefficient and ice shape are presented, and these factors include free-stream velocity, statictemperature, angle of attack and the roughness height of surface, and so on. At last, the prediction ofthree-dimensional ice shape is implemented based on the two-dimensional analysis.
In order to improve the capability of integration and users orientation for icing software, thedetailed study on the development of the icing simulation software is given in this work. Thecalculation of ice accretion is devided into four modules; grid generation and reconstruction (GRID),flow field calculation (FLOW), particle trajectory and impingement calculation (DROP),thermodynamic and ice growth calculation (ICEC). At first, a new module programming method isused to convert the source code into the file format called Dynamic Link Library. Then, a multi-threadsimulation platform is designed based on the MFC framework to execute related functions, includingthe implement of each module, data storage, data communication, displays of results and so on. Besides,two execute modes are adopted in icing calculations in order to simulate the multiple ice-layersaccretion. It is found that these methods used in this work have made the software efficient and easy tobe updated. The validation and robustness of the software are also well tested. In addition, theFLUETN flow solver and UDF codes for calculating the water droplet impingements are alsointegrated into our software. All the initial conditions can be input via the user interface.
The functions of the key parts of ice tunnel are described in this thesis, and the full size of icetunnel and the turning vane are designed together based on the wind tunnel design principle. Thesecharacteristic parameters including total pressure, static pressure, and velocity are computed for all thesections in the different locations of ice tunnel. As the ice tunnel has been designed, three-dimensionaldiagram is drawn clearly. In order to decrease the pressure loss in the turning period, three kinds ofturning vanes which sections are airfoil, arc-line, and arc shape are well designed to fit the demands oftunnel corners. Then, the numerical simulation of flow field for the first expanding section, first turningsection (including nine vanes) and transition section is completed when the inlet condition is V=80,100,120m/s, and t=-30℃. The design features and flow qualities near this corner are discussed.
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