Analysis of an internally mountable accelerometer balance system for use with non-isotropic models in shock tunnels

Knowledge of drag force is an important design parameter in aerodynamics. Measurement of aerodynamic forces at hypersonic speed is a challenge and usually ground test facilities like shock tunnels are used to carry out such tests. Accelerometer based force balances are commonly employed for measuring aerodynamic drag around bodies in hypersonic shock tunnels. In this study, we present an analysis of the effect of model material on the performance of an accelerometer balance used for measurement of drag in impulse facilities. From the experimental studies performed on models constructed out of Bakelite HYLEM and Aluminum, it is clear that the rigid body assumption does not hold good during the short testing duration available in shock tunnels. This is notwithstanding the fact that the rubber bush used for supporting the model allows unconstrained motion of the model during the short testing time available in the shock tunnel. The vibrations induced in the model on impact loading in the shock tunnel are damped out in metallic model, resulting in a smooth acceleration signal, while the signal become noisy and non-linear when we use non-isotropic materials like Bakelite HYLEM. This also implies that careful analysis and proper data reduction methodologies are necessary for measuring aerodynamic drag for non-metallic models in shock tunnels. The results from the drag measurements carried out using a 60 degrees half angle blunt cone is given in the present analysis.

Measurement of aerodynamic forces for missile shaped body in hypersonic shock tunnel using 6-component accelerometer based balance system

This paper reports the basic design of a new six component force balance system using miniature piezoelectric accelerometers to measure all aerodynamic forces and moments for a test model in hypersonic shock tunnel (HST2). Since the flow duration in a hypersonic shock tunnel is of the order of $1$ ms, the balance system [1] uses fast response accelerometers (PCB Piezotronics; frequency range of 1-10 kHz) for obtaining the aerodynamic data. The alance system has been used to measure the basic aerodynamic forces and moments on a missile shaped body at Mach $8$ in the IISc hypersonic shock tunnel. The experimentally measured values match well with theoretical predictions.

Accelerometer-Based Force Balance for High Enthalpy Facilities

A single component accelerometer-based force balance is developed, calibrated, and used for high enthalpy applications. Functionality of this force balance, for such applications, is demonstrated for the first time during high enthalpy tests in a newly established free piston-driven shock tunnel, HST3, using a 60 degrees apex angle blunt cone model at 0 degrees angle of incidence. Usefulness of this force balance is also confirmed, for much complicated high enthalpy flow situations, during the drag reduction studies with counterflow supersonic jet from the stagnation point.

A new 6-component accelerometer force balance for short duration ground testing facilities

A new six-component accelerometer force balance is developed and used in the HST2 shock tunnel of Indian Institute of Science. Aerodynamic forces and moments for a hypersonic slender body measured using this balance system at a free stream Mach number of 5.75 and Reynolds number of 1.5 million and stagnation enthalpy of 1.5 and 2 MJ/kg are presented. These measured values compare well with the theoretical values estimated using modified Newtonian theory.

A novel free floating accelerometer force balance system for shock tunnel applications

In order to overcome the interference of the model mounting system with the external aerodynamics of the body during shock tunnel testing, a new free floating internally mountable balance system that ensures unrestrained model motion during testing has been designed, fabricated and tested. Minimal friction ball bearings are used for ensuring the free floating condition of the model during tunnel testing. The drag force acting on a blunt leading edge flat plate at hypersonic Mach number has been measured using the new balance system. Finite element model (FEM) and CFD are exhaustively used in the design as well as for calibrating the new balance system. The experimentally measured drag force on the blunt leading edge flat plate at stagnation enthalpy of 0.7 and 1.2 MJ/kg and nominal Mach number of 5.75 matches well with FEM results. The concept can also be extended for measuring all the three fundamental aerodynamic forces in short duration test facilities like free piston driven shock tunnels.

An approach for assessing the accuracy of accelerometer responses during axial impact tests

The primary objective of the present study is to show that for the most common configuration of an impactor system, the accelerometer cannot exactly reproduce the dynamic response of a specimen subjected to impact loading. An equivalent Lumped Parameter Model (LPM) of the given impactor set-up has been formulated for assessing the accuracy of an accelerometer mounted in a drop-weight impactor set-up for an axially loaded specimen. A specimen under the impact loading is represented by a non-linear spring of varying stiffness, while the accelerometer is assumed to behave in a linear manner due to its high stiffness. Specimens made of steel, aluminium and fibre-reinforced composite (FRC) are used in the present study. Assuming the force-displacement response obtained in an actual impact test to be the true behaviour of the test specimen, a suitable numerical approach has been used to solve the governing non-linear differential equations of a three degrees-of-freedom (DOF) system in a piece-wise linear manner. The numerical solution of the governing differential equations following an explicit time integration scheme yields an excellent reproduction of the mechanical behaviour of the specimen, consequently confirming the accuracy of the numerical approach. However, the spring representing the accelerometer predicts a response that qualitatively matches the assumed force-displacement response of the test specimen with a perceptibly lower magnitude of load.

Evaluation of the accuracy of an accelerometer response generated by axial impact loading

The basic objective in the present study is to show that for the most common configuration of an impactor system, an accelerometer cannot exactly reproduce the dynamic response of a specimen subject to impact loading. Assessment of the accelerometer mounted in a drop-weight impactor setup for an axially loaded specimen is done with the aid of an equivalent lumped parameter model (LPM) of the setup. A steel hat-type specimen under the impact loading is represented as a non-linear spring of varying stiffness, while the accelerometer is assumed to behave in a linear manner due to its high stiffness. A suitable numerical approach has been used to solve the non-linear governing equations for a 3 degrees-of-freedom system in a piece-wise linear manner. The numerical solution following an explicit time integration scheme is used to yield an excellent reproduction of the mechanical behavior of the specimen thereby confirming the accuracy of the numerical approach. The spring representing the accelerometer, however, predicts a response that qualitatively matches the assumed load–displacement response of the test specimen with a perceptibly lower magnitude of load.

Compact in-plane dual-axis spring-steel accelerometer

Presented in this paper is an improvement over a spring-steel dual-axis accelerometer that we had reported earlier.The fabrication process (which entails wire-cut electro discharge machining of easily accessible and inexpensive spring-steelfoil) and the sensing of the displacement (which is done using off-the-shelf Hall-effect sensors) remain the same. Theimprovements reported here are twofold: (i) the footprint of the packaged accelerometer is reduced from 80 mm square to 40mm square, and (ii) almost perfect de-coupling and symmetry are achieved between the two in-plane axes of the packageddevice as opposed to the previous embodiment where this was not the case. Good linearity with about 40 mV/g was measuredalong both the in-plane axes over a range of 0.1 to 1 g. The first two natural frequencies of the devices are at 30 Hz and 100Hz, respectively, as per the experiment. The highlights of this work are cost-effective processing, easy integration of the Hall-effect sensing capability on a customised printed circuit board, and inexpensive packaging without overly compromising eitherthe overall size or the sensitivity of the accelerometer. Through this work, we have reaffirmed the practicability of spring-steelaccelerometers towards the eventual goal of making it compete with micro machined silicon accelerometers in terms of sizeand performance. The cost is likely to be much lower for the spring-steel accelerometers than that of silicon accelerometers, especially when the volume of production is low and the sensor is to be used as a single packaged unit.

A MICROMACHINED WIDE-BAND IN-PLANE SINGLE-AXIS CAPACITIVE ACCELEROMETER WITH A DISPLACEMENT-AMPLIFYING COMPLIANT MECHANISM

With the premise that electronic noise dominates mechanical noise in micromachined accelerometers, we present here a method to enhance the sensitivity and resolution at kHz bandwidth using mechanical amplification. This is achieved by means of a Displacement-amplifying Compliant Mechanism (DaCM) that is appended to the usual sensing element comprising a proof-mass and a suspension. Differential comb-drive arrangement is used for capacitive-sensing. The DaCM is designed to match the stiffness of the suspension so that there is substantial net amplification without compromising the bandwidth. A spring-mass-lever model is used to estimate the lumped parameters of the system. A DaCM-aided accelerometer and another without a DaCM-both occupying the same footprint-are compared to show that the former gives enhanced sensitivity: 8.7 nm/g vs. 1.4 nm/g displacement at the sensing-combs under static conditions. A prototype of the DaCM-aided micromachined acclerometer was fabricated using bulk-micromachining. It was tested at the die-level and then packaged on a printed circuit board with an off-the-shelf integrated chip for measuring change in capacitance. Under dynamic conditions, the measured amplification factor at the output of the DaCM was observed to be about 11 times larger than the displacement of the proof-mass and thus validating the concept of enhancing the sensitivity of accelerometers using mechanical amplifiers. The measured first in-plane natural frequency of the fabricated accelerometer was 6.25 kHz. The packaged accelerometer with the DaCM was measured to have 26.7 mV/g sensitivity at 40 Hz.

Investigation of Missile-Shaped Body with Forward-Facing Cavity at Mach 8

A blunt-nosed hypersonic missile mounted with a forward-facing cavity is a good alternative to reduce the stagnation heating rates. The effects of a forward-racing cavity on heat transfer and aerodynamic coefficients are addressed in this paper. Tests were carried out in hypersonic shock tunnel HST2, at a hypersonic Mach number of 8 using a 41 deg apex-angle blunt cone. The aerodynamic forces on the test model with and without a forward-facing cavity at various angles of attack are measured by using an internally mountable accelerometer force balance system. Heat flux measurements have been carried out on the test model with and without a forward-facing cavity of the entire surface at zero degree angle of attack with platinum sensors. A numerical simulation was also carried out using the computational fluid dynamics code (CFX-Ansys 5.7). An important result of this study is that the smaller cavity diameter has the highest lift-to-drag ratio, whereas the medium cavity has the highest heat flux reduction. Theshock structure around the test model has also been visualized using the Schlieren flow visualization technique. The visualized shock structure and the measured aerodynamic forces on the missile-shaped body with cavity configurations agree well with the axisymmetric numerical simulations.

Drag reduction by a forward facing aerospike for a large angle blunt cone in high enthalpy flows

Drag reduction studies are conducted using a flat disc tipped aerospike for a 120-degree apex angle blunt cone model in high enthalpy flows. Accelerometer based force balance is used for the drag force measurement in the newly established free piston driven shock tunnel, HST3. Drag reduction upto about 58 percent has been achieved for Mach 8 flow of 5 MJ/kg specific enthalpy at zero degree angle of attack.

Drag reduction by counterflow supersonic jet for a blunt cone in high enthalpy flows

Counterflow supersonic jet is used as a drag reduction device during the experiments in free piston driven shock tunnel, HST3. Accelerometer based force balance is employed to measure the drag force experienced by the 60-degree apex angle blunt cone model without and with the supersonic jet opposing the hypersonic flow. It is observed that the drag force decreases with increase in injection pressure ratio until the critical injection pressure is reached. Maximum reduction in drag force of 44 percent is recorded at the critical injection pressure ratio 22.36. Further increase in injection pressure ratio has reduced the percentage drag reduction. Change in nature of the flowfield around the model has also been observed across the critical injection pressure ratio.