Parametric study of manifolds using finite element analysis

Abstract: Volvo Aero Corporation takes part in a development project called Future Launchers Preparatory Program (FLPP) which aims to develop Next Generation Launchers (NGL) for future space flights. FLPP involves several projects and one these are focused on the development of the next generation rocket engines for the NGL. The environment of a rocket engine is extremely hostile, characterized by high pressure levels and rapid thermal transients. Even though the components are manufactured from super alloys, the life of these components is measured in seconds. In the light of these facts, it is obvious that all components have to be optimized to the last detail. This thesis work is a part of the optimization procedure with the objective to perform a parametric study of manifolds that will be particular useful during the concept work of the turbines for the FLPP program. The methods of probabilistic analysis have been employed in this study. This approach involves Ishikawa analysis (Cause and Effects) as well deriving transfer functions through defining and performing simulations in a structured manner according to a Design of Experiment model. Transfer functions, which are derived through a series of Finite Element Analysis, describe the relation between design parameter and stress levels. The transfer function can be considered as a simplified physical model which only is applicable within the range used of the design parameters. The use of transfer function is especially powerful when performing Monte Carlo simulations to determine the likelihood of plasticity. One short coming of transfer functions is that only the parameters included from the beginning can be altered and assessed. One also have to consider the simplifications introduced through the modelling, such as transfer functions derived using linear elastic simulations can not be used for assessment of plastic deformations. The method developed in this thesis will be further developed in following studies. This report is therefore meant to serve as a guide for the next investigator at Volvo Aero Corporation.