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CSAR Legacy
Michael T. HeathFebruary 21, 2007
©2007 Board of Trustees of the University of Illinois
Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Center for Simulation of Advanced Rockets
Detailed, whole-system simulation of solid propellant rockets under normal and abnormal operating conditions
Accurate models of physical components Subscale simulations of materials and
accident scenarios Software framework to facilitate
component integration Computational infrastructure to support
large-scale simulations Research collaborations with government
laboratories and rocket industry
Overarching Goal: Simulation of solid propellant rockets from first principles
STS Discovery
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Solid Rocket BoosterIgniter
Case
Core flow
Propellant
Nozzle
Joint & slot
Ammonium perchlorate (oxidizer)
Polymeric binder and aluminum particles (fuel)
200 m
Micrograph of solid propellant
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Challenges in Rocket Simulation
Full 3-D modeling essential to capture physics Strong, nonlinear coupling among components Complex, dynamically changing geometry Extremely diverse spatial and temporal scales Complex material properties and physical
processes
Enormous computational capacity required for high-resolution simulation of full burn
Scalability to 1000s of processors essential
CSAR Legacy
Rocstar code Major simulations Fundamental research Impact
CampusState and localNational and international
Human resources Lessons learned
QuickTime™ and aGIF decompressor
are needed to see this picture.
Aft Joint Slot
ForwardJoint Slot
Titan IV Turbulence
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Rocstar Code Suite Nation’s only 3-D integrated simulation capability for solid rocket
motors How did we accomplish this?
Fully-coupled RSRM— fluid temperature and
propellant stressprofiles
Adequate financial resourcesLong time horizonCritical mass of talent across
disciplinesAvailability of massively parallel
platforms
Now in position to solve problems of national interest, and already doing so
Five-segment RSRM for lunar program
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Rocstar Code Suite
Scalable to thousands of processors Applicable to many other problems
Fluid-structure interactionReactive, multiphase flows
ExamplesPyrovalveHelicopter bladesVolcanoesTall buildings
NASABooster Separation Motor
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Major Simulations“Science with the Code”
Full RSRM Titan propellant slumping Turbulence around
flexible inhibitor Aluminum impingement
on nozzle
Al particles impacting nozzle
Flow field near slumping
propellant
Verification, Validation, and Uncertainty Quantification
Verification Convergence studies Comparison with analytical solutions Method of manufactured solutions Comparison between codes
e.g., do Rocflo and Rocflu give similar results for same problem?
Code coverage Coupled codes — verify component
codes first Validation
RSRM (ATK/Thiokol & NASA) Titan IV (Lockheed Martin) 15 and 70 lb BATES (AFRL) Lab scale rocket (NAWC) Attitude Control Motor (Aerojet) Shock tube with thin steel panel
New sampling techniques for UQ
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Navy “StarAft” Motor
Full burnout Tactical motor
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Titan IV Motor
Heavy-lift booster Accident scenario Detailed vorticity
studies
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
NASA RSRM
Late stage in full burn (~100 s)
Flexible inhibitor 3-D vorticity
study
NASA RSRM Burnout simulation
Red is burning propellant; blue is at insulated surface
Viewing Propellant/fluid interface Inhibited surfaces
Unique capabilities High rate “time zooming” Significant burnout — never seen in
industry Case constraints Propellant walkback Inhibitor regression Dynamically changing topology
Initially inhibited
surface
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Fundamental Research inFluids and Combustion
Multiphase flowEquilibrium Eulerian method
for fine particlesLagrangian superparticles
Turbulence modelingOptimal LES
Time zooming Propellant morphology
Parallel packing code
Propellant modeling3-D simulations with Rocfire
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Fundamental Research inStructures and Materials
Constitutive and damage modeling
Heterogeneous propellants and HEMetallic components
Crack propagationBurning, pressure driven
Multiscale materials modeling Molecular-level modeling of
material interfaces Space-time discontinuous
Galerkin methods
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Fundamental Research inComputer Science & Applied Math
Parallel programming environmentsCharm++, AMPI, ParFUM
Parallel I/OPanda
Parallel performance monitoring/modelingRocprof
MeshingMesh smoothing, repair, and
remeshingMesh quality metricsHybrid geometric/topological
partitioner Visualization
Rocketeer
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Fundamental Research inIntegration Methodology
Object-oriented integration framework Flexible parallel orchestration Stable component coupling and time-stepping
Accurate and conservative data transfer based on common refinement
Stable and efficient explicit surface propagation
Fluid DynamicsSolid MechanicsCombustion
Mesh GenerationCAD ModelingPreprocessingIntegrationInterface
Orchestration Solution TransferSurface PropagationMesh ModificationProfilingData FormatsParallel I/OVisualization
Computational Scienceand Engineering
EducationProgram
13 departments
130 faculty associates
130 grad students
10 graduate fellows
ResearchProgram
Computational Science &
Engineering Option
©2007 Board of Trustees of the University of Illinois
Center for Simulation of
Advanced Rockets
Center forProcess
Simulation and Design
DOE funded$4-5 million per year 10 year program20 faculty35 graduate students5 undergrads20 professional staff
NSF funded$6 million over 6 years
12 faculty13 students & postdocs
Midwest Structural SciencesCenter
AFRL funded$5 million over 5 years
10 faculty15 students & postdocs
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Campus Impact CSAR put CSE “on the map” CSAR followed by two additional centers hosted by CSE
Center for Process Simulation and DesignMidwest Structural Sciences Center
CSE seen as “center of centerness” on campus, advising other groups seeking or establishing centers
CSE taken as model in developing other new interdisciplinary programs (e.g., bioinformatics)
CSE’s Turing cluster Established value of large-scale computing facilities
for local usersFinancial commitment from campus administration
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Turing G5 Xserve Cluster
1536 compute processors Dual 2GHz G5 processors
per node 4GB RAM per node Myrinet interconnection
network
6 Xserve head nodes 49TB Xserve RAID
512 and 256 node partitions
23 racks (15 and 8 racks, respectively)
Mac OS 10.4 Server
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
State and Local Impact
Economic development through industrial collaborations
Boeing, Caterpillar
Visibility of simulation promoted through various venues
Recurring appearances in media (TV, newspapers)
RSRM
inhibitor vorticity
Flexible inhibitor
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
National and International Impact Publications (~900 journal articles and proceedings) Conference sessions Industrial collaborations
ATK ThiokolAerojetBoeingCaterpillar
Other government agency funded researchUSAFNASA
Technology transfer to and from NNSA labs Participation in Integrated Product Team for USAF
solid propulsion program
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Pedagogical Impact
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are needed to see this picture.
QuickTime™ and aTIFF (Uncompressed) decompressor
are needed to see this picture.
1st edition, 1997 2nd edition, 2002
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Human Resources
Supported 160 graduate students, about 40 of whom have gone on to DOE labs and many others to positions in government or industry
Recruited and developed 50 research staff members, many of whom have gone on to positions at DOE labs, industry, and academia
Contributed to faculty career development (promotions, awards, etc.), counter to conventional wisdom about collaboration
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
CSAR Students and Staffin DOE/NNSA Labs
Boyana Norris, ANL Michael Parks, SNL Jason Petti, SNL Ali Pinar, LBNL Jason Quenneville, LANL Christopher Siefert, SNL Donald Siegel, SNL Christopher Tomkins, LANL Michael Tonks, LANL Jason Weber, BBL Bradley Wescott, LANL Amanda White, LANL Steven Wojtkiewicz, SNL Jin Yao, LLNL Jack Yoh, LLNL
Former CSAR Staff Now at DOE Labs (5)
Michael Ham, ORNL (LANL) Dennis Parsons, LLNL James Quirk, LANL Mark Short, LANL Jeff Vetter, LLNL (ORNL)
Former CSAR Students Now at DOE Labs (34)
Tyler Alumbaugh, LLNL Balakumar Balasubramanium, LANL Michael Bange, LANL Benjamin Chorpening, SNL Nathan Crane, SNL Zhiqun Deng, PNNL Erik Draeger, LLNL Michelle Duesterhaus, SNL Jeff Grossman, LBNL (LLNL) Arne Gullerud, SNL Thomas Hafenrichter, SNL Rebecca Hartman-Baker, ORNL Jason Hales, SNL Jonghyun Lee, ANL Vanessa Lopez, LBNL Xiaosong Ma, ORNL Greg Mackey, SNL Burkhard Militzer, LLNL Jeffrey Murphy, SNL-L
Gray now in other employment.
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
What Worked Well?
Single, over-arching applicationMaintain focus, avoid mission creep
Pre-existing, interdisciplinary framework independent of individual academic departments
Tight integration of CS with application disciplines
Professional staff in addition to faculty and students
Wealth of thesis-sized research issues for graduate students
Pipeline of students from Illinois to lab employment
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
What Could Have Worked Better?
Collaborations with NNSA labs were numerous, but could have been tighter and more comprehensive
Suggestions for improvementCommon application focus between labs and
universityDeeper commitment to joint activities, such as long-
term visits and joint hiring (e.g., postdocs)Two-way software exchanges
Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign
©2007 Board of Trustees of the University of Illinois
http://www.csar.uiuc.edu
©
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Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign©2007 Board of Trustees of the University of Illinois
Prof. Michael T. Heath, Director
Center for Simulation of Advanced Rockets
University of Illinois at Urbana-Champaign
2270 Digital Computer Laboratory
1304 West Springfield Avenue
Urbana, IL 61801 USA
http://www.csar.uiuc.edu
telephone: 217-333-6268
fax: 217-333-1910