Injector Propellant Trajectory Simulation

I am working on developing a 300-lbf thruster, and to design the injection system, I spent much of my free time reading and learning about injector and fluid atomization over summer. To assist in the development of the project, I wanted to create a way to visualize the effectiveness of different injector iteration.

My goal for the program is to allow for a wide range of basic input parameters (propellant types, mass flow, engine chamber pressure, O/F ratio, etc) to create an impinging injector design. Then, using the design, run a simulation tracking the trajectories of the desired propellants exiting orifices into the combustion chamber. All of the propellant jet paths are plotted in 3D to let the user maneuver to, and investigate, different regions of interest.

I wanted this to be a rapid-use tool to both solve for dimensions I need for a CAD and to provide basic verification of performance. While this is no replacement for CFD software, those programs would require updating a CAD model with new dimensions and rerunning simulations after every design iteration. The usefulness of my modeling system is to reduce the number of times the injector needs to be tested in a CFD software by providing simple simulations to quicken early development.

Moving around the 3D simulation graph to examine different trajectory patterns.

Mass flow - 2.2 lb/s

Chamber pressure - 180 psi

# Oxidizer orifices - 6

Film cooling percent - 18%

*More parameters are required than those shown.

The simulation was written in Python using several libraries including ‘matplotlib’ for graphing and ‘pint’ for dimension manipulation.

The physics modeling primarily deals with simplified ‘liquid jet in gaseous crossflow’, but future improvements like the inclusion of free-jet expansion and jet-jet interactions will improve the usefulness of the program. The break-up and atomization mechanism for the liquid jets are based on experimental models with applicable relation to what I am trying to simulate. More detailed simulation is in constant development.

The state of the fluid jet is shown by the jet cross-sectional outline, where solid represents liquid jets and dotted represents either gaseous or atomized liquid.

Different inputs lead to different simulation plots

Mass flow - 1 lb/s

Chamber pressure - 200 psi

# Oxidizer orifices - 5

Film cooling percent - 13%

Central oxidizer injector orifices are surrounded by several fuel orifices, denoted in red and blue, respectively. The green jets along the outside of the injector face are the film cooling jets. The black outlines the injector.

Mass flow - 5 lb/s

Chamber pressure - 240 psi

# Oxidizer orifices - 8

Film cooling percent - 18%

Mass flow - 8 lb/s

Chamber pressure - 200 psi

# Oxidizer orifices - 9

Film cooling percent - 10%