Aerothermal Performance of an Open Source Methane-Fueled Rocket Engine

Paper in proceeding, 2025

This study investigates the feasibility of integrating all relevant physics into a single simulation of a rocket engine nozzle, including the supercritical coolant, the supersonic reacting flame, along with the heat transfer between them. Traditionally, multiple simulations coupled with a thermal boundary condition would be utilized, which is time-consuming as it requires manually iterating between the simulations. A holistic simulation approach within one simulation was therefore developed. By comparing two CFD codes, STAR-CCM+ and Fluent, their suitability for this holistic simulation approach was evaluated based on accuracy, time consumption, and the required amount of manual input needed to complete a holistic simulation. The methodology involved setting up comprehensive models in both CFD codes, ensuring that all relevant physical phenomena were accurately represented. The simulations were run under identical conditions to ensure a fair comparison. The results indicated that both codes produced outputs consistent with previous studies and with each other, validating the holistic approach. However, STAR-CCM+ demonstrated greater efficiency, making it more suitable for practical applications. These findings suggest that a single, integrated simulation approach can significantly streamline the design and analysis process for rocket engine nozzles, potentially leading to more efficient and cost-effective development cycles.