Mass reduction of a conceptual microsatellite aluminum structure via employing perforation patterns
Mass reduction is a primary design goal pursued in satellite structural design, since the launch cost is proportional to their total mass. The most common mass reduction method currently employed is to introduce honeycomb structures, with space qualified composite materials as facing materials, i...
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| Format: | Thesis |
| Language: | English |
| Published: |
2022
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| Subjects: | |
| Online Access: | http://psasir.upm.edu.my/id/eprint/114885/1/114885.pdf http://psasir.upm.edu.my/id/eprint/114885/ http://ethesis.upm.edu.my/id/eprint/18199 |
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| Summary: | Mass reduction is a primary design goal pursued in satellite structural design,
since the launch cost is proportional to their total mass. The most common mass
reduction method currently employed is to introduce honeycomb structures, with
space qualified composite materials as facing materials, into the structural
design, especially for satellites with larger masses. However, efficient
implementation of these materials requires significant expertise in their design,
analysis, and fabrication processes; moreover, the material procurement costs
are high, therefore increasing the overall program costs. Thus, the current work
proposes a low-cost alternative approach through the design and
implementation of geometrically-shaped, parametrically-defined metal
perforation patterns, fabricated by standard processes. Four geometric shapes
(diamonds, hexagons, squares, and triangles) were designed parametrically,
and hence implemented onto several components of a structural design for a
conceptual sub-100 kg microsatellite. Subsequently, a parametric design space
was defined by developing two scale factor and also two aspect ratio variations
on the four baseline shape designs. The change in the structure’s fundamental
natural frequency, as a result of implementing each pattern shape and
parameter variation, was the selection criterion, due to its importance during the
launcher selection process. The best pattern from among the four alternatives
was selected, after having validated the computational methodology. This
validation was achieved through implementing experimental modal analysis on
a scaled-down physical model of a primary load-bearing component of the
structural design. The selected pattern design was hence refined iteratively, to
yield the same value of fundamental natural frequency, but with significant mass
reduction. From the findings, a significant mass reduction percentage of 23.15%,
from 84.48 kg to 62.42 kg, utilizing the proposed perforation concept, was
achieved in the final parametric design iteration. This reduction was relative to
the baseline unperforated case, while maintaining the same fundamental natural
frequency. Dynamic loading analyses were also performed, namely, quasi static, random, and shock loading analyses, utilizing both the baseline and the
finalized perforated designs. These analyses investigated the contrast in the
capabilities of the two design to withstand the nominal dynamic launch loads.
The findings showed that the final perforated design did have the capacity to
withstand the launch loads without yield failure, as indicated by the computed
positive yield margins of safety for each loading type. With these encouraging
outcomes, the perforated design concept proved that it could provide an
opportunity to develop low-cost satellite structural designs with reduced mass,
and with reasonably good structural performance. |
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