FEMAP Use in Mechanical Analysis for Design and

Test of GEOStar Satellites and Subcomponents

Andrew Sayles / Thomas McQuigg

Orbital ATK Space Systems Group, Mechanical Analysis and Test

4/14/2015

Orbital ATK Proprietary 1

Agenda

Introduction
Orbital ATK Space Systems Group (SSG)
SSG Mechanical Analysis and Test
GEOStar Communication Satellites
Science Satellites
ISS Commercial Resupply Service
Primer on Satellite Design Requirements
FEMAP for Satellite Modeling

Example GEOStar Analysis with FEMAP:

1. Detailed Hold Down Release Mechanism
2. Specialized Mesh Approach in a Corrugated
Wave Tube Assembly Model
3. Component Level Test Model Correlation for
Test Prediction
4. Structural Test and Strain Prediction for Large
Scale Structures

Orbital ATK Proprietary 2

A Combination of Two Industry Leaders

Merger of Orbital and ATK was completed in February 2015

Orbital ATK Proprietary 3

A New Global Space and Defense Leader

Dulles campus is prime facility for Geosynchronous satellite manufacturing

Orbital ATK Proprietary 4

Over 800 Space Missions Since 1982*

78 Commercial Satellites 77 Government Satellites 40 Space Payloads

78 Space Launch Vehicles 202 Interceptor & Target Vehicles 346 Sounding Rockets

Orbital ATK Proprietary *April 1982-July 2014 5

Premier Aerospace and Defense Customers

Orbital ATK Proprietary 6

Extensive Human and Physical Resources

Over 13,000 Employees Dedicated

to Aerospace and Defense Business
4,300 Engineers and Scientists
7,400 Manufacturing and
Operations Specialists
1,400 Management and
Administration Personnel

Facilities in 17 States With 19.6

Million Sq. Ft. of R&D,
Manufacturing, Test, Operations and
Office Space
6.1 Million Sq. Ft. Owned
5.4 Million Sq. Ft. Leased
8.1 Million Sq. Ft. U.S.
Government Owned

Orbital ATK Proprietary 7

Orbital ATK Space Systems Group

SSG Mechanical Analysis/Test Working Out of Dulles, VA

Focuses on Satellites and Space Systems Areas of Our
Business
Commercial Satellites
Science Satellites
Commercial Resupply Mission (Cygnus Service
Module)
National Security Satellites

Orbital ATK Proprietary 8

GEOStar Satellite Bus:
Modular Design Tailored to Customer Needs

Emergence of GEOStar3 Product in 2014

5.0 kW

Orbital ATK Proprietary 9

 Satellite Design:
Requirements and
Environments

10

Orbital Proprietary and Confidential

 Sources of Mechanical Design Requirements

Structural requirements are derived based on multiple phases of the satellite mission
Manufacture and Assembly
Transport and Handling
Testing
Launch and Ascent
On-orbit Mission Operations satisfies business needs of customer
Re-entry and landing (if applicable)

Antares Launch of Cyngus

Vehicle at Wallops Island
GEOStar2 Sine Vibration Test

Orbital ATK Proprietary 11

Satellite Environments

Multiple environments must be considered during analysis:

Quasi-static (launch vehicle engine thrust and ascent)
Dynamic
Random/Acoustic (LV engine, aerodynamic loading, energy reflection in fairing)
Sine vibration (LV engine)
Shock (separation from LV, deployment of appendages)
Thermal (on-orbit loading)

Cygnus Vehicle preparing for Acoustic Testing

Orbital ATK Proprietary 12

 FEMAP in Multi-Phase
Satellite Design-Analysis
Life Cycle

13

Orbital Proprietary and Confidential

 Illustrated Overview of the Satellite Structure
Design Life Cycle
(3) (2)
(1)

1. CAD Geometry Design Generation

2. Finite Element Model Generation
(4) 3. Modal Analysis
4. Dynamic Analysis for LV Environments
5. Design Load Case Generation
6. Stress Analysis (Dyn/QS/Thermal)
7. Margin of Safety Reporting and Design Iteration
8. Testing Verification and Validation
9. Completed Design for System Level Testing and
Launch
(8)
(7)
(5) (6) (9)

Orbital ATK Proprietary 14

Analysis Types and Requirements:
Modal
Example Deformed Shape First Bending
Free boundary conditions used to
assess separation of elastic modes

Fixed-base modal analysis

characterizes dynamic behavior
Evaluates compliance of S/C with LV
requirements
Component frequency requirements
are based on separation from support
structure/vehicle modes
AMZ-4A As-Run Z Axis Protoflight Input Notch

1
S/C Primary Mode separation from
launch vehicle modes is key for
reducing loads generated by coupling
Input (g)

between the two vehicles

0.1

0.01
10 Frequency (Hz) 100
AMZ-4A Protoflight Input Envelope Ariane 5 MUA Protoflight AMZ-4A Z Axis Protoflight Predicted
CLA Interface SRS and As-Run Spacecraft Sine Test
AMZ-4A As-Run Z Axis Manual
Longitudinal Input
AMZ-4A As-Run Z Axis Protoflight
Notched Input
Ariane FCLA Z SRS Envelope
Protoflight Input Control channel Scaled to Protoflight (Q=20) 15
Ariane FCLA Minima Scaled to Protoflight acc_op1s111s_Z_AMP acc_op1s121s_Z_AMP
Analysis Types and Requirements:
Dynamic

Dynamic modal characteristics are evident in various types of dynamic environments

Sinusoidal vibration oscillating load with a specific frequency
Random vibration amplitude and frequency of load are random in nature
Acoustic excitation defined by sound pressure level at a given frequency and somewhat
random in nature
Shock Input short duration high frequency acceleration event and rapid attenuation
Dynamic loads are typically a source for derivation of design loads
Pre-test/flight predictions used to derive loads for stress analysis

Sine Vibration Test Prediction Transfer Function Acoustic Vibration Test Response

Orbital ATK Proprietary 16

Analysis Types and Requirements
Quasi-Static Quasi-Static Accelerations (Flight) for Launch Vehicle

Loads that do not vary in time or 6

5
magnitude 4

Point loads (specific application) 3

P
S

Axial Acceleration (g)

2
Body loads (gravitational, LV 1
A

acceleration) 0
S

Boundary Displacement (applied or -1 S

-2
global-local approach) -3
H

-4 S
E
-5
Loads are governed by specific -6 Negative a
Positive ac
Launch Vehicle or on-orbit mission -7
-3 -2 -1 0 1 2 3
requirements Lateral Acceleration (g)

Launch Vehicle QS Load

Factor Envelope

Panel Facesheet Failure

Index Contour Plot
Orbital ATK Proprietary 17
Analysis Types and Requirements
Thermoelastic

Temperature loads derived from Thermal Group

analysis or design requirement
Apply temperatures to finite element mesh as
nodal loads
Multiple loading conditions and combinations
often considered to identify worst case condition

Conduction is used to derive nodal loads when

detailed temperature gradients are not available

Distortion analysis is used to find resulting

displacements (horn pointing, clearance)
Coupled with vendor distortion analysis of reflector
surface this feeds into the antennas accuracy and
performance

Strength analysis is used to validate structure design

Common problem is material CTE mismatch

Spacecraft Temperature Contour and Deformed

Shape Shown in On-Orbit Deployed Configuration

Orbital ATK Proprietary 18

 FEMAP Models of
Orbital ATK Satellites

19

Orbital Proprietary and Confidential

FEMAPs Role in Satellite Design

Efficiency in model creation and model management is key to producing analyses

that support the programs schedule

CAD FEM Launch

Orbital ATK Proprietary 20

CAD to FEM - Overview

Antenna support structure are comprised of

Composite panels
Metallic brackets,
Mechanical fasteners
Bonded clips
Other specialized features that support mission concept of operations

Orbital ATK Proprietary 21

CAD to FEM Subcomponent CAD Geometry
Preparation

Solid objects are decomposed into basic shapes which are then used for meshing

Remove filets Create midsurfaces

Orbital ATK Proprietary 22

CAD to FEM Subcomponent CAD Geometry
Preparation

More complex shapes can be

efficiently decomposed using
FEMAPs Meshing Toolbox

Orbital ATK Proprietary 23

CAD to FEM Mesh Connectivity

Subcomponents are then integrated using single DOF elements to model interfaces,
for which FEMAP Custom Tools are very useful

Orbital ATK Proprietary 24

CAD to FEM On-Spacecraft FEM

Integrate model to spacecraft

Verify the design loads and complete

integrated analysis

Orbital ATK Proprietary 25

 Modeling Example 1:
Reflector Retention and
Release Mechanism

26

Orbital Proprietary and Confidential

Example 1: Deployment Introduction

GEOStar spacecraft travel to orbit in a stowed position.

Loads induced from launch driven stowed design loads

Once on-orbit, solar arrays, reflectors and other structures are

deployed

Deployment mechanisms must function reliably, since there is

no second chance for on-orbit failure CAD

Stowed Deployed

FEM
Orbital ATK Proprietary 27
Example 1: Model Summary

Internal assembly bolted are modeled with preload Spring

Retainer Cup

Contact with friction defined at cup/cone interface as

well as others Cone

Reflector interface loads are derived from on-

spacecraft analysis considering acoustic and sine
loading from launch vehicle environment

Interface loads are applied for detailed stress analysis

Mounting
Flange

ERM
Housing

Detailed Solid
Mesh of Cup
Orbital ATK Proprietary 28
 Modeling Example 2:
Specialized Meshing Approach
of Corrugated Waveguide

29

Orbital Proprietary and Confidential

Example 2: Corrugated Tube
Problem Statement

Process forms tube from nominal (straight) into desired shape (bend in corrugations)
Forming process changes angle of corrugations
Geometry was not available for formed shape
Detailed stress analysis was required for formed configuration
Generating consistent mesh that accurately represented the formed shape in expanded and
compressed corrugations proved difficult

Unformed Shape
Corrugation Expanded

Formed Shape
Corrugation Compressed

Orbital ATK Proprietary 30

Example 2: Corrugated Tube
Meshing Approach

Unit rotation was applied to sections of mesh, constrained with RBE2 rigid elements
and SPC
Custom Tool command Nodes move by Deform under Post Processing toolbar
Corrugations were compressed and expanded as observed in manufactured shape

Formed Shape Mesh Fidelity

Isometric View of Unformed Shape Unformed Shape (Actual Deformation)

SPC

SPC and Rotation

Orbital ATK Proprietary 31

Example 2: Corrugated Tube
Analysis and Results

Dynamic response and stress analysis performed on assembly

Modal and random test responses correlated very well with numerical predictions

Detailed Stress Analysis Contour - Random Modal Deformed Animation

Area of Peak Stress

Orbital ATK Proprietary 32

 Modeling Example 3: Model-
Test Correlation of an
Electronics Assembly

33

Orbital Proprietary and Confidential

Example 3: Electronics Assembly

Electronics assembly required dynamic assessment and stress analysis

Mass = 100 lbm
Model uses plates, solids, and concentrated mass elements for large chips
FEMAP Layering, grouping features enabled efficient model management

Solid Model Detailed Finite Element Model

Orbital ATK Proprietary 34

Example 3: Electronics Assembly

Analytically predicted first major mode nearly identical to test

Modal and random test responses correlated very well with numerical predictions

Deformed Modal Shape First Mode Transfer Function Comparison of Prediction and Test Response
For Random

First Mode

Orbital ATK Proprietary 35

 Modeling Example 4:
GEOStar Primary
Structure Static Load Test

36

Orbital Proprietary and Confidential

Example 4: GEOStar Primary Structure Static
Load Test Introduction

Primary structure static load used to verify workmanship and design loads

Forces are applied to structure to simulate various loading conditions

Finite Element Model Test Plan Article Test

Orbital ATK Proprietary 37

Example 4: GEOStar Primary Structure Static
Load Test Analysis Results

Attach NASTRAN .OP2 files to large spacecraft primary structure FEMAP models
Use of global plies is ideal for core shear stress plot generation for a panel and load
case envelope when composite panels have multiple layups/ply counts associated
with them
Import analysis results function is easily used to import .CSV raw analysis results
generated using other in-house analytical tools (spreadsheets or MATLAB Scripts)

Safety Margin Criteria Plot

Honeycomb Shear Stress Contour Plot
Orbital ATK Proprietary 38
Example 4: GEOStar Primary Structure Static
Load Test Strain Predictions

Strain gages placed at areas of interest on the structure

Finite Element Model predictions are used as justification to continue with test

FEMAP enables efficient composite element processing

Test Instrumentation Plan

Orbital ATK Proprietary
Strain Field and Gage Placement 39
 Thanks for your Attention!
Any Questions?

Orbital ATK Proprietary 40