Simulation Driven Design and Additive

Manufacturing applied for Antenna Bracket of

Sentinel 1 Satellite

Innovation Intelligence
Alejandro Cervantes Herrera
cervantes@altair.de

Frankfurt, Nov 26 2014

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Content

Overview
Model preparation
Conceptual optimization
Concept interpretation
Concept design
Detailed optimization
Stress Verification
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The Challenge

Baseline CAD Conceptual Optimization

Design Interpretation

Geometry creation

Manufacturing 1 Note 1: Image courtesy of RUAG Space

Geometry validation Evaluation of design

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Overview: Why we look at the ALM technologies?

Manufacturing technology w.r.t design technology.

Manufacture
Design
?
Complexity

Efficiency
Industrial
BC Medieval 1900s 1950s 2000s 2014
revolution

Time
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The answer

Topology optimization offers the best way to create applications and load-specific
structures, enabling the industry to unlock the enormous lightweight design potential
in combination of a powerful design tool and the use of Additive Manufacturing.

Conceptual Concept Detailed Stress Additive

Model Preparation Optimization Interpretation
Concept Design
Optimization Verification manufacture
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Model preparation

Conceptual Concept Detailed Stress Additive

Model Preparation Optimization Interpretation
Concept Design
Optimization Verification manufacture

Understand where to start

Generation of Design Space
Multiple load case creation and
handling

Baseline Design Space Envelope

Hexahedral Elements
Design Space
Total Elements = 236004
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Conceptual Optimization

Conceptual Concept Detailed Stress Additive

Model Preparation Optimization Interpretation
Concept Design
Optimization Verification manufacture

OptiStruct topology optimization:

Finite element discretization of the design space
Function between density and elasticity using penalty factor p

Density = 1

Density = 0

E/E0
1

1 r/r0
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Conceptual Optimization

Conceptual Concept Detailed Stress Additive

Model Preparation Optimization Interpretation
Concept Design
Optimization Verification Manufacture

Optimization problem formulation:

Objective: Minimize Mass OR Compliance
Constrains: Volfrac 20%, 10% 7.5% / Stress (110MPa) / 1st mode > 70 Hz
Variables: Element densities

Goals of multiple runs:

1. Understand tendency of the
optimization
2. Which are the primary and
secondary load paths
3. Numerical noise?
4. Explore different designs
5. Observe similarities
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Conceptual Design

Conceptual Concept Detailed Stress Additive

Model Preparation Optimization Interpretation
Concept Design
Optimization Verification Manufacture

Obtained topology must be realized into a proper CAD design

Apply design principles and interpret results
Understand results from optimization
Cross sections geometries depending on structural behavior
Apply design principles to generate an organic design

Understand and apply design principles from AM

Printing orientation
Overhang angle consideration
Heat dissipation and stress concentration

Pictures Courtesy: EOS GmbH

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Conceptual Design

Conceptual Concept Detailed Stress Additive

Model Preparation Optimization Interpretation
Concept Design
Optimization Verification Manufacture

Concept
freeze

Traditional CAD tools does not provide sufficient power to maximize the benefits of AM
High level of freedom is required
Surface modelling tools
Evolve (Altair software for industrial design) allows designer to unleash creativity in a reduced
time.

Standard formats:
Parasolid
STEP
IGES
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Detailed Optimization

Conceptual Concept Detailed Stress Additive

Model Preparation Optimization Interpretation
Concept Design
Optimization Verification Manufacture

Secondary Topology iterations are carried out to evaluate

and tweak the Interpreted model from Loop1.
Many sections highligted proved to be redundant after
incorporating mounting platform for antenna. Findings
from Loop2 Topology iterations to be implemented in the
new CAD
Cross member could be
discarded

Iso-Plot: Material density 0.3

Shear web could be replaced

with cross members
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Final Optimized CAD Model:

Conceptual Concept Detailed Stress Additive

Model Preparation Optimization Interpretation
Concept Design
Optimization Verification Manufacture

Second order mesh for precise results:

First Frequency in 91.44 Hz

Stress distribution is below 110 MPa
Loadcase Title First Buckling LoadFactor
U_LC1 18.2
U_LC2 18.3 The buckling loadfactors
U_LC3 46.1 are all above 1.2
U_LC4 45.9
U_LC5 46.1
U_LC6 45.9
U_LC7 18.2
U_LC8 18.3
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Final Optimized CAD Model:

Conceptual Concept Detailed Stress Additive

Model Preparation Optimization Interpretation
Concept Design
Optimization Verification Manufacture

Final CAD model:

Final Weight: 0.936 Kgs

1st Frequency = 91.44 Hz
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Summary

This activity emanated in a systematic evolution of a Load driven Design

concept while still incorporating Engineering design rules in less than 4 weeks.
The concept is interpreted into 3D CAD model and resulting *.stl / parasolid files
are verified and given as STL formats for Additive Manufacturing.

The Final weight of the bracket is 0.936 kg with the first frequency of 91.44 Hz.
Original weight was of 1.626 kg

The Final CAD is validated for its static behaviour and its strength, stiffness and
stability parameters are documented. All the design criteria's are satisfied.

The first prototype is printed and will be tested for qualification. (See appendix)
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Next steps

Short term: Manufacturing and post-processing (Images courtesy of

EOS GmbH).

Mid term: Test campaign to be performed by RUAG Space.

Long term: Possible flight on next Sentinel 1 Satellite after successful

qualification (?)
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Conclusions

Process efficiency
Reduced time for realizing AM design
The technology available in HyperWorks
Ready to be used
Partnership
Engineering Know-how
Software Know-how

Thank you for the great collaboration

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Questions / Comments

Thank you