Simulation Driven Design and Additive Manufacturing applied for Antenna Bracket of Sentinel 1 Satellite

Transcription

1 Simulation Driven Design and Manufacturing applied for Antenna Bracket of Sentinel 1 Satellite Innovation Intelligence Alejandro Cervantes Herrera cervantes@altair.de Frankfurt, Nov

2 Content Overview Model preparation ual optimization interpretation design optimization

3 The Challenge Baseline CAD ual Design + Geometry creation Manufacturing 1 Geometry validation Evaluation of design Note 1: Image courtesy of RUAG Space

4 Complexity Efficiency Copyright 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Overview: Why we look at the ALM technologies? Manufacturing technology w.r.t design technology. Manufacture Design? BC Medieval Industrial revolution 1900 s 1950 s 2000 s 2014 Time

5 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 Manufacturing. ual Design manufacture

6 Model preparation ual Design manufacture Understand where to start Generation of Design Space Multiple load case creation and handling Baseline Design Space Envelope Design Space Hexahedral Elements Total Elements =

7 ual ual Design 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/E r/r 0

8 ual ual Design Manufacture problem formulation: Objective: Minimize Mass OR Compliance Constrains: Volfrac 20%, 10% 7.5% / (110MPa) / 1 st 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

9 ual Design ual Design 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

10 ual Design ual Design Manufacture 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

11 Copyright 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. ual Design 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

12 Copyright 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Final Optimized CAD Model: ual Design Manufacture Second order mesh for precise results: First Frequency in Hz Loadcase Title First Buckling LoadFactor U_LC U_LC U_LC U_LC U_LC U_LC U_LC U_LC distribution is below 110 MPa The buckling loadfactors are all above 1.2

13 Copyright 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Final Optimized CAD Model: ual Design Manufacture Final CAD model: Final Weight: Kgs 1st Frequency = Hz

14 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 Manufacturing. The Final weight of the bracket is kg with the first frequency of Hz. Original weight was of 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)

15 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 (?)

16 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

17 Questions / Comments Thank you