FEM Analysis of Satellite Hardware for Design Optimization and Cost Reduction

FEM modelling plays an indispensable role in space engineering. Models for the space industry can be divided into two main groups:

• Models that support satellite design

• Models required for payload integration
  

In the case of design support, one of the main benefits is the significant reduction in testing resources, as the entire test flow can be simulated using a mathematical model. As a result, only the final, virtually verified, and optimized design is physically manufactured and subjected to real-world testing. It is also possible to simulate how target parameters change depending on selected inputs. In the presented model, the adhesive contact between selected parts of the structure had a direct influence on the natural frequencies. The relationship between adhesive contact and natural frequencies was therefore determined – a critical factor not only for satellite design but also for its integration into the launch vehicle. This is because the natural frequencies of the deployed payload must remain within the frequency band defined by the integrator.

Additionally, the forces acting on structural fasteners during harmonic excitation were monitored to prevent excessive stress and potential failure during qualification testing. Finally, stress distribution on critical structural elements – which could significantly impact the device’s functionality – was evaluated during the simulated vibration tests.

Note: To protect the client's design, the attached illustrations are shown using the geometry of a 1U CubeSat from the COMSOL Multiphysics application library. The calculated natural frequency is presented as a percentage deviation.