FEMAP at

Airbus Defence & Space, Portsmouth

Graham Dew

Team Leader, Stress & Thermal

Airbus DS Market Share*:

Commercial satellite launches: 50% of the market with Ariane

Earth observation satellites: 40-50% of the international market. #1 Exporter of Earth observation satellites

Telecommunication satellites: 25% of the market. Only supplier to deliver to all seven major telecom operators

We successfully aim for the stars.

25% – #1 in 2015!

40 – 50%

* Source: Internal analysis, average sales volume over several years

50%

market share

A RENDEZ-VOUZ IN DEEP SPACE:

Making the impossible possible.

10 years, 6.4 billion kilometres: First-ever mission to orbit a comet racing along at more than 10 km/s – and sending a small lander to its surface!

Rosetta

READY FOR HUMAN SPACE FLIGHT

beyond low earth orbit.

The first-ever mission-critical element of a NASA mission, produced by a non-US company.

Orion’s European

Service Module

MORE CAPACITY WITHOUT COSTS

going into orbit.

The benchmark for in-orbit lifetime of telecommunication satellites – now also available as an all-electric variant.

Eurostar E3000/E3000e

FEMAP at Airbus Defence & Space, UK

In production use since 2007

• Replacement for I-Deas & Patran

Current License Inventory:

• 50 FEMAP Base

• 3 FEMAP Thermal Analysis

• 1 FEMAP Advanced Thermal Analysis

• 1 FEMAP Flow

• 1 FEMAP Structural Toolkit

• 1 NX Nastran Analysis

• 1 NX Nastran Nonlinear

• 1 NX Nastran Dynamics

In Portsmouth 10 Users (peak 16 in 2015)

CAD and CAE Environment

Very mixed environment

• Catia V5

– CAD authoring

• VPM

– Hierachical product manager for CATIA

• MDODB

– Collate and control all MDO activities and report to other groups

• Windchill

– PDM system

• FEMAP

• QWANTA2

– automatic waveguide mesher

• MSC Nastran

• SA Toolkit

– Nastran Post Processor

• Isight

– Analysis process control

• CBP

– Common Business Portal for transfer of data with manufacturers

• IPS

• Integrated Planning System – for Integration, Assembly and Test

• Other internal tools, DBs, schedules etc

Complexity

– the Challenge

Bandwidth

Power

Payload Density

Temperatures

Mechanical Support

+

Complexity

– the Challenge

Complexity

Schedule

More Analysis reqd

Faster Analysis

+

Random vibration analysis

Loads

• 10-2000 Hz frequency range

• First Mode > 140Hz

• Simple PSD loading

Outputs

• Frequencies

• Component Stresses

• Insert reaction forces

Random Vibration Analysis

Post-Processed in SA Toolkit

Nastran Normal Modes solve

• MAYA supplied DMAP

• 3σ Von Mises Stress Output

• Uses Segalman method

• Fast, simple set-up

Mechanical Solutions typically

• Additional support if feasible

• Move flexible element where appropriate

• Specify high temper material

Thermal Analysis – Using TMG

Conduction and Radiation analysis

Heating arises from ‘Insertion Loss’

• Limited by Solder, paint and plating temperature limits for WG

• Adhesive softening for inserts

Thermal Solution achieved by-

• Waveguide Finish & Manufacture

• Improved conduction

– Additional conductive brackets

– Thermal Straps

• Improved Radiation

– Radiative Fins

– Change of paint

Thermoelastic Analysis

One model for thermal and structural

• Thermal profile generated by TMG Model

• Thermoelastic solution in Nastran

Key Issues –

• Insert forces

• Waveguide stresses

Solutions achieved by -

• Increased bend radii

• Introduction of additional bends into WG path

TMG – Solar Radiation Calculation

Used for all external components

• Diurnal & Seasonal calculations

Used Occasionally for Payloads & Equipments

• Most components are enclosed by S/C

• MLI protection

Equipments

The Payload Equipment Group produce many discrete RF equipments for telecom satellites

• LNA

• SSPA

• Beacon

• Digital Processor

• DownConvertor

2012

1186 WG

Growth In Analysis Demand

Analysed

Similarity

Guidelines

Growth In Analysis Demand

Analysed

Similarity

Guidelines

2012

1186 WG

2015

2501 WG

25 May 2016

Waveguide Meshing – QWANTA2

Internally developed waveguide mesher

• Works directly from Catia model

• Tubing meshed directly

• Features (flanges, clamps, etc) read from

library of pre-meshed parts

• Mesh automatically generated by MDODB on

completion of CAD model

• Different mesh densities available

Random Vibration Analysis Process - 2006

Fully manual process

Post process

execs + Excel

Solve

Dynamic

Response in

Nastran

Post process

execs

Solve Normal

Modes in

Nastran

Mesh in I-

Deas

Import CAD

from CATIA

40 hours

Random Vibration Analysis Process - 2016

CAD verified

in MDODB

Generate

CAD in

CATIA V5

Automated

meshing

QWANTA2

Results

Summary

Macro

TED if

required

NASTRAN

Random

Vibration

Analysis SA

Toolkit

Isight

Solve Normal

Modes in

Nastran

Mesh

cleaning in

FEMAP

3 Hours

The things we like about FEMAP – and some we don’t!

TMG within FEMAP is

helped by easy

creation of groups

and good

visualisation of results

Best thing about

FEMAP is how it

works with TMG

ESATAN

convertor is not

useable

Good visualization

in post processing

Difficult to create

free body loads

from output

Can’t find display

of coordinate of CG

A simplified ‘Create

nodes on lines’, by

simply selecting lines

and entering number of

nodes to be created.

Meshing works

very well

especially with the

meshing tool box

Geometry editing

features are very

good

Reviewing and editing

a model is easy with

the help of highlighter

in Model Info tree

“Extend” option for

extending the curves on

to the surface – for

multiple curves please

“Extend” option for

extending the curves on

to the surface – for

multiple curves please Constraints on

Geometry are not

always transferred

onto nodes

It would be

useful to see

which groups an

element belongs

to

A vector showing

the measured

distance

Simply convert

FEMAP surfaces

to STEP

FEMAP Programming

is brilliant!

New Challenges

Rapidly Changing Market

• New customers

– GAFA, OneWeb

• New competitors

– Space-X, Blue Origin

• Alternative technology

– HAPS, Project Loon

A LAUNCHER WITH A 30-YEAR TRACK RECORD

that is also brand new.

The successor to the record-breaking Ariane 5 will allow Europe to continue reaching for the stars.

Ariane 6

Alternative Technologies

Airbus Defence & Space Zephyr8 HAPS

New Challenges

What might this mean for Analysis?

• Reduced time and costs – Faster, Smarter

– Automatic batch analysis

– Simulation Lifecycle Management

• New technologies

– Topology Optimisation for ALM components

• Big Data – machine learning

– Leveraging existing analysis data for

predictive design support

– Reduced iteration