N32.

CubeSat Frame Analysis

N32.
Mechanical Design of CubeSat Frame

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▐ Introduction of CubeSat
Cubesat is a cubic shaped small satellite which has a dimension of 10X10X10cm for 1
unit. 10X10X30 cm are called 3 Units or 3U. Studies of cubesat started in 2001.
Currently most engineering university studied their own subsystem development
research on multiunit Cubesat system.

Figure 1 CubeSat Frame Chassis

There will be huge cost and risk for designing the space structure. However, CubeSat
studies were mostly done by university and even personal level. Thus, many studies
regarding the CubeSat chassis are performed by FEM based analysis. Recently, 3U is
the most widely used multi-unit form of the CubeSat. Especially in estimation of natural
frequencies and mode shapes, and its stress level during launch period, its temperature
distribution at the space environment and thermal stress distribution of the satellite
governing form the temperature distribution are basic requirement of structural
assessment. In this workshop, the simple basic CubeSat model (1U) and more realistic
CubeSat (3U) are used to estimate its structural characteristics under space
environment.

▐ Finite element model

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There two types of FE models were used for structural assessment under launch and
space environment. A 1U CubeSat model is shown below. It is designed from CAD
program and provided in working folder. The two types (Al7075 and Al6061) of
aluminums were used to manufacture this model.

Figure 2 FE model of 1U CubeSat Frame Design

Figure 3 FE model of Realistic 3U CubeSat Frame Design

Structural Analysis Type for CubeSat

 ANALYSIS A : Modal Analysis

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 ANALYSIS B : Quasi-Static Launch Analysis

 ANALYSIS C : Heat transfer Analysis

 ANALYSIS D : Thermal stress analysis

The first dominant Natural frequency of the CubeSat must be higher than 100 Hz which
is the environment frequency during the launching phase. Also, CubeSat frame should
be endure during the high acceleration period of launch, which is 12g in upward and 6g
in side way. In this environment, max stress occurred in the frame must be less than
yield strength of the material. Additionally, the CubeSat systems must maintain its
structural integrity under harsh space environment such as radiation from the Sun,
albedo reflecting form the Earth, and infrared energy emitting from the Earth. So, the
heat transfer analysis needs to be done considering these worst environment cases.
Sequentially coupled thermal stress analysis has to be performed using the output of
the heat transfer analysis to evaluate the thermos-stress distribution on the frame. Those
are the primary analysis to assess the structural integrity of CubeSat frame.

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Analysis A: Modal Analysis

MODULE Part 
The 1U geometry model was created by using CAD program. Basically, it’s a simplified
form of the 1U CubeSat model. The CubeSat structure consists of various components
and joints, rather than a single part, as well as panels and additional weight elements
for subsystem mounting. The provided 1U model is just single body model for the
training purpose. 3U model similar to the realistic shape will be introduced later.
Specific modeling techniques of the 3U model are described later for reader’s reference.
The unit system of this model is MKS system.

 File→ Import→ Part→ Select 1U CubeSat frame.sat

MODULE Mesh 
The part geometry requires additional partitioning to apply the brick element. In this
example, simply 2mm TET elements are applied.

 Model Tree→Part | Mesh | double click→Seed | Part | 0.002→Apply

 Mesh→ Control | select whole part→Tet→OK

 Mesh→Element type→Standard | 3D Stress | C3D10→ OK

 Mesh→ Part→ Yes

 Query→Mesh→Done (check total number of elements 82k)

MODULE Property 
The CubeSat consists of two sections (panel and support column), each with Al6061
and Al7075 materials. Since Heat transfer analysis is required to be performed, both
thermal and mechanical properties need to be created. It is recommended that creating
a set of columns and panels in advance makes the process easy.

 Material→ Create, name=Al6061→Thermal | General | Mechanical, input properties

(see below table)

* Repeat for Al6061 and Al7075 Material

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Material Al6061 Al7075

Conductivity 130 135
Density 2850 2780
Elastic 72e9, 0.33 80e9, 0.33
Expansion 2.52e-5 2.52e-5
Specific Heat 960 965

 Section→ Create, name=panel | Solid, Homogeneous → OK

* Repeat for column

 Assign→ Section | select panel → Select Panel(set)→ Done

Figure 4 Material Section Assignment

MODULE Assembly 
Since it is a single body, create an instance.
 Instance→ Create→ select part→OK

MODULE Step 
This example performs four analysis. First, create an analysis step to estimate the
natural frequency analysis. The frame’s natural frequency should not be less than 35
Hz and avoid 100 Hz.

 Step→ Create→ Linear Perturbation | Frequency→ Lanczos | Value=5 | Defaults for

others→ OK

MODULE Interaction 

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Simply simulate the weight of the subsystem inside the frame and add 1 kg of mass
inertia to the center point. This RP connects to both sides of the frame using kinematic
coupling constraints.

 Tools→Datum→ Create→ Point | Midway between two points→ create center point

datum
 Tools→ Reference point→ pick datum point at center

 Constraint→Create→Coupling→ control point=RP-1, constraint region=surface,

select both surfaces

 Special→ Inertia→Create→point mass→select RP-1, mass=1

Figure 5 Add mass inertia for subsystem weight

MODULE Load 
Fixes four support surfaces mounted inside the pod to launch the CubeSat.
 BC→Create→Mechanical→Select 4 mounting Surfaces→Encastre→OK (see image)

Figure 6 Boundary Condition

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MODULE JOB 
It will be completed in a short time because it is the simple analysis of structural
geometry.
 Job→create, name=Mode→submit

 Job manager→monitor→check the progress

MODULE Visualization 
Open the ODB result data file to check the resonant frequency and mode shape of the
1U CubeSat Frame. According to the technical data, the resonant frequency of the
CubeSat frame should exceed the 100hz region, which is the resonant frequency region
of the Launching vehicle, and the 1st mode resonant frequency should not be less than
35Hz.
 Result →Step/Frame→Check the 5 Eigen frequency

Figure 7 Mode analysis result showing Eigen frequency and Mode Shape(First mode)

The results show that the primary mode is 1.2kHz, which is much higher than the design
criteria. In fact, this FE model is a model for training and is significantly simplified
without joints. Therefore, since the stiffness and bulky than the actual structure, the first
vibration frequency is calculated higher than realistic value.

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Figure 8 Lateral bending in 3rd mode shape

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Analysis B: Quasi-Static Launch Analysis

During the launch phase, the cube sat frame must withstand the acceleration conditions
in the launch environment. In this analysis, we will explain the steps involved in
analyzing mission conditions and perform the analysis.

MODULE Step 
Go to the step module, move the mouse to the previous model in the model tree, and
right mouse button click to copy it. Set the name appropriately. Delete the existing step
and set new step ‘Static, General’. If a new step is created, the various boundary
conditions and load conditions that were set in the previous step will disappear.

 Move mouse to Model Tree→ Right mouse button click→Copy Model

 Step→Step Manager→Select existing step | Delete→Create | Static, General |

Period=1→OK

Figure 9 Create new step, static general.

MODULE Load 
Fixes four support surfaces mounted inside the pod to launch the CubeSat as shown
below. Satellite Launch Vehicle, quasi-static launch loads are 12 g in “z” axis and 6 g
in both for “x” and “y” axes. So, setup this load using gravity load which is applied to
whole body

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 BC→Create→Mechanical→Select 4 mounting surfaces→Encastre→OK (see image)

 Load→Create→Gravity→Region: Whole Model→Component 1,2,3 : 58.86, 58.86,

117.72 respectively (gravity = 9.81 m/s x n)

Figure 10 Boundary Condition

Figure 11 Loading Condition

MODULE JOB 
It will be completed in a short time because it is the simple analysis of structural
geometry.
 Job→create, name=’Launch’→submit

 Job manager→monitor→check the progress

MODULE Visualization 
Open the resulting file to see where the stress concentration occurs. As shown in the
figure below, it can be seen that a lot of stress is generated at the site fixed to the
projectile during the launch phase period, and also the stress is partially applied at the
site where the internal component weight is connected. The maximum load is about 3.5
MPa, so the stress concentration is negligible considering the yield strength of
aluminum. If stress concentrations are not well identified in the tower plot, lowering
the maximum value of the legend can be more easily identified.

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 Contour option→Max specify→ make number smaller to check stress concentrated

area easily

Figure 12 Stress concentration area during launch period

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Analysis C: Heat Transfer Analysis

In LEO space orbit, the CubeSat is subjected in three different types of environmental
heating in form of radiation such as the direct sunlight, sunlight reflected from the Earth
(Albedo) and infrared (IR) energy emitted from the Earth. The satellite electronics
package also creates internal heat which must be also considered. The radiation values
for an object in LEO, the Heat flux caused by direct sunlight would be 1370 W/m2.
Albedo 470 W/m2, and Reflected IR from Earth 230W/m2 should be used for the heat
transfer analysis. Period of the CubeSat to be exposed direct solar radiation and albedo
and earth infrared energy is determined as 5000sec.
In space, convection can be neglected. The worst case is the hot case where the CubeSat
is positioned between the Sun and Earth. The amplitude of this radiation is applied to
the CubeSat frame and shown below.

 Load→Tools→Amplitude→Type: Tabular

Figure 13 Heat flux induced from three sources (amplitude)

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 Load→Tools→Amplitude→Type: Tabular→Enter values (see image)

* Repeat this two times for Albedo and Reflected radiation

Figure 14 Amplitude of Direct Sunlight Heat Flux

MODULE Step 
Go to the step module, move the mouse to the previous model in the model tree, and
right mouse button click to copy it. Set the name appropriately. Delete the existing step
and set new step ‘Heat Transfer’. Set the period of step time as 5,000 sec in Transient
response. After this heat transfer analysis, the sequentially coupled thermal stress
analysis will be performed using the output of the heat transfer analysis in order to
evaluate the stress levels on the frame induced from the thermal loads. There are a
couple of method to extract thermal profile of the heat transfer result. It could use *.fil
file which was stored the nodal data, or *.odb file can be used too if we request the
nodal profiles during the step setup. In this workshop, later method is adopted.

 Step→Create→Heat Transfer | Response=Transient | Time period=5000 →

Incrementation tab | setup (see image)→ Ok

 Output→Field output request→ Evenly spaced | 50→ HFL, NT, RFL→OK

Figure 15 Heat Transfer Step Creation

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Figure 16 Field output setup

MODULE Load 
Before move to Load module, the element type should be changed for heat transfer
analysis. Next is to setup predefined fields and heat fluxes induced from radiation
resources.

 Model Tree→Part | Mesh | Double Click→Mesh→Element Type | Heat Transfer |

DC3D10 element→OK

 Predefined Field→Create→ Region=select whole body, Initial | Other |

Temperature→Direct | Constant | Magnitude=23→OK

 Load→Create→Step-1 | Thermal | Surface Heat Flux→ Region select exposed

surfaces to direct sunlight (see image) | Magnitude=1000 | Amp=Amp-1(direct

sunlight amplitude)→OK

* Repeat this for Albedo and Reflected radiation cases (see images)

Figure 17 Element type setup

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Figure 18 Predefined field setup

Figure 19 Heat flux setup for Direct Sunlight

Figure 20 Heat flux setup for Albedo (same surfaces for reflected radiation)

The physical constants related to thermal properties should be entered as shown below
since this model is the thermal analysis.

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 Model tree→Mouse on model→Right mouse button click→Edit attributes→Input

values (see image)

Figure 21 Thermal physical value setup

MODULE JOB 
This completes the heat transfer analysis model to account for radiation. It will be
completed in a short time because it is the simple analysis of structural geometry.
 Job→create, name=’Rad’→submit

 Job manager→monitor→check the progress

MODULE Visualization 
Open the resulting file to check thermal profiles of the frame due to heat fluxes from
the radiation. 50 frames were requested and the below image shows the temperature
status at the 6th frame. Since this analysis is the transient analysis, the thermal profiles
were changes along the step time 5000 sec. If you want to check the temperature status
change along the time step, XY data feature can be used to review the temperature
change at the specific nodes.

 Create XY data→Odb field output→Position=Unique Nodal, NT11 Nodal temperature

| Element/Node | Edit Selection → Select some nodes to extract temp profile → Plot

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Figure 22Temperature (NT11) distribution

Figure 23 XY Data setup to extract temperature profiles

Figure 24 Temperature change at the specific node

Above plot shows the temperature change at the corner nodes of the frame is shown.
During direct sunlight exposure, the temperature rises to 150 degrees and then gradually
decreases over time.

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Analysis D: Thermal Stress Analysis (Sequentially Coupled)

This analysis step will introduce the process of calculating the thermal stress using the
thermal profile calculated in the heat transfer analysis step. This thermo-mechanical
analysis has two types of analysis. First one is fully coupled analysis which is
performed simultaneously, and second one is a sequentially coupled analysis which
performs a separate stress analysis after the heat transfer analysis.

MODULE Step 
Go to the step module, move the mouse to the previous model in the model tree, and
right mouse button click to copy it. Set the name appropriately. Delete the existing step
and set new step ‘Static, General’. Since the previous heat transfer analysis result
should be extracted and mapped to current model, the same element and node
information, the step time and the number of analysis frames should be matched.

 Move mouse to Model Tree→ Right mouse button click→Copy Model

 Step→Step Manager→Select existing step | Delete→Create | Static, General |

Period=5000→OK

Figure 25 Step setup for thermal stress analysis

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MODULE Load 
Boundary conditions can be fixed by setting one specific node that does not affect the
overall thermal deformation. Since this analysis is a thermal stress analysis, change the
element back to the stress element type.

 BC→Create→Sym/Anti/Enc→Select corner node (see image)→Encastre→OK

Figure 26 Boundary condition setup

 Model Tree→Part | Mesh | Double Click→Mesh→Element Type | 3DStress | C3D4

element→OK

Figure 27 Element type setup

The following is the process of applying the initial 23 ° C in the predefined field, and
then importing and mapping the data of the previous analysis, which stores the
temperature distribution for 5000 seconds.

 Predefined field→Create→Initial | Others | Temperature→Region=whole body, Direct

| Constant | Magnitude=23→OK

 Predefined field→Create→Step-1 | From output dafabase file | select *.odb file in

working folder | Begin step=1 | Begin increment=1→OK

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Figure 28 Predefined field setup

MODULE JOB 
This completes the thermos-mechanical stress analysis model.
 Job→create, name=’TM’→submit

 Job manager→monitor→check the progress

MODULE Visualization 
Below image shows the von misses stress distribution at the frame 50th. High stress
concentration occurs the edge of the frame plate and internal beam links. We can
extract the stress values over step time using Create XY data. Temperature variation
of the nodes having the highest thermal stress is shown in below image. The highest
thermal stress is approximately 2 MPa which is lower than endurance limit of the
aluminum at high temperature.

 Create XY data→Odb field output→Position=Unique Nodal, Von Mises |

Element/Node | Edit Selection → Select some nodes to extract temp profile → Plot

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Figure 29 Von mises stress distribution and the extracted stress at the edge of the frame

This model is a simplified model as a training model, and structural integrity of the
CubeSat frame in the space environment through four types of analysis were practiced.
Below image shows the realistic 3U CubeSat including multiple materials such as
titanium, aluminum and PCB board material. Also, various types of joint and faster
element were implemented. The lumped mass element to account for internal
electronics were included too. The analysis method for this model can be applied in
much the same way as the one applied in this exercise to analyze the structural integrity
in space environment.

Figure 30 3U CubeSat FE Model

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