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Reda R, Ahmed Y, Magdy I, Nabil H, Khamis M, Lila MA, Refaey A, Eldabaa N, Elmagd MA, Ragab AE, Elsayed A. Wall panel structure design optimization of a hexagonal satellite. Heliyon 2024; 10:e24159. [PMID: 38293483 PMCID: PMC10824784 DOI: 10.1016/j.heliyon.2024.e24159] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/12/2023] [Revised: 12/31/2023] [Accepted: 01/04/2024] [Indexed: 02/01/2024] Open
Abstract
Considering that it satisfies high strength and stiffness at a low weight, the grid structure is the ideal option for meeting the requirements for developing the wall panel structure for the satellite. The most attractive grid structures for the satellite wall panel industry are isogrid and honeycomb structures. The first part of this work involves studying the mechanical and dynamic performance of five designs for the satellite wall panel made of 7075-T0 Al-alloy. These designs include two isogrid structures with different rib widths, two honeycomb structures with different cell wall thicknesses, and a solid structure for comparison. The performance of these designs was evaluated through compression, bending, and vibration testing using both finite element analysis (FEA) with the Ansys workbench and experimental testing. The FEA results are consistent with the experimental ones. The results show that the isogrid structure with a lower rib thickness of 2 mm is the best candidate for manufacturing the satellite wall panel, as this design reveals the best mechanical and dynamic performance. The second part of this work involves studying the influence of the length of the sides of the best isogrid structure in the range of 12 mm-24 mm on its mechanical and dynamic performance to achieve the lowest possible mass while maintaining the structure's integrity. Then, a modified design of skinned wall panels was introduced and dynamically tested using FEA. Finally, a CAD model of a hexagonal satellite prototype using the best-attained design of the wall panel, i.e., the isogrid structure with a 2 mm rib width and 24 mm-long sides, was built and dynamically tested to ensure its safe design against vibration. Then, the satellite prototype was manufactured, assembled, and successfully assessed.
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Affiliation(s)
- Reham Reda
- Department of Mechanical Engineering, Faculty of Engineering, Suez University, P.O.Box: 43221, Suez, Egypt
| | - Yasmeen Ahmed
- Department of Mechanical Engineering, Faculty of Engineering, Suez University, P.O.Box: 43221, Suez, Egypt
| | - Islam Magdy
- Department of Mechanical Engineering, Faculty of Engineering, Suez University, P.O.Box: 43221, Suez, Egypt
| | - Hossam Nabil
- Department of Mechanical Engineering, Faculty of Engineering, Suez University, P.O.Box: 43221, Suez, Egypt
| | - Mennatullah Khamis
- Department of Mechanical Engineering, Faculty of Engineering, Suez University, P.O.Box: 43221, Suez, Egypt
| | - Mohamed Abo Lila
- Department of Mechanical Engineering, Faculty of Engineering, Suez University, P.O.Box: 43221, Suez, Egypt
| | - Ahmed Refaey
- Department of Mechanical Engineering, Faculty of Engineering, Suez University, P.O.Box: 43221, Suez, Egypt
| | - Nada Eldabaa
- Department of Mechanical Engineering, Faculty of Engineering, Suez University, P.O.Box: 43221, Suez, Egypt
| | - Manar Abo Elmagd
- Department of Mechanical Engineering, Faculty of Engineering, Suez University, P.O.Box: 43221, Suez, Egypt
| | - Adham E. Ragab
- Department of Industrial Engineering, College of Engineering, King Saud University, P.O. Box 800, Riyadh, 11421, Saudi Arabia
| | - Ahmed Elsayed
- Advanced Forming Research Centre, Strathclyde University, Renfrew, Glasgow, PA4 9LJ, Scotland
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