Simulation Optimization And Additive Manufacturing Of Thin-walled Multi-ribbed Aluminum Alloy Satellite Propulsion Cabin

With the development of science and technology,the enthusiasm of human beings to explore the mystery of space is getting higher and higher,which leads to more and more requirements for the number of satellites,higher and higher functional requirements,and more and more complex systems.Therefore,the lightweight and long-term service of on-orbit working satellites has become an important research topic.In this paper,a thin-walled multi-stiffened aluminum alloy satellite propulsion cabin is designed and can be formed by additive manufacturing technology.Compared with the satellite propulsion cabin manufactured by traditional processes such as casting,riveting and welding,it not only improves the structural performance of the satellite propulsion cabin,but also realizes the large-scale lightweight of the satellite propulsion cabin.The design of the propulsion module reduces the development cycle and production cost of the satellite,and further expands the product spectrum of the satellite platform series in China.The finite element simulation technology is used to optimize the structure of the satellite propulsion cabin under different working conditions,and the additive manufacturing forming process is simulated.Finally,the additive manufacturing forming test of the satellite propulsion cabin sample is carried out.Based on the simulation comparison between the A-type traditional structure and the B-type new structure satellite propulsion cabin,it was determined that the B-type structure was more in line with the design development trend of lightweight and fuel tank volume.A B-type satellite propulsion cabin with thin-walled multi-ribbed structure was designed.ANSYS Workbench finite element analysis software was used to simulate the different working conditions of the satellite propulsion cabin to determine whether it meetted the design requirements.The lightweight structure optimization of the satellite propulsion cabin was carried out to obtain the optimal parameters of the propulsion cabin structure.The total mass of the final thin-walled multi-ribbed satellite propulsion cabin structure was 133.43g,which was 22.5%less than the original design.The tank can accommodate a fuel volume of 4×102160.4mm³,which was 76.43%higher than the traditional configuration satellite propulsion cabin.The ANSYS Additive Print software was used to simulate the additive manufacturing process of the satellite propulsion cabin.When the satellite propulsion cabin was printed along the axial direction,the maximum total deformation was about 0.79mm.When the satellite propulsion cabin was printed along the radial direction,the maximum total deformation was about 1.3mm,and the results show that the printing accuracy along the axial direction is higher.Compared with the design model,the size error of the satellite propulsion cabin sample prepared by the additive manufacturing test was less than 5%.The grain structure of the molded sample was relatively uniform.The grain size was between 20-50 m,and the relative density reaches 97.1%.There ware holes at the fracture.The diameter of the hole is 2-10m,accounting for 2.61%of the total area of the fracture,resulting in uneven strain during the tensile test.The tensile strength,yield strength and elongation meet the requirements.X-ray diffraction and EDS analysis showed that there were mainly Al,Si and Mg₂Si phases in the initial powder,and Al₉Si phase was formed in the printed sample.