Evaluation of Dimensional Stability of Composite Structure

for Space Application

N. B. Phakade a, N. R. Raykar a,*, S. C. Prabhune b
a Department of Mechanical Engineering, Sardar Patel College of Engineering, University of Mumbai, Mumbai-400058, India
b Larsen & Toubro Limited, Powai Campus, Saki Vihar Road, Powai, Mumbai-400072, India

*Corresponding author. Tel: +91-22-26232192, Fax: +91-22-26237819, email: nileshrraykar@gmail.com

ABSTRACT

The quality and accuracy of images from satellites depend upon the dimensional stability of the
telescope and antenna support structure such as bench table. This paper provides finite element method
based evaluation of the dimensional stability of a bench table structure. The study involves material
selection through investigation of two alternate aerospace composite materials AS/H3501 and T300/N5208 and
different their layup sequences. The aim of work is to achieve near zero coefficient of thermal expansion
of components while meeting the Tsai-Wu failure criterion. Bench table is analysed for temperature
loading in the range of -101˚C to 125˚C. Deformation and stress results are compared for different
combinations of material and layup sequence and the best combination suitable for the bench table is
established. The results show a significant influence of ply orientations and layup sequence on the
deformation of structure.

Keywords: Dimensional stability; Carbon fiber reinforced polymer; Quasi-isotropic composites;

layup sequence

List of abbreviations
CTE Coefficient of thermal expansion
CFRP Carbon Fiber Reinforcement Polymer
FE, FEM Finite Element, Finite Element Method
LEO Low Earth Orbit
UV Ultraviolet

1. Introduction

Fiber reinforced polymer composites are increasingly used in a wide range of load bearing
engineering applications structures including those in aerospace industry. Composite materials have the
advantage of high strength-to weight and stiffness-to-weight ratios compared to metals. Composite
materials typically consist of a load-carrying material phase, such as fibers, held together by a binder or
matrix material, often an organic polymer. Different types of composite materials use carbon, glass,
boron, aramid, etc. as reinforcement in fibre form and epoxy, polyimide, polyester, thermoplastics,
polysulfone, etc. as the matrices. Composite laminates are anisotropic in nature. Exact analysis of their
elastic responses should beis based on the theory of anisotropic elasticity [1].
Fiber-reinforced composites are used extensively in the form of relatively thin plates, and the load
carrying capability of these composite plates has been intensively considered investigated by researchers
under various loading and boundary conditions [2]. Laminated composite have been used successfully in
many engineering applications because they have better strength and modulus over traditional metal.
During the operational life of typical engineering structures, laminated composite may experience
elevated temperature conditions acting throughout the laminated composite may be experienced. Due to

1
this such temperature condition, thermo-elastic properties of the composite will vary with the change of
temperature [3]. The research of fiber reinforced composites is still focused on mechanical properties,
while only a few investigations on their thermal expansion behavior and dimensional stability [4].
For majority of spacecraft components CFRP composites are widely accepted because they
provide highest trade-off metrics based on weight and performance [2]. The LEO space environment
constituents consist of high vacuum, UV radiation and thermal cycles [5]. Thermal cycling is one of
environmental effects of space that which is known to induce environmental degradation on satellite in
LEO, (between 100 and 1500 km above the Earth’s surface) as it passes in and out of the earth’s shadow.
As a result tThe exterior surface is exposed to long-term periodic sharp temperature changes [6]. In
general, temperature of space components varies between -101°C to 125°C [7]. Near to zero coefficient of
thermal expansion is desired for dimensional stability of space structures, especially those employed for
image sensing. For fabrication of ultra-stable space components, dimensional stability of CFRP is
concerned because of thermal loadingimportant. The dimensional stabilityis is directly related toclosely
connected with morphologycomposition, structure and chemistry of fiber/resin of the composite used [8].
However, the limited understanding of composite structure’s dimensional stability remains a serious
problem against the selection of CFRP composites for this class of space structures. Carbon/epoxy
composites are example of high-end materials, known for their low density and considerable stiffness and
strength to weight ratio. Dimensionally stability of CFRP is influenced by factors like fiber and resin
used, fiber volume fraction and the number and orientation of individual layers. HoweverAmongst these,
the most influential factor is the layup sequence [9]. As the composite analysis methods continue to
improve, designers are learning to utilize composites consisting of laminas (plies) of oriented fibers to
obtain unique material properties. Typically, this is accomplished by orienting unidirectional laminae at
various angles to obtain a laminate with the desired properties.
In engineering applications, structural parts made of carbon/epoxy materials frequently work at
high temperatures which leads to thermal aging. Recently several experimental results are reported on the
influence of thermal loading on composite strength and aging<<CHECK?>> properties [9]. However,
there is still a lack of FEM software resultsbased studies, regarding the effect of thermal loading on
dimensional stability. Composite materials can be tailored in order to obtain a minimal thermal
deformation. Furthermore, composites, with their high specific stiffness (E/ρ) and thermal stability (K/α),
can avoid a weight penalty (E is modulus of elasticity, ρ is density, K is thermal conductivity and α is
coefficient of thermal expansion) [10]; E is modulus of elasticity, ρ is density, K is thermal conductivity
and α is coefficient of thermal expansion. Therefore, composites have become more employed for
satellite structures and optical space components.
Dimensional and alignment errors among constituting subcomponents can cause serious degradation
of space components’ in functional performance. There has been some study on the degradation due to
dimensional instability of space components [10]. In order to evaluate such dimensional instability, an
approach based on finite element analysis program (such as, ANSYS® APDL, ) may be employed.
Thermal expansion coefficient is an important property of composite material which affects deformations
and thermally induced stresses in a composite component. The matrix material typically exhibits
significantly different coefficient of thermal expansion than fibers. An accurate determination of thermal
expansion coefficient taking into account combined effect of matrix and fiber is necessary. In laminated
composites, this coefficient depends largely on the orientation of fibers, the fiber fraction, type of resin
and reinforcement.
The objective of this work is to select suitable composite material in order to design a typical
dimensionally stable bench table for space application. A bench table is a support structure which houses
antenna and allied electronic and mechanical components to obtain digital images from a space satellite.
The influence of thermal environment on dimensional stability of carbon/epoxy composite based bench
table is investigated by varying following composite material propertiesparameters: combination of
fiber/matrix material, fiber orientation and layup sequence. The most suitable composition of composite
material for bench table is established through this study.

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 2. Theoretical Basis for Analysis

For isotropic bodies, the coefficient of thermal expansion is the same in all directions. For composite
materials, the coefficient of thermal expansion, like other properties, changes with direction. Because of
the structure of the composite, a unidirectional composite shows different CTE in the longitudinal and
transverse directions. Thus the unidirectional composites are orthotropic with the axes 1 (longitudinal), 2
(transverse) and 3 (thickness) as the axes of symmetry. Because of the random fiber distribution in the
cross section, material behaviour in directions (2 and, 3) is nearly identical. Therefore a unidirectional
composite or ply can be considered to be transversely isotropic that is, it is isotropic in 2-3 plane [11].
Unidirectional composites have two principal coefficients of thermal expansion, the longitudinal
coefficient of thermal expansion αL and the transverse coefficient of thermal expansion αT . Schapery [12]
has derived the following expression for the longitudinal and transverse coefficient of thermal expansion
in terms of fiber and matrix material properties.
1
αL = (αf Ef Vf + αm Em Vm ) .................................................................................................................... (1)
EL

αT = (1 + µf )αf Vf + (1 + µm )αm Vm − αL µLT ....................................................................................... (2)

where
αf and αm are coefficient of thermal expansion of fibers and matrix
EL is the elastic modulus of the composite in the longitudinal direction
Ef and Em are elastic modulus of fibers and matrix
Vf and Vm are volume fraction of fibers and matrix
µLT is the major passion ratio of the composite
In this work the values of αL and αT for composite materials AS/H3501 and T300/N5208 are
directly available obtained from bookpublished data [11].
Procedure to calculate laminate stress and strain in composite materials (Fig.1) is explained by
Agarwal, Broutman and Chandrashekhara et al. [11].

Input

Laminate construction Laminate elastic constants Applied loads

Laminate stiffness matrices [Q]

[Q] For different orientations

Laminate stiffness matrices [A], [B] and [D]

Mid-plane strains (ε) and plate curvatures (k)

Global laminae strains (εX , εY , γXY )

Local laminae strains (εL , εT , γLT )

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 Local laminae stresses (𝜎L , σT , τLT )
Fig.1: Flow chart for laminate stress analysis [11].
In unidirectional fiber form, longitudinal direction is fiber direction and transverse direction is
perpendicular to fiber direction. Subscript for fiber is denoted by ‘f’ and for matrix is denoted by ‘m’.

For transversely isotropic material values of EL , ET , GLT , µLT are generally available for standard
materials. In order to calculate laminate stiffness matrix [Q], following additional relations are used [13].
EL µLT ET
0
1−µLT µTL 1−µLT µTL
[Q] = µLT ET ET ............................................................................................................ (3)
0
1−µLT µTL 1−µLT µTL
[ 0 0 GLT ]

Orthotropic material with tTransversely isotropic materials are characterized by are having following
relations.: [?]. Formatted: Highlight

E2 = E3 = ET ............................................................................................................................................ (4)
G12 = G13 = GLT ....................................................................................................................................... (5)
µ12 = µ13 = µLT ....................................................................................................................................... (6)
E
1+µm −(µLT m )
EL
µ23 = µf Vf + µm (1 − Vf ) [ E
] ............................................................................................ (7)
1−µ2m +(µm µLT m )
EL
ET
G23 = ............................................................................................................................................ (8)
2(1+µ23 )
where

EL Young’s modulus in longitudinal direction

ET Young’s modulus in transverse direction
GLT Shear modulus
µLT Major poisson’s ratio
µTL Minor poisson’s ratio
µ23 Poisson ratio in 2-3 plane
G23 Shear modulus in the 2-3 plane
Vf Volume fraction for fiber
µf Poisson ratio for fiber
µm Poisson ratio for matrix
Em Young’s modulus for matrix

Using After formulating [Q] then formulation the stresses and strains are obtained by employing
procedure shown in Fig. 1. The stresses and strains are evaluated by appropriate failure theory to
determine design acceptability. is obtained.

The present work employs Tsai-Wu failure theory to check the sufficiency of composite
component design. This theory has more general applicability than other failure theories such as,
Maximum-stress failure theory, Maximum-strain failure theory, Tsai-Hill failure theory, because it

4
distinguishes between the compressive and tensile strengths of a lamina [14]. This theory provides a
single criterion to predict the failure of lamina.

The Tsai-Wu failure criterion states [15]: under plane stress condition the failure will occur when the
following inequality is not satisfied.

0 < ξ <1....................................................................................................................................................... (9)

where
1
ξ= ...................................................................................................................................... (10)
A A 2 1
− +√ ( ) +
2B 2B B

1
Fs = ....................................................................................................................................................... (11)
ξ
σ2L σ2T τ2LT 1 1
A= + + + 2F12 √ × σ σU ………................................................... (12)
σLU σLU ′ σTU σTU ′ τ2LTU σLU σLU ′ σTU σTU ′ L

1 1 1 1
B=( − ) σL + ( − ) σT ……............................................................................................ (13)
σLU σLU ′ σTU σTU ′

F12 to be within the range -1 < F12 < 1 (in this study, F12 is considered as -0.5 [16])

ξ Inverse of the strength ratio

Fs Factor of safety
σL Stress in longitudinal direction
σT Stress in transverse direction
τLT Shear stress in longitudinal and transverse direction
σLU Ultimate tensile strength in longitudinal direction
σLU ′ Ultimate compressive strength in longitudinal direction
σTU Ultimate tensile strength in transverse direction
σTU ′ Ultimate compressive strength in transverse direction
τLTU Ultimate shear strength in longitudinal and transverse direction

Prior to carrying out the present study using commercial finite element code ANSYS®, the validation
of ANSYS® code for stress/strain calculations was performed. Analytical results of stresses and strains
were obtained using MATLAB® code for a rectangular plate subjected to uniform thermal load. Tsai-Wu
theory was employed as failure criterion. For the same case, stress/strain results were also obtained by
ANSYS® software code. The results from ANSYS® code such as, values for A, B and D matrix; local and
global stresses and strain, were found to be matching with the analytical results. Details of this study are
not covered here and are being reported separately.

3. Design for Bench table

Bench table consist of two components a) sandwich structure base and b) cylinder as show in
Fig.2. Sandwich structure is used for design and construction of lightweight structures such as satellites,
aircraft, missiles, high speed trains. Weight saving is the major concern in space satellites and the
sandwich construction is often to be used instead of increasing material thicknessheavier metal plates.
This type of construction consists of two thin facing layers separated by a core material. Depending on the
specific requirements of the structures, composites, aluminium alloys or titanium are used as the material
of facings skinslayers. Several core shapes and material may be utilized in the construction of sandwich
structure among them; . it has been known that tThe aluminium honeycomb core has excellent properties
with regard to weight savings and fabrication costs [17]. Design of bench table consists involves of

5
selection ofng appropriate composite material to achieve dimensional stability and also to protection
againstsatisfy the Tsai-Wu failure criterion.

Formatted: Font: (Default) Times New Roman

Formatted: Left

<<Remove text box borders, increase font>>

Fig.2: Schematic representation of bench table on satellite structure

In bench table, the cylinder is mounted on sandwich structure using bolted connection. The
sandwich structure consists of metallic honeycomb structure of aluminium7075-T6 material which is
covered on both flat surfaces using carbon-epoxy composite materials. Dimensions for sandwich structure
base are given in Table 1.

Table 1: Dimension for sandwich structure base.

Dimension for base (mm)
Length 830
Breadth 814
Height of honeycomb structure 98
Thickness of honeycomb foil 0.07
Height of Top and Bottom faceplate 2.75

Fig.3: Model for sandwich structure base

6
 Carbon-epoxy is used as face plate to provide better strength for withstanding bending stresses.
The Ccylinder part of is used in bench table acts as support structure on which antenna is to be mounted.
Cylinder is made up ofconstructed with Carbon-epoxy material. Dimensions for cylinder are given in
Table 2.

Table 2: Dimension for cylinder

Dimension for cylinder (mm)
Thickness 2
Height 1000
Cylinder inner diameter 698
Cylinder outer diameter 700
Flange inner diameter 700
Flange outer diameter 800
circular face blend radius 5

Fig.4: Cylinder

Twelve holes of 10mm radius at angular pitch of 30 degreess are drilledprovided in the base plate
and flange of cylinder for their assembly using threaded bolts. Both the components are joined with the
help of M10 size stainless steel (SS) bolt and nut. Cylinder and base are modelled in UG-NX software
version 8.5.

3.1 Material selection: Formatted: Font: Bold

Different types of CFRP materials are availablemay be used for design of cylinder and base, such
as, T300/N5208, AS/H3501, AS4/APC2, IM6/epoxy and T300/Fiberite 934. In this work AS/H3501 and
T300/N5208 are selected as possible design options as since both are having very low CTE. Combination
of fiber and matrix leads to formation of lamina. Differences in the CTE in the longitudinal and transverse
directions indicate that laminate CTEs are strong functions of layup. Material Properties for carbon/epoxy
(AS/H3501) and (T300/N5208) are as follows [11].

Table 3: Material properties for carbon/epoxy (AS/H3501)

Elastic constants Strength
VF 0.66 σLU (MPa) 1447
ρ (Kg/𝑚3 ) 1600 σ′LU (MPa) 1447
EL (GPa) 138 σTU (MPa) 51.7
ET (GPa) 8.96 σ′TU (MPa) 206
GLT (GPa) 7.10 τLTU (MPa) 93

7
 µLT 0.3 Thermal expansion coefficients (10−6 /˚C)
µ23 0.3 αL -0.3
G23 (GPa) 3.4461 αT 28.1

Table 4: Material properties for carbon/epoxy (AS/H3501)

Elastic constants Strength
VF 0.7 σLU (MPa) 1500
ρ (Kg/𝑚3 ) 1600 σ′LU (MPa) 1500
EL (GPa) 181 σTU (MPa) 40
ET (GPa) 10.30 σ′TU (MPa) 246
GLT (GPa) 7.17 τLTU (MPa) 68
µLT 0.28 Thermal expansion coefficients (10−6 /˚C)
µ23 0.28 αL 0.02
G23 (GPa) 4.0234 αT 22.5

Material properties of aluminium 7075-T6 and structural stainless steel (SS) are as follows:

Table 5: Material properties of aluminium 7075-T6

Aluminium 7075-T6 Values
Density (kg/m3 ) 2810
Young’s modulus (GPa) 71.7
Poisson’s ratio 0.33
Coefficient of thermal expansion (10−6 /˚C) 23.6
Yield strength (MPa) 503

Table 6: Material properties of structural stainless steel

Stainless Steel (SS) Values
Density (kg/m3 ) 7800
Young’s modulus (GPa) 200
Poisson’s ratio 0.3
Coefficient of thermal expansion (10−6 /˚C) 12
Yield strength (MPa) 250

3.2 Finite Element Discretization: Formatted: Font: Bold

The bench table has been discretized using 2D shell elements SHELL 181 of ANSYS®. Quad
elements are generated by mapped meshing using HYPERMESH v12.0 software. Washer split or circular
partition is made around all the holes. Element size used for base and cylinder is 20 mm and 10 mm
respectively. The FE mesh is checked and cleared for element connectivity, duplicates, jacobian, warpage,
aspect and skewness.

8
 Fig.5: Discretization details for Base.
Base and cylinder are aligned and assembled. Surface to surface contact has been established
between the two components using contact elements. The bench assembly is bolted using 12 numbers of
M10 bolts which are modelled in FE using 1D bar elements, BEAM 188. Assembly is show below in
figFig.7.

Fig.6: Discretization details for Cylinder.

9
 Fig.7: FE model for assembly of bench table structure.

3.3 FE Analysis: Formatted: Font: Bold

ANSYS® 15.0 is used to conduct the FE analysis of the bench table. The number/thickness of
layers considered for composite material was 8/0.125 mm for cylinder and 8/0.2 mm for base
respectively. Before carrying out the actual analysis, preliminary evaluation of 7 layup sequences (Table
7) were evaluated forwas carried out with the bench table subjected to thermal loading of 100˚C, -100˚C
as load cases. Based on the Tsai-Wu criterion, two of these layup sequences were shortlisted for design of
bench table (Table ?). <<Shift table 9 from results section here>> for actual load cases and analysis which Formatted: Highlight
is shown in results section.

Table 7: Different combinations of layup sequences studied <<Remove this table and shift Table Formatted: Highlight
9 showing two layup sequences here>>
Combination no. Layup sequence for cylinder Layup sequence for base
N1 [90/180/135/45]s [0/90/45/-45]s
N2 [150/120/60/30]s [60/30/-30/-60]s
N3 [90/90/150/30]s [0/0/60/-60]s
N4 [90/90/165/15]s [0/0/75/-75]s
N5 [90/120/60/180]s [0/30/-30/90]s
N6 [90/90/180/180]s [60/30/-30/-60]s
N7 [90/90/90/90]s [0/0/0/0]s

For aluminium and SS materials, isotropic material model was employed.

3.4 Boundary conditionThermal Loadings, Element coordinate system and Boundary conditions: Formatted: Font: Bold
Formatted: Font: Bold
Cylinder and base are coupled to each other using beam elements at the centre of 12 bolt holes.
Formatted: Indent: First line: 0 cm
For coupling purpose, master nodes are created at top and bottom surfaces of assembly (Fig.8). Master
node of bottom of each beam is constrained in all degree of freedoms.

10
 Formatted: Font: (Default) Times New Roman, 10 pt

For the bench table components in space environment, the temperature variation is in the range of
-101˚C to 125˚C. The tThermal loads are induced due to thermal gradient and/or the difference in CTE of
different layers. Reference temperature for thermal loading is the temperature at which assembly of
satellite is carried out and at this temperature zero thermal strains exist. The reference temperature
considered in this study is 25 deg. C.

When the satellite is launched in space, temperatures vary in the range of -101˚C to 125˚C.

<<show -126/125 deg. C in figure>>

Fig.9?: Thermal Lload cases.

The temperature states corresponding to each load cases is as shown in Table 8.

Table 8: Thermal load cases

Load cases Temperature (˚C)
Case:1 100
Case:2 -126
Case:3 Half 100 & half -126

Element Coordinate system: Formatted: Font: Bold

For correctness obtaining correctof FE results, all composite elements should have same type of
element coordinate system and the flow of element coordinate system should be smooth. X-axis, Y-axis
and Z-axis, is in black, green and blue colour respectively for element coordinate system. The alignment
of element coordinate systems for cylinder and face plates is shown below in figFigs.11 ? and fig.12 ?
respectively. X-axis, Y-axis and Z-axis, axes are represented is in black, green and blue colours
respectively in these figures.for element coordinate system.

11
 Fig.10?: Element coordinate system

<<Show global and ele.CS clearly>>

Fig.11?: Cylinder element coordinate system for surface layer.

<<Show global and ele.CS clearly>>

Fig.12?: Face plates element coordinate system for surface layer.

Structural boundary conditions:

12
 Cylinder and base are coupled to each other using beam elements at the centre of 12 bolt holes.
For coupling purpose, master nodes are created at top and bottom surfaces of assembly (Fig.?). Master
node of bottom of each beam is constrained in all degree of freedoms.

Formatted: Font: (Default) Times New Roman, 10 pt

<<Write text annotation for master nodes/beam ele>>

Fig.?: Structural boundary condition for bench table assembly.
Formatted: Indent: First line: 0 cm
Surface to surface contact is given provided between flange of cylinder and top face of sandwich
structure (Fig.13?). Both the surfaces are allowed to make contact or separate but these cannot penetrate
each other.

Fig.13?: Target and Contact nodes showing surface to surface contact.

FE discretization for components of base Ssandwich structure, i.e., base consist of honeycomb
structure, faceplates and bolts as is shown in Figs. 14, 15 and 16. Discretization for entire assembly is
shown in Fig. 17 shows entire assembly.

13
 Fig.14: FE discretization for Hhoneycomb structure

Fig.15: FE discretization for Ttop and bottom plate of honeycomb structure

Fig.16: FE discretization for Bbeams acting as bolts with displacement boundary condition (constraint at
bottom.)

14
 Fig.17: FE discretization for entire Bbench table after assembly of all components

4. Results and discussion

AS/H3501 has carbon fiber with negative CTE along fiber direction while T300/N5208 has
positive CTE in fiber direction. Response of the structure to space conditions was studied for two layup
sequences (Table ?). Minimum deformation of the structure and safety in Tsai-Wu failure criteria are the
basis for the evaluation of material/layup sequence. Out of seven different combinations only first and Formatted: Highlight
second combinations are safe against Tsai-Wu criteria for AS/H3501 material which is further considered
for analysis. And then, the number/thickness of layers considered for composite material was 8/0.25 mm
for cylinder and 10/0.275 mm for base respectively <<shift highlighted text to section 3.3>>. Different Formatted: Highlight
combinations of layup sequence were studied for real thermal load cases are as shown in Table 9.

Table 9: Layup sequence considered for design of bench table. <<shift to section 3.3>> Formatted: Highlight
Combination no. Layup sequence for cylinder Layup sequence for base
N1 [90/180/135/45]s [0/90/45/45/-45]s
N2 [150/120/60/30]s [60/-60/0/30/-30]s

Out of two material types T300/N5208 is eliminated due to less dimensional stability (Table ??) and Formatted: Highlight
relatively less strength properties as compared to AS/H3501.

Table ??: Comparison of dimensional stability between T300.N2508 and AS/H3501 materials Formatted: Highlight
Formatted: Highlight

The results for Maximum value of Tsai-Wu criterion <<add symbol for zeta here>> is as shown in Table
9?.

Table 9?: Values of Tsai-Wu criterion <<add symbol for zeta here>>a
Orientations Maximum value of Tsai-Wu Criteria (ξ)
Notations AS/H3501
100˚C -126˚C Both Half
N1 0.27 0.85 0.89
N2 0.25 0.92 0.94

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 Table 13 ? shows Both N1 and N2 are safe for all three load cases. Factor of safety for N1 and N2
nearly equal<<less than?>> to 1.1 as required recommended for space application [?]. Maximum <<add
Tsai-Wu value at 100˚C is for ninth layer in bottom plate and at -126˚C is for tenth layer in top plate.
18(B) show the variation of <<add symbol for zeta here>>above mentioned Tsai-Wu value for N2.

Fig.18 (A): Maximum valueVariation of <<add symbol for zeta here>> Tsai-Wu with N2 orientation at
100˚C

Fig.18 (B): Maximum valueVariation of <<add symbol for zeta here>> Tsai-Wu with N2 orientation at -
126˚C

Results for total maximum deformation are as follows.

Table 10: Total maximum deformation

Orientation Total maximum deformation (mm)
Notations AS/H3501
100˚C -126˚C Both Half
N1 0.570 0.757 1.475
N2 0.583 0.695 1.304

16
 The overall least values for deformation are obtained for layup sequence N2. Maximum
deformation with N2 orientation at 100˚C occurs in honeycomb core and at -126˚C occurs in bottom face
plate. In Bench table, total deformation is very less and symmetric along axis of symmetry which is along
the length of the cylinder. This gives a dimensionally stable bench table. Figures 19(A), 19(B) and 19(C)
show total maximum deformation.

Fig.19 (A): Deformation with N2 orientations at 100˚C

Fig.19 (B): Deformation with N2 orientations at -126˚C

17
 Fig.19 (C): Deformation with N2 orientations both half (-126˚C and 100˚C)

Stresses in aluminium and steel materials are checked for failure as per Von Mises criteria. These
checks for failure for N2 are shown in Table 15.

Table 11: Von Mises stress

Aluminium 7075-T6 Structural steel (SS)
Von Mises stress for
Von Mises stress for bolts
honeycomb
Allowable (250)
Allowable (503)
Both Both
100˚C -126˚C 100˚C -126˚C
half half
381.8 479.7 475 240 240 240

Von Mises stresses in metallic materials are maximum at in the regions corresponding to the
boltswasher split area.. However, Iin actual assembly, the real stresses would be much less less as
compared to the simulation results due to the presence of washers which will distribute the stresses over a
larger surface. Figures 20(A), 20(B) and 20(C) show Von Mises stress.

Fig.20 (A): Honeycomb Von Mises stress at 100˚C

18
 Fig.20 (B): Bolts Von Mises stress at 100˚C

Fig.20 (C): Honeycomb Von Mises stress at -126˚C

The stresses in composite and metallic materials are within acceptable limit. Hence the support
bench design with AS/H3501 as composite material and layup sequence N2 is selected as the best choice
against both requirements of dimensional stability and strength.

5. Conclusions

The dimensional stability for space borne bench table structure of composite material has been
successfully established using finite element based study. The choice of material and selection of layup
sequence is observed to play an important role in achieving the dimensional stability as well as in meeting
the Tsai-Wu strength criterion for the components of structure. Composite material with positive and
negative coefficient of thermal expansion for fiber and matrix materials provided the optimum design.
The layup sequence is found to have significant influence on the deformations of the bench table.

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