Study On Design And Forming Technology Of Composite Material Polyhedron Support

Satellite integrated assembly parts are usually installed on shell plate in the manner of a cantilever. As it has to bear big concentrated load and poor external environment, it is usually shaped up by high-performance aluminum alloy machine, in order to ensure its strength and stiffness requirements. As it has the advantages of big structural weight, complex process and long development cycle, this method restricts the overall development plan of the satellite. In this paper, the research of design and molding technology of carbon fiber composite polyhedral support was carried out based on the requirement of support structure design and on the background of the research and development task of digital antenna support of a certain type of satellite integrated assembly part.Firstly, through the contrastive analysis, polyhedral support configuration made up of composite laminated plate was determined to use in this paper. PATRAN/NASTRAN software was used to establish finite element model of polyhedral support, rigidity and intensity of 2.4mm thick support were analyzed. The results showed that it met the rigidity requirements but failed to satisfy the intensity requirements. Three strengthening design schemes, including beam strengthening, local strengthening and global enhancement, were put forward, and through analytical calculation global enhancement scheme was determined to use and the structure of composite polyhedral support was designed.Through the analysis of modality, frequency and random response, the structural design of composite polyhedral support was assessed comprehensively, and all the calculation results met the relevant technical requirements which verify the feasibility of polyhedral support design theoretically. Compared with the data of aluminum alloy support, the intrinsic frequency of polyhedral support has increased about 6Hz and the end value of response analysis of each measuring point position in x, y, z axes are smaller.According to basic principles of preform molding process and structural features of composite polyhedral support, integral molding method for male mold layer and female mold curing was proposed, mold for composite polyhedral support was designed and composite polyhedral support that can meet technical requirements was developed. With the structural weight of 2.3kg and manufacturing cycle of 10 workdays, the final support can meet the relevant technical requirements.The molding quality of polyhedral support was verified through ultrasonic non-destructive testing and mechanics performance testing. Vibration environment simulated test scheme was proposed to polyhedral support, and vibration test was carried out in x, y, z axes respectively. The results showed that, the support can meet the dynamic load specified in technical requirements and its structural design and molding process is reasonable and feasible.