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| 1 | +# ASTERION FCTA-1 V0.5 — ANSYS Workbench Structural Analysis Guide |
| 2 | + |
| 3 | +## Purpose |
| 4 | + |
| 5 | +This guide converts the V0.3 BEAM188 primary-structure model and V0.4 subsystem mass state into a controlled V0.5 structural-analysis project. The supplied project contains no claimed solved ANSYS database. Results must be generated and reviewed on the user's licensed ANSYS installation. |
| 6 | + |
| 7 | +## Recommended project systems |
| 8 | + |
| 9 | +Create one Engineering Data cell and connect it to: |
| 10 | + |
| 11 | +1. Static Structural — docking compression. |
| 12 | +2. Static Structural — electric-propulsion thrust. |
| 13 | +3. Static Structural — twin-ring centrifugal loading. |
| 14 | +4. Static Structural — ring emergency braking. |
| 15 | +5. Static Structural — misaligned docking. |
| 16 | +6. Modal — free-free flight model. |
| 17 | +7. Modal — aft-supported ground-test model. |
| 18 | +8. Eigenvalue Buckling — linked from docking static pre-stress. |
| 19 | + |
| 20 | +Duplicate systems for mesh and joint-stiffness sensitivity instead of overwriting evidence. |
| 21 | + |
| 22 | +## Units and material |
| 23 | + |
| 24 | +Use mm, N, s and tonne consistently in APDL imports. The preliminary material is aluminium 7075-T6 with E = 71,700 MPa, ν = 0.33, density = 2.81×10⁻⁹ tonne/mm³ and room-temperature yield screening strength = 503 MPa. Replace this with temperature- and product-form-specific allowables before making design claims. |
| 25 | + |
| 26 | +## Global line model |
| 27 | + |
| 28 | +Import or execute `analysis/ansys/v0_3/apdl/asterion_line_model.inc`. Confirm: |
| 29 | + |
| 30 | +- 222 structural nodes; |
| 31 | +- 580 BEAM188 elements; |
| 32 | +- seven tube section families; |
| 33 | +- no zero-length or duplicate elements; |
| 34 | +- beam orientation is consistent; and |
| 35 | +- section assignment matches `beam_sections.csv`. |
| 36 | + |
| 37 | +## Non-structural masses |
| 38 | + |
| 39 | +Use `analysis/ansys/v0_4/model/remote_mass_definitions.csv` as the mass ledger. Prefer Mechanical Remote Mass objects connected to reviewed attachment frames. The included MASS21 macro is a seed only; uncoupled mass nodes are invalid. |
| 40 | + |
| 41 | +For the rotating habitation sectors, place mass at the ring nodes and include centrifugal acceleration. For modal analysis, include suitable rotary inertia estimates once the subsystem geometry is available. |
| 42 | + |
| 43 | +## Supports |
| 44 | + |
| 45 | +The aft-fixed support is a ground-test/screening boundary condition. It is not a realistic flight condition. For flight static studies, use a minimum 3-2-1 stabilisation scheme or inertia relief and confirm reactions do not dominate the reported load path. |
| 46 | + |
| 47 | +## Required result objects |
| 48 | + |
| 49 | +For every static case request: |
| 50 | + |
| 51 | +- total deformation; |
| 52 | +- directional deformation X/Y/Z; |
| 53 | +- equivalent stress; |
| 54 | +- beam axial force; |
| 55 | +- beam bending moment and torsion; |
| 56 | +- reaction forces and moments; |
| 57 | +- interface loads; and |
| 58 | +- factor-of-safety user result. |
| 59 | + |
| 60 | +For modal studies request at least 16 modes, participation factors and effective mass. For free-free analysis, the first six modes must be rigid-body modes near zero frequency. |
| 61 | + |
| 62 | +## Mesh convergence |
| 63 | + |
| 64 | +Run B1, B2 and B3 from `mesh_convergence_plan.csv`. Compare a physically meaningful displacement, member force, first ten flexible frequencies and non-singular stress. A converged contour picture alone is not sufficient. |
| 65 | + |
| 66 | +## Buckling |
| 67 | + |
| 68 | +Link Eigenvalue Buckling to LC-STR-01 pre-stress. Inspect mode shapes and reject local numerical artefacts. A positive eigenvalue above the criterion does not prove stability; follow with geometric nonlinearity and seeded imperfections in V0.8. |
| 69 | + |
| 70 | +## Evidence capture |
| 71 | + |
| 72 | +Complete the CSV templates in `results_templates/`. Save screenshots showing model tree, mesh statistics, boundary conditions, solver messages, deformation scale, legends and probe locations. Record the exact ANSYS release and project checksum. |
| 73 | + |
| 74 | +## Student-computer strategy |
| 75 | + |
| 76 | +Keep the global model as beams. Use shells only for ring hubs and docking frames, then solids only as local submodels. Do not solve the complete spacecraft as a detailed solid mesh. |
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