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Manufacturing Error-Based Surface Profile Correction Method for Accurate Modeling Composite Antenna Panels

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Abstract

To improve the simulation accuracy and evaluate the potential failure regions, this study proposes two finite element model correction methods based on surface manufacturing error: the direct numerical correction method and the deformation coordination correction method. Their methods aim to accurately describe the profile state of the composite antenna panel. The initial finite element model of prototype panel (Model IN) is respectively corrected by the direct numerical correction method (Model DN) and the deformation coordination correction method (Model DC). The prototype panel is then subjected to temperature difference testing. A comparison between the simulations and the test results reveals that Model DN and Model DC can predict the surface error distribution (SED) that Model IN lacks. The simulation results from Model DN and Model DC are overall consistent with the actual measurements obtained from the prototype panel tests. The average deviation of the simulated surface accuracy root mean square (rms) by Model DC from the test rms is only 1.66%, whereas that by Model DN is 19.44%. This demonstrates that the deformation coordination correction method effectively maintains simulation reliability in predicting antenna panel surface accuracy. Consequently, finite element model corrected by this method can provide valuable data support for evaluating the influence of potential failure regions and mitigating the impact on antenna surface accuracy.

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Acknowledgments

This work was partially supported by the National Key Basic Research and Development Program (Grant No. 2019YFA0708904), the National Natural Science Foundation of China (Grant No. 52005256), the Postgraduate Research and Practice Innovation Program of NUAA (No. xcxjh20220103) and the Priority Academic Program Development of Jiangsu Higher Education Institutions.

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Authors and Affiliations

  1. State Key Laboratory of Mechanics and Control for Aerospace Structures, Nanjing University of Aeronautics and Astronautics, Nanjing, China

    Dongrun Wu, Zhihao Qiu, Yanpeng Hu & Deng’an Cai

  2. Purple Mountain Observatory, Chinese Academy of Sciences, Nanjing, China

    Xincheng Tan & Yuan Qian

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  1. Dongrun Wu
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  2. Zhihao Qiu
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  3. Xincheng Tan
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  4. Yanpeng Hu
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  5. Yuan Qian
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  6. Deng’an Cai
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Correspondence to Deng’an Cai.

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Wu, D., Qiu, Z., Tan, X. et al. Manufacturing Error-Based Surface Profile Correction Method for Accurate Modeling Composite Antenna Panels. J Fail. Anal. and Preven. 23, 2386–2401 (2023). https://doi.org/10.1007/s11668-023-01787-5

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  • DOI: https://doi.org/10.1007/s11668-023-01787-5

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