Appendix I. The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models

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1 119 Appendix I The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models Anton Zhukov Markus Czupalla Alexander Kuisl Gerhard Bleicher Winfried Gambietz (Kayser-Threde GmbH, Müchen, Germany)

2 120 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models Abstract The analysis of the thermo-opto-mechanical performance of optical instruments is a complex and time consuming process. It spans across multiple disciplines and multiple tools (e.g. ESATAN, NASTRAN, ZEMAX) which are not designed to interface with one another. To allow precise end-to-end thermo-opto-mechanical analyses of instruments, without the loss of data, KT establishes a software suite (MULTIPAS), which inherently connects the thermal, structural and optical tools. An important part of the MULTIPAS software suit is the Thermal Mapping Tool (TMT) providing the link between the thermal and structural model. The tool realize an automated temperature mapping process based on in-house interpolations routines and has the ability to handle mismatching meshes of the thermal and structural models. To preserve thermal boundaries between the parts a recognition of single parts is built in the TMT, allowing to map geometrically adjacent but thermally decoupled parts correctly. Further, edge effects are covered in a way that guarantees no extrapolations at the edges, preserving the temperature range prescribed by the thermal model. A built in batch mode allows for handling of thousands of time steps, opening the door to transient stability analyses of entire orbits. Demonstration of the TMT functionality, results from application experience will be presented and discussed in the presentation. Further, conclusions shall be presented and discussed for the build of GMMs which are to be used as mapping "templates".

The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models 121 Kayser-Threde GmbH Space Industrial Applications 27th European Space Thermal Analysis

3 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models 121 Kayser-Threde GmbH Space Industrial Applications 27th European Space Thermal Analysis Workshop KT Thermal Mapping Tool A. Zhukov, M. Czupalla, A. Kuisl, G. Bleicher, W. Gambietz SUMMARY Thermal Mapping Rationale KT MultiPAS Tool KT Thermal Mapping Tool (TMT) Introduction Mapping Process Software Modules Example Structural Model Thermal Model Model Comparison Mapping Process Mapping Verification Summary Kayser-Threde GmbH, Munich

25 20 15 10 5 0-5 -10-15 -20 0 1 2 3 4 5 6 7 8 9 time (s) x 10 4 22 20 18 16 122 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models Thermal

2 4.4 4.6 x 10 4-5 -10-15 -20 0 1 2 3 4 5 6 7 8 9 time (s) x 10 4 3 03.12.

PRESERVATION HANDLING OF MISMATCHING GEOMETRIES Thermo-Opto-Mechanical Performance is a driver for the design of optical instruments KT has formalized the process with the MultiPAS tool, which

4 time (s) x The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models Thermal Mapping Rationale MultiPAS THERMAL MODEL STRUCTURAL MODEL OPTICAL MODEL Thermo-Opto-Mechanical Performance is a driver for the design of optical instruments WFE (nm RMS) x time (s) x Kayser-Threde GmbH, Munich Thermal Mapping Rationale MultiPAS AUTOMATED MAPPING SINGLE PART RECOGNITION BATCH HANDLING OF THOUSANDS OF TIME STEPS EDGE COVERAGE WITH TEMPERATURE RANGE PRESERVATION HANDLING OF MISMATCHING GEOMETRIES Thermo-Opto-Mechanical Performance is a driver for the design of optical instruments KT has formalized the process with the MultiPAS tool, which connects the corresponding models and provides orbital performance results R E S U L T S GRAVITY RELEASE THERMAL MODEL STRUCTURAL MODEL OPTICAL MODEL M U L T I P A S C A S E S E L E C T I O N MOISTURE RELEASE I/F DEFORMATIONS THERMAL LOADS MICRO-VIBRATIONS WFE (nm RMS) x 10 4 TRANSFER OF STRUCTURAL DEFORMATIONS TO OPTICAL SURFACE SAG CALCULATION OF ZERNIKE POLYNOMIALS BATCH CALCULATIONS OF OPTICAL PERFORMANCE METRICS AUTOMATED OPTICAL ELEMENT RECOGNITION & ASSIGNMENT Kayser-Threde GmbH, Munich CORRECTION OF FEM OPT. SURFACE MESHES

The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models 123 Thermal Mapping Rationale MultiPAS AUTOMATED MAPPING SINGLE PART RECOGNITION BATCH

5 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models 123 Thermal Mapping Rationale MultiPAS AUTOMATED MAPPING SINGLE PART RECOGNITION BATCH HANDLING OF THOUSANDS OF TIME STEPS EDGE COVERAGE WITH TEMPERATURE RANGE PRESERVATION HANDLING OF MISMATCHING GEOMETRIES Thermo-Opto-Mechanical Performance is a driver for the design of optical instruments KT has formalized the process with the MultiPAS tool, which connects the corresponding models and provides orbital performance results R E S U L T S GRAVITY RELEASE THERMAL MODEL STRUCTURAL MODEL OPTICAL MODEL M U L T I P A S C A S E S E L E C T I O N MOISTURE RELEASE I/F DEFORMATIONS THERMAL LOADS MICRO-VIBRATIONS TRANSFER OF STRUCTURAL DEFORMATIONS TO OPTICAL SURFACE SAG CALCULATION OF ZERNIKE POLYNOMIALS Kayser-Threde GmbH, Munich BATCH CALCULATIONS OF OPTICAL PERFORMANCE METRICS AUTOMATED OPTICAL ELEMENT RECOGNITION & ASSIGNMENT CORRECTION OF FEM OPT. SURFACE MESHES Thermal Mapping Rationale MultiPAS AUTOMATED MAPPING SINGLE PART RECOGNITION BATCH HANDLING OF THOUSANDS OF TIME STEPS EDGE COVERAGE WITH TEMPERATURE RANGE PRESERVATION HANDLING OF MISMATCHING GEOMETRIES Thermo-Opto-Mechanical Performance is a driver for the design of optical instruments KT has formalized the process with the MultiPAS tool, which connects the corresponding models and provides orbital performance results THERMAL MODEL STRUCTURAL MODEL Thermal Mapping Tool Features automated mapping single part recognition batch handling of thousands of time steps edge coverage with temperature range preservation handling of mismatching geometries Kayser-Threde GmbH, Munich

6 124 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models TMT Introduction Mapping Process : Models are separated into conductive units Thermal Model Structural Model Model Assignment Model Parting Kayser-Threde GmbH, Munich TMT Introduction Mapping Process : Models are separated into conductive units CS Correction: Models are positioned to allow initial 3-D mapping Thermal Model Structural Model Model Assignment Model Parting parted models Coordinate System Correction Kayser-Threde GmbH, Munich

7 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models 125 TMT Introduction Mapping Process : Models are separated into conductive units CS Correction: Models are positioned to allow initial 3-D mapping Thermal Mapping: Main Mapping: Algorithm defines temperatures for main structural (FEM) nodes as a function of thermal elements Rest Node Mapping: not covered structural areas are defined based on existing ones (no further use of the thermal model) Thermal Model Structural Model Model Assignment Model Parting parted models Coordinate System Correction parted & positioned models Thermal Mapping Main Mapping Rest Nodes Mapping Kayser-Threde GmbH, Munich TMT Introduction Mapping Process : Models are separated into conductive units CS Correction: Models are positioned to allow initial 3-D mapping Thermal Mapping: Main Mapping: Algorithm defines temperatures for main structural (FEM) nodes as a function of thermal elements Rest Node Mapping: not covered structural areas are defined based on existing ones (no further use of the thermal model) NASTRAN Export: Mapping Algorithm defines temperatures for structural (FEM) nodes as a function of thermal nodes Thermal Model Structural Model Model Assignment Model Parting parted models Coordinate System Correction parted & positioned models Thermal Mapping Main Mapping Rest Nodes Mapping temperature maps NASTRAN Export FEM nodes with temperatures in NASTRAN-Format Temperature File Kayser-Threde GmbH, Munich

126 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models TMT

Structural Model Model Assignment Model Parting parted models Coordinate System Correction parted & positioned models

NASTRAN-Format Temperature File 11 03.12.

8 126 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models TMT Introduction Software Modules CS Correction Thermal Mapping Main Mapping Rest Node Mapping NASTRAN Export Thermal Model Structural Model Model Assignment Model Parting parted models Coordinate System Correction parted & positioned models Thermal Mapping Main Mapping Rest Nodes Mapping temperature maps NASTRAN Export FEM nodes with temperatures in NASTRAN-Format Temperature File Kayser-Threde GmbH, Munich TMT Introduction Software Modules GLOBAL MULTIPAS MODULE TMT MODULES CS Correction Thermal Mapping Main Mapping Rest Node Mapping NASTRAN Export Kayser-Threde GmbH, Munich

The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models 127 Example

and cover Bolted bridge danger of mapping from the wrong part 13 03.12.

HOUSING COVER Structural Model Mixed mesh (solids (3-D) and shells (2-D)) High level of details (holes, chamfers,

9 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models 127 Example MERTIS TMA Three Mirror Assembly of MERTIS complex 3-D structure Bolted cover high temperature gradient between housing and cover Bolted bridge danger of mapping from the wrong part Kayser-Threde GmbH, Munich Example Structural Model MERTIS TMA Three Mirror Assembly of MERTIS complex 3-D structure Bolted cover high temperature gradient between housing and cover Bolted bridge danger of mapping from the wrong part HOUSING COVER Structural Model Mixed mesh (solids (3-D) and shells (2-D)) High level of details (holes, chamfers, edges) BRIDGE CAGE Kayser-Threde GmbH, Munich

128 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models Example

between housing and cover Bolted bridge danger of mapping from the wrong part Structural Model HOUSING BRIDGE COVER

degree of defeaturing NO holes, chamfers, edges No modeled depiction of bolted I/F (considered in TMM) CAGE 15 03.12.

structure Bolted cover high temperature gradient between housing and cover Bolted bridge danger of mapping from the

(considered in TMM) Model comparison must detect/prescribe part limits Algorithm must deal with mismatching meshes 16

10 128 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models Example Thermal Model MERTIS TMA Three Mirror Assembly of MERTIS complex 3-D structure Bolted cover high temperature gradient between housing and cover Bolted bridge danger of mapping from the wrong part Structural Model HOUSING BRIDGE COVER Mixed mesh (solids (3-D) and shells (2-D)) High level of details (holes, chamfers, edges) Thermal Model (GMM) High degree of defeaturing NO holes, chamfers, edges No modeled depiction of bolted I/F (considered in TMM) CAGE Kayser-Threde GmbH, Munich Example Model Comparison STRUCTURAL THERMAL Three Mirror Assembly of MERTIS complex 3-D structure Bolted cover high temperature gradient between housing and cover Bolted bridge danger of mapping from the wrong part Structural Model Mixed mesh (solids (3-D) and shells (2-D)) High level of details (holes, chamfers, edges) Thermal Model (GMM) High degree of defeaturing NO holes, chamfers, edges No modeled depiction of bolted I/F (considered in TMM) Model comparison must detect/prescribe part limits Algorithm must deal with mismatching meshes Kayser-Threde GmbH, Munich

11 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models Kayser-Threde GmbH, Munich Kayser-Threde GmbH, Munich

12 130 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models Kayser-Threde GmbH, Munich Kayser-Threde GmbH, Munich

13 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models 131 CS Correction Kayser-Threde GmbH, Munich CS Correction Kayser-Threde GmbH, Munich

132 The KT Thermal Mapping Tool an semi-automated

models CS Correction Thermal Mapping Main Mapping

2013 Kayser-Threde GmbH, Munich CS Correction

14 132 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models CS Correction Thermal Mapping Main Mapping Rest Node Mapping Kayser-Threde GmbH, Munich CS Correction Thermal Mapping Main Mapping Rest Node Mapping Kayser-Threde GmbH, Munich

15 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models 133 CS Correction Thermal Mapping Main Mapping Rest Node Mapping Kayser-Threde GmbH, Munich CS Correction Thermal Mapping Main Mapping Rest Node Mapping Kayser-Threde GmbH, Munich

134 The KT Thermal Mapping Tool an semi-automated

Mapping Verification was performed for generic cases

solids) was used as reference When boundary load

16 134 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models CS Correction Thermal Mapping Main Mapping Rest Node Mapping NASTRAN Export NASTRAN compatible output Kayser-Threde GmbH, Munich Mapping Verification Mapping Verification was performed for generic cases A FEM analysis of continuous parts (beams, plates, solids) was used as reference When boundary load injection issues are disregarded (middle of element is ESATAN vs. node on the side of FEM in FEM) an excellent mapping quality is reached error better than 2% in all cases Kayser-Threde GmbH, Munich

The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models 135 Mapping Verification Mapping Verification was performed for generic cases A FEM analysis

node on the side of FEM in FEM) an excellent mapping quality is reached In every-day mapping the success of the process is verified by visual inspection comparison of 2-D maps part by part) 29 03.12.

17 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models 135 Mapping Verification Mapping Verification was performed for generic cases A FEM analysis of continuous parts (beams, plates, solids) was used as reference error better than 2% in all cases When boundary load injection issues are disregarded (middle of element is ESATAN vs. node on the side of FEM in FEM) an excellent mapping quality is reached In every-day mapping the success of the process is verified by visual inspection comparison of 2-D maps part by part) Kayser-Threde GmbH, Munich Mapping Verification Mapping Verification was performed for generic cases A FEM analysis of continuous parts (beams, plates, solids) was used as reference error better than 2% in all cases When boundary load injection issues are disregarded (middle of element is ESATAN vs. node on the side of FEM in FEM) an excellent mapping quality is reached In every-day mapping the success of the process is verified by visual inspection comparison of 2-D maps part by part) Comparison of transient plots part by part Kayser-Threde GmbH, Munich

136 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models Summary KT has generated an highly

Performance Analysis Software Suite (MultiPAS) The TMT allows a fast and precise transfer of temperatures from thermal models onto FE Models for

Mapping Rest Node Mapping NASTRAN Export (incl.

18 136 The KT Thermal Mapping Tool an semi-automated temperature transfer between structural and thermal models Summary KT has generated an highly automated Temperature Mapping Process The Process is reflected in a corresponding software Thermal Mapping Tool The TMT is part of a bigger Optical Performance Analysis Software Suite (MultiPAS) The TMT allows a fast and precise transfer of temperatures from thermal models onto FE Models for multiple time points over the orbit The process is broken down into four main parts Model Parting Coordinate System Correction Thermal Mapping Main Mapping Rest Node Mapping NASTRAN Export (incl. verification) The mapping preserves temperature boundaries defined by the thermal model edge temperatures (temperature regions) defined by the thermal model The mapping algorithm was successfully verified against FEM thermal analyses Kayser-Threde GmbH, Munich

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