TOMARES - Topology optimization of an additive manufactured reaction flywheel designed for an Earth-observation satellite

Abstract

In aerospace industry, saving mass on spacecrafts always remain in large demand to save launch costs or increase the available payload mass. A case study is carried out designing a frst concept of an additive manufactured fywheel of a reaction wheel, as it is one of the heaviest parts of wheel systems. As an objective the mass is minimized, while obtaining an angular momentum suitable according to mission requirements and maintaining recent performances. As references the SeaSAT mission and a commercial reaction wheel are used. The work includes a preliminary dimension of the fywheels design space by MATLAB calculations, where in total 15 shapes are analyzed and compared. The most promising design space is afterwards analyzed via the fnite-element tool ANSYS and is defned as the reference fywheel. The reference fywheel is used for topology optimizations (ANSYS Topology Optimization), where diferent boundary conditions are considered. The fnal designed fywheel obtains 16% higher energy density than the reference fywheel and withstands the mission loads. It can be concluded that it was possible to design a fywheel obtaining less mass while keeping the expected performance.