The satellite structural mass is considered a crucial parameter during the process of satellite structural design. Sandwich structures acquire a considerable role in minimizing such mass while maintaining structural integrity. This article discusses the structural configuration, design, and analysis of a small satellite. A small Earth remote sensing satellite is chosen from the published data as a case study. Its structural design configuration is of a rectangular box that is based upon metallic alloys. Through a comprehensive study, the most suitable design configuration for the given mission is selected. A contribution has been made in developing a novel hexagonal primary structure that is based upon Aluminum honeycomb sandwich panels. The satellite configuration process and structural design procedure are thoroughly presented. The finite element modeling of honeycomb sandwich panels according to sandwich theory is introduced. Such modeling is validated numerically in comparison with published data. The analysis process is implemented using finite element analysis considering the loads during the ground and launch phases. The proposed structural design results in a significant mass reduction of 15% when compared with the baseline case study.

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The honeycomb sandwich structures have a crucial participation in aerospace industry, especially in the design of satellite structures due to their exceptional mechanical properties. The equivalent finite element modeling of such structures is initially presented through the implementation of modal analysis via the three-layered sandwich theory. Subsequently, the computational results are validated by carrying out an experimental modal testing. In addition, sensitivity analysis based upon design of experiments and parameters correlation, is executed for the sake of selecting the most appropriate design parameters for the optimization problem. Finally, finite element model updating of a honeycomb sandwich plate is thoroughly introduced using three optimization algorithms including genetic algorithms, adaptive-multiple optimization, and response surface method. A good agreement between the previously-mentioned optimization algorithms is obtained. Meanwhile, response surface method and its related design of experiments tool succeed in avoiding such time-consuming process and reduce the involved computational expense with an acceptable accuracy.

Honeycomb structures have been widely used in several applications and industries in the past decades. Such structures have a significant role in aerospace engineering especially in building up the satellite structures. Honeycomb structures provide key benefits represented in high specific strength, high specific stiffness, and superior dimensional stability. Detailed finite element modelling of such structures is a great challenge as it involves high computational expense. Thus, equivalent modelling is mandatory. The detailed and equivalent finite element models of a honeycomb plate are introduced intensively throughout analyzing its dynamic behaviour using the modal analysis module in ANSYS workbench software. The equivalent modelling is carried out via the three-layered sandwich theory and leads to the calculation of the first four natural frequencies and the related mode shapes. An experimental modal testing of the honeycomb sandwich plate is implemented for the sake of validating the computational results. A good agreement is obtained when comparing both experimental and computational results with mean error not exceeding 5%. Finally, a parametric study is performed to relate the modal analysis results with different boundary conditions cases. The results show that the model can be a reliable basis for satellite honeycomb sandwich structures design.