Finite Element Analysis of Frame Section from ESCARGO BEXUS Gondola

This project, part of the EMS724 module, investigates the static performance of a 3D frame structure used in ESA’s BEXUS high-altitude balloon missions. Through ABAQUS modeling and analysis, the frame design was refined to withstand the stresses encountered at altitudes up to 30 km over multi-hour flights.

Project Overview:

• Structure and Model: The study focuses on a 45x45mm frame section from the ESCARGO gondola. The 3D model in ABAQUS captures the frame’s essential features to simulate realistic stress conditions.

• Mesh Convergence: A mesh convergence study was conducted to ensure accuracy while optimizing computational resources. This refinement process balanced element size with solution precision.

• Design Revisions: After achieving convergence, structural modifications were tested in ABAQUS to examine their impact on stress distribution and overall performance.

Visuals:

Figure 1: ESCARGO Frame

Figure 2: Cross-Section Schematic of Simplified ESCARGO Frame

Figure 3: Simplified ESCARGO Frame Within ABAQUS

Learning Outcomes:

This project improved my FEA skills, particularly in ABAQUS, and provided valuable experience in iterative design analysis.

Key Skills: FEA, Mesh Convergence, Structural Simulation, Design Iteration, Analytical Problem Solving.