The aerospace sector is playing an increasingly important role at Merkle CAE Solutions.

Thanks to our strategic partnership with OHB System AG, one of the three largest aerospace companies in Germany, we are able to describe and simulate an ever-growing range of topics at a level of detail previously unheard of in this industry.

Created by Dipl.-Ing. (TU) Stefan Merkle

08/22/2023

Simulation and Multiphysics Engineering for the Aerospace Industry

Merkle CAE Multiphysics in the Aerospace Industry

The development of modern space systems places the highest demands on design, material selection, and system understanding. Satellites, instruments, and space systems must withstand extreme environmental conditions—from intense vibrations during rocket launch to thermal cycles in orbit.

Virtual development and numerical simulation are therefore a central component of modern space projects. They make it possible to understand complex physical interactions at an early stage, reduce risks, and optimize development cycles.

Merkle CAE supports companies and research institutions in simulating complex space systems—from individual components to integrated system analyses.

Merkle CAE Aerospace Particle Accumulation Simulation — Particle accumulation in the vicinity of a scientific satellite

Simulation as a Key Technology in Space Exploration

Space systems must operate under conditions that can only be replicated to a limited extent on Earth. At the same time, repairs in orbit are usually not possible. A reliable system design is therefore crucial.

Typical challenges include:

Extreme environmental conditions

· Significant temperature gradients

· Thermal cycles in orbit

· Vacuum and outgassing

Merkle CAE Aerospace Outgassing 1 — Outgassing in laminar flow

Merkle CAE Aerospace Outgassing 2 — Outgassing in turbulent flow

Mechanical stresses

· Vibration and shock loads during rocket launch

· Structural and natural frequency issues

· Lightweight construction combined with high rigidity

Merkle CAE Aerospace Chime — Complexity of an assembly in the CHIME project.

Multiphysical interactions

· Thermal Effects on Optical Systems

· Structure-Thermal Couplings

· Electromagnetic Effects on Electronic Systems

Merkle CAE Aerospace Project CHIME — Flow conditions regarding velocity near the wall in CHIME.

Aerospace as a Growing Area of Application at Merkle CAE

Merkle CAE Ariane 5 Rocket Nose Cone — Ariane 5 rocket nose cone

For many years, the automotive sector at Merkle CAE served as a key driver of technology for complex simulations. The methods developed there for analyzing complex physical relationships now form an important foundation for applications in high-tech industries such as aerospace.

In recent years, Merkle CAE has increasingly established itself in the aerospace sector. A key factor in this has been the collaboration with OHB System AG, one of Germany’s largest aerospace companies.

In addition, Merkle CAE is increasingly involved in projects for the European Space Agency (ESA), including those under the ESA Spark Funding Programs.

These projects enable the development and validation of new simulation methods and innovative applications for space systems.

Initial particle accumulation in crevices and on the communications satellite

Dissolution of the particles by the cooling air flow

Particle accumulation in the vicinity of the scientific satellite

CFD Flow Analysis of a Horizontal Cleanroom

Flow Velocities in a Horizontal Cleanroom (CFD)

Detailed view of the integration hall with FFU and satellite

Our simulation expertise for aerospace projects

Merkle CAE has many years of experience in the numerical simulation of complex technical systems.

Typical applications in the aerospace industry include:

Structural and Strength Simulation

· Start-up loads

· Vibration and modal analysis

· Lightweight design optimization

· Structural stability

Thermal Simulation

Thermal management is a key challenge in space systems.
Simulation is used for:

· Thermal Management in Orbit

· Thermal design of satellite components

· Thermally induced deformations

Optomechanical simulation

In optical systems in particular, even the slightest structural deformations or temperature changes can affect performance.

Learn more:
Simulating optomechanical systems

https://www.merkle-cae.com/optomechanical-systems

Multiphysics System Analysis

Spaceflight systems consist of many closely interrelated physical effects.
Typical analyses include:

· Thermomechanical couplings

· Structure-optics interactions

· System behavior of complex assemblies

Example from the aerospace industry: Simulation of purging and contamination control

Sensitive satellite components must be protected from contamination during integration, transport, and storage. Even the smallest particles can impair optical systems, sensors, or sensitive surfaces.

A commonly used method is known as purging: in this process, components are flushed with high-purity gases such as air or nitrogen to prevent the ingress of particles.

Computational fluid dynamics (CFD) simulations can be used to analyze key issues in this context:

Flow distribution within containment volumes
Potential dead zones
Transport and deposition of particles
Optimization of gas flow

Simulation makes it possible to optimize purging concepts as early as the development phase and reduce the risk of contamination.

Merkle CAE Aerospace Flow Analysis CHIME — Flow Analysis for the CHIME Purge Project

Insights and Projects from the Space Industry

Lunar Missions – The Challenge of Lunar Dust

Merkle CAE Aerospace Clean Air Lunar Dust — Airflow in a clean air chamber

Fine lunar dust is far more than just a byproduct of lunar landings. Due to its sharp-edged structure and electrostatic charge, it can impair mechanical systems, damage seals, and contaminate optical components.

For future long-duration missions, managing lunar dust will be a critical factor in the reliability and service life of systems. This article explains which physical effects play a role in this context and how simulation can help identify these risks early on.

➡ Feature article

From classic “rocket science” to modern simulation

Ariane Rocket Test Flight — Test stand for the Ariane 6 upper stage at the DLR site in Lampoldshausen

The development of space systems has undergone a fundamental transformation in recent decades. Whereas extensive physical testing was once necessary, simulation now enables a deep understanding of complex systems even in the early stages of development.

This development is particularly crucial in the space industry, where errors are virtually impossible to correct. This article demonstrates how modern simulation expands upon traditional “rocket science” and makes development processes more efficient and safer.

➡ Post

Young Talent and Innovation in Space Exploration

The future of space exploration is shaped not only by major research centers, but also by the next generation of talent, interdisciplinary collaboration, and new ideas. Events like MAKE 2024 vividly demonstrate how technologies become tangible and how enthusiasm for complex technical topics is sparked.

This article provides insights into current developments, innovative projects, and the importance of nurturing the next generation of talent for the space industry.

➡ Report on MAKE 2024

Vision Meets Simulation: The Lunar Airport as a Digital Concept

What will the infrastructure of tomorrow look like - beyond Earth?

Video: A realistic animation depicting the vision of a lunar airport

For our client OHB SE, we brought the vision of a lunar airport to life in a realistic animation. The scenario shown is more than just a futuristic depiction: it is an example of how complex space systems can already be digitally conceptualized, analyzed, and evaluated today.

A lunar airport places extreme demands on design and operation. Vacuum, reduced gravity, and especially the behavior of lunar dust (regolith) influence virtually all processes - from landing maneuvers and material stresses to the contamination of sensitive systems.

This is precisely where simulation-based development comes into play.

By using modern numerical methods such as CFD and FEM, critical issues can be investigated as early as the initial stages of development:

How does regolith behave when it is kicked up during landings?
What forces act on structures and systems?
How can infrastructure and procedures be designed to be robust and safe?

The combination of physics-based simulation and high-quality visualization fosters a deep understanding of the system. It allows us not only to demonstrate concepts, but also to rigorously evaluate them and refine them in a targeted manner.

Moonport exemplifies our approach to space exploration:

Making complex physical relationships visible –
and thereby laying the groundwork for informed decisions.