Dynamic Modeling and Thermo-Mechanical Coupling Analysis of Variable-Geometry Spacecraft Antenna with Clearance Hinges Under Extreme Thermal Environment

Extreme cyclic temperature fluctuations (−200 °C to 200 °C) and inherent clearance nonlinearity in deployment hinges severely threaten the on-orbit deployment accuracy and dynamic stability of large variable-geometry spacecraft antennas for geosynchronous Earth orbit applications. However, current modeling approaches suffer from three critical limitations: single-configuration models requiring manual switching, there are inherent geometric nonlinear errors from conventional floating frame formulations, and incomplete thermo-mechanical coupling neglects the temperature effects on contact stiffness and friction. To address these gaps, we propose a unified high-fidelity dynamic model based on the Absolute Nodal Coordinate Formulation (ANCF). This model eliminates geometric errors and mesh mismatch, enables seamless multi-configuration deployment without switching, and fully incorporates temperature-dependent material properties and nonlinear contact forces. An improved Hilber–Hughes–Taylor- (Formula presented.) implicit integration algorithm with second-order accuracy and unconditional stability is adopted to solve the strongly nonlinear differential-algebraic equations. Numerical results demonstrate that the proposed model achieves a calculation error below 3% against experimental data, significantly outperforming the traditional floating frame of reference formulation with an error of 15–22%. Non-uniform temperature fields increase thermally induced vibration amplitudes by 32–45%, and every 0.1 increase in the friction coefficient raises the impact force at the clearance hinge by 15–20%. The proposed unified modeling framework provides a solid theoretical basis for deployment stability prediction and the on-orbit control optimization of large variable-geometry spacecraft antennas.