Experimental and numerical study of composite sandwich panels for lightweight structural design

Thiagarajan, Suryaprakash; Munusamy, Raguraman

doi:10.1080/13588265.2020.1838178

Cited by 14 publications

(4 citation statements)

References 16 publications

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“…[1][2][3][4] For example, sandwich structures provide a non-magnetic hull with low heat and noise signature in marine applications, 5 they are critical for impact energy absorption in transportation, 6 they make up a large portion of the airframe (e.g., >50% in the Boeing 787), 7 and they also serve as effective thermal insulation in trailers. 8 These structures, which serve as primary load-bearing components and are subjected to various loading conditions, require high specific strength, energy absorption, and low density. Nevertheless, these 3D-printed structures can fail when exposed to compressive or impact loads due to brittle fracture, crushing or low energy absorption.…”

Section: Introductionmentioning

confidence: 99%

“…Sandwich composite structures, which consist of two thin face sheets with a low‐density core structure, are widely used due to their mechanical advantages such as low density, high strength, significant bending stiffness and improved energy absorption capacity 1–4 . For example, sandwich structures provide a non‐magnetic hull with low heat and noise signature in marine applications, 5 they are critical for impact energy absorption in transportation, 6 they make up a large portion of the airframe (e.g., >50% in the Boeing 787), 7 and they also serve as effective thermal insulation in trailers 8 . These structures, which serve as primary load‐bearing components and are subjected to various loading conditions, require high specific strength, energy absorption, and low density.…”

Section: Introductionmentioning

confidence: 99%

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Effect of varying core density and material on the quasi‐static behaviors of sandwich structure with 3D‐printed hexagonal honeycomb core

Ainin,

Azaman,

Majid

et al. 2024

Polymer Composites

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Additive manufacturing (AM) involves the development of complex, lightweight sandwich structures for the automotive and aerospace industries. These structures are essential for load bearing and impact resistance. Nevertheless, there is a significant obstacle of failure under compressive loading, e.g. through brittle fractures and crushing. To address this issue, this study evaluates the compressive properties, energy absorption and failure damage in quasi‐static tests (flatwise, in‐plane, and flexural) of sandwich composites with 3D‐printed hexagonal honeycomb cores of different unit cells (6, 8 and 10 mm) and materials (polylactic acid (PLA), PLA‐Carbon and PLA‐Wood). The results show that increasing the core density enhances compressive strength, modulus, and energy absorption. An 8 mm unit cell absorbs energy optimally for lightweight structures. In PLA flatwise testing, the 8 mm unit cell absorbed 419.49 J more energy than the 10 mm unit cell. Additionally, PLA‐Wood has better mechanical performance than PLA‐Carbon due to the better filler with the PLA‐ matrix. In flatwise testing with an 8 mm unit, PLA‐Wood absorbs 214.01 J, while PLA‐Carbon absorbs 122.49 J. The failure modes vary depending on tests performed. The study highlights the potential of 3D‐printed honeycomb core structures for load‐bearing applications in various industries, including aerospace and automotive.Highlights Quasi‐static loading behavior of 3D‐printed hexagonal honeycomb cores. Increased core density improves compressive stress, modulus, and absorbed energy. An optimal unit cell size for lightweight 3D printed core structures is 8 mm. PLA‐Wood performs better in energy absorption due to filler compatibility. The failure modes are related to the type of quasi‐static loads applied.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effect of varying core density and material on the quasi‐static behaviors of sandwich structure with 3D‐printed hexagonal honeycomb core

Ainin,

Azaman,

Majid

et al. 2024

Polymer Composites

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“…Aluminum alloy is abundantly used for the light structure application because easier to manufacture and fabricate. Aluminum alloys with more than 1 mm thicknesses have been used for decades to save weight in a structural body or small parts in the automobile or vehicle industry, such as aluminum sandwich sheets for automotive hoods [1,2]. In addition, it allows for increased fuel efficiency and performance.…”

Section: Introductionmentioning

confidence: 99%

Optimizing and selecting tool design of micro friction stir spot weld for corrugated sandwich panel applications

Amat,

Andhika,

Pratama

et al. 2023

Preprint

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Tool geometries and plunge depth play significant roles in the stirring process of micro friction stir spot weld (µFSSW). Those two variables affecting the hook and joint formation, which leads to the joint strength of a single spot weld. The present work investigates the influence of tool geometry and plunge depth on the weld's quality. Furthermore, the result from the investigation will be used for reference to optimize the tool's design in the future based on the joint strength characteristics. It is performed on a 0.42-mm-thick AA1100 lap-shear joint and investigates each tool's macrostructure and mechanical properties. There were seven tool designs and three plunge depth variations. The plunge depth was varied to determine the hook and joint formation evolution in each tool design using macrostructural studies and determine the best plunge depth for the highest tensile shear load. While the tool design variation investigates the influence of size and geometry on joint characteristics, finding the best geometry corresponds with the highest tensile shear load. Regression and prediction interval analysis is used for the tensile shear load (max. load). The result shows that the formation of a hook, such as a straight or bending shape, depends on the feature of the stir zone, which is affected by the tool's geometry. The hook shape and location would determine the possibility of crack propagation path and ultimately affect the max load.

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“…In addition, the designed vehicles must be robust enough to meet the safety regulations and meet the pedestrian and passenger safety criteria (Pan, et al, 2020;Xiong, et al, 2018). Sandwich composite structures are materials that can meet all expectations in the automotive industry in the most ideal way, with their high specific strength, specific bending stiffness and superior crash energy absorption capacity (Thiagarajan and Munusamy, 2020;Hung, et al, 2022;Shu, et al, 2018). Moreover, these materials have important advantages as they can be produced in one piece and monocoque in desired part shapes and can also offer sound and heat insulation depending on the characteristics of the core structure used (Wang et al, 2021).…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation of Crush Energy Absorption and Strength Properties of Sandwich Plates With Aluminum Facesheet/ Expanded Polypropylene Foam Core

Türkoğlu

2022

UUJFE

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Due to the developing electric vehicle industry in the last decade, weight reduction studies on vehicle bodies have gained great importance. Foam core sandwich structures stand out as the most ideal materials in terms of providing both weight reduction and strength conditions in the bodies of electric individual and public transportation vehicles. In this study, EPP foams with two different densities were placed between aluminum plates and sandwich structures were obtained by combining the two structures with an EVA-based adhesive. Compression and bending behaviors of the produced sandwich structures were investigated under quasi-static and dynamic loading conditions. With the tests carried out, the strength of the sandwich structures and the amount of energy they absorb were calculated and compared experimentally. According to the results obtained, it was observed that the denser D2 foam exhibited approximately 1.4 to 2.05 times more strength than the lower density D1 foam in all tests. In terms of the energy they absorb, the D2 foam absorbs 1.25 to 2.5 times more energy than the other foam. Contrary to this situation, only the dynamic compression test occurred in the tests performed. When the post-damage behavior of the sandwich structures was examined, it was also observed that the D2 foam returned to a very similar dimensions to its original size, giving more of the deformation after the damage at the end of 72 hours.

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Experimental and numerical study of composite sandwich panels for lightweight structural design

Cited by 14 publications

References 16 publications

Effect of varying core density and material on the quasi‐static behaviors of sandwich structure with 3D‐printed hexagonal honeycomb core

Effect of varying core density and material on the quasi‐static behaviors of sandwich structure with 3D‐printed hexagonal honeycomb core

Optimizing and selecting tool design of micro friction stir spot weld for corrugated sandwich panel applications

Experimental Investigation of Crush Energy Absorption and Strength Properties of Sandwich Plates With Aluminum Facesheet/ Expanded Polypropylene Foam Core

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