Insert of sandwich panels sizing through a failure mode map

Rodríguez-Ramírez, Juan de Dios; Castanié, Bruno

doi:10.1016/j.compstruct.2019.111724

Cited by 11 publications

(14 citation statements)

References 24 publications

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“…In the literature (Ramírez et al ., 2020), the behaviour of the inserts during pull-out and shear-out tests is similar to the results presented in our study. For the shear-out test results, the force-displacement diagrams show there were clearances in the measuring system, but this behaviour is due to the tolerances of the mounting device and of the dimensions of the samples and does not affect the quality of the method used.…”

Section: Results Discussionmentioning

confidence: 99%

Design, manufacturing and testing of pull-out and shear-out insert allowable for sandwich applications

Pelin,

Axenie,

Gaz

et al. 2023

AEAT

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Purpose This paper aims to present the procedures necessary to determine the insert allowable for a composite sandwich, considering that the inserts were the most commonly used means to install equipment on the composite structure of Clean Sky 2 (CS2)-RACER compound helicopter. Design/methodology/approach The installation of the equipment inside of the airframe shall comply with the certification regulations, especially in relation to the inertial factors. Establishing of the needed number of inserts to fix the equipment is directly linked to the allowable coming from coupon tests. The materials and test procedures to which they were subjected are part of the process qualification used in the development of the CS2-RACER Main Fuselage. The samples were tested in two different static mechanical loadings, consisting of pull-out insert and shear-out insert tests. The mechanical behaviour and failure mechanism of the materials were evaluated using optical and scanning electron microscopy. Findings The insert installation on the sandwich structure influences the behaviour and mechanical properties during pull-out and shear-out testing. Research limitations/implications The limited data available in standardized documents related to insert testing makes it difficult to compare results with certified baseline values. Practical implications To reduce the effort of selecting the optimized insert system, specific parameters are included in analytical pre-sizing, i.e. type of loads, geometry, materials, failure modes, special conditions such as manufacturing and testing. Originality/value The results of the study presenting the design, manufacturing and mechanical testing of pull-out and shear-out inserts used in composite materials sandwich-type coupons provide valuable information regarding the insert allowable determination.

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Section: Results Discussionmentioning

confidence: 99%

Design, manufacturing and testing of pull-out and shear-out insert allowable for sandwich applications

Pelin,

Axenie,

Gaz

et al. 2023

AEAT

View full text Add to dashboard Cite

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“…In addition, the main reason is linear finite element analysis was used which cannot adequately simulate the true effects of various sandwich components, non-linearity of Nomex honeycomb cells [28], and material degradations especially involving material yielding and large deformations. Thomsen [20] used the high-order theory to accurately estimate stress distribution in the core, face-sheet, and more currently, Rodríguez-Ramírez et al, in [25] proposed advanced nonlinear numerical simulation methods that can provide accurate pull-out strength estimations. Time and cost were the main factors when performing similar non-linear analyses.…”

Section: Simulation Results and Discussionmentioning

confidence: 99%

Analysis of Hard Point Mechanical Behaviour Due to Variations of Potting Agent Volume on a Composite Sandwich Panel

Mali

Hussain

HASSAN³

et al. 2022

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Composite sandwich panels are widely used in lightweight structures, especially in aerospace, automotive, and marine industries. They are chosen mainly because of the superiority of their specific stiffness as compared to solid panels. Stingray, a solar car designed by the UiTM Eco-photon team, applied this technology for its lightweight property. However, the honeycomb sandwich constructions were susceptible to localized load. Thus, load attachment points using metal inserts, also known as ‘hard points’, were introduced. In this study, the behaviour of hard points based on three volume variations of the potting agent was investigated. ESA recommended static pull-out tests to be conducted on the sandwich panels composed of Nomex honeycomb core, two laminates of carbon fibres/epoxy composite as the face-sheets to determine the failure load of the hard points. A finite element simulation using ANSYS was also performed to determine the displacement of the inserts in presence of normal-to-plane load. The results include load versus extension curves obtained by both methods. Potting agents were found to elevate the stiffness and the strength of the inserts by some degree. Therefore, the application of these hard points on the solar car was found to be effective.

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“…From the early work [ 27 ] about ’fully potted’ inserts in 1998, tests and numerical models (namely finite element models) have been used to study the pull-out strength of the metal insertions in thick CFRP laminates [ 28 ] or resin-filled cores in sandwich panels [ 29 , 30 , 31 , 32 , 33 , 34 , 35 ]. Based on the same type of analysis, some authors [ 36 , 37 ] developed parametric analysis for sizing the insert to the panel to help in the design stage.…”

Section: Analysis Case: Potting Of An Aircraft Doormentioning

confidence: 99%

Structural Potting of Large Aeronautic Honeycomb Panels: End-Effector Design and Test for Automated Manufacturing

2022

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Structural potting is used to prepare honeycomb panels to fix metallic elements, typical in aircraft doors. In this paper, a full procedure for structural potting using robotic arms is presented for the first time. Automating this procedure requires the integration of, first, machining operations to remove the skin layers and prepare the potting points and, then, resin injection into the honeycomb cells. The paper describes the design, prototyping, and testing of specific end-effectors. Different end-effectors were explored to ensure efficient injection. The results obtained with the prototypes show that the potting quality is adequate to accomplish the required process checks for industrial manufacturing. The injection process time can be reduced by a factor greater than 3.5, together with the extra assets associated with the automation of complex tasks. Therefore, structural potting automation is demonstrated to be feasible with the end-effectors proposed for milling and injection, which are ready for use with conventional robotic arms in manufacturing lines.

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Insert of sandwich panels sizing through a failure mode map

Cited by 11 publications

References 24 publications

Design, manufacturing and testing of pull-out and shear-out insert allowable for sandwich applications

Design, manufacturing and testing of pull-out and shear-out insert allowable for sandwich applications

Analysis of Hard Point Mechanical Behaviour Due to Variations of Potting Agent Volume on a Composite Sandwich Panel

Structural Potting of Large Aeronautic Honeycomb Panels: End-Effector Design and Test for Automated Manufacturing

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