Manufacturing of three dimensional sandwich parts by direct thermoforming

Rozant, O.; Bourban, P.-E.; Månson, J.-Å. E.

doi:10.1016/s1359-835x(00)00184-6

Cited by 28 publications

(33 citation statements)

References 11 publications

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“…Nevertheless, the problems in two-dimensional honeycomb construction have been reported, including the lack of surface area of core for bonding and the limitation of the honeycomb cell dimension (Chen et al, 2009;Pflug et al, 2003). Many research works documented the improvement in the manufacturing method for two-dimensional honeycomb structures (George and Stucker, 2006;Rozant et al, 2001;Tavares et al, 2010). However, the other potential technique to minimize those problems is the use of the additive manufacturing technique for the honeycomb production.…”

Section: Introductionmentioning

confidence: 99%

Fabrication of three-dimensional honeycomb structure for aeronautical applications using selective laser melting: a preliminary investigation

Chantarapanich

Laohaprapanon

Wisutmethangoon

et al. 2014

Rapid Prototyping Journal

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Purpose -The purpose of this paper was to investigate the feasibility on design and production of a three-dimensional honeycomb based on selective laser melting (SLM) technique for use in aeronautical application. Design/methodology/approach -Various polyhedrons were investigated using their mechanical property, i.e. strain energy density (SED), by means of finite element (FE) analysis for the suitability of use in aerospace application; the highest SED polyhedron was selected as a candidate polyhedron. From the FE analysis, the truncated octahedron (three-dimensional honeycomb) structure was considered to be the potential candidate. Polyhedron size and beam thickness of the open-cellular three-dimensional honeycomb structure were modelled and analysed to observe how the geometric properties influence the stiffness of the structure. One selected model of open-cellular honeycomb (unit cell size: 2.5 mm and beam thickness: 0.15 mm) was fabricated using SLM. The SLM prototypes were assessed by their mechanical properties, including compressive strength, stiffness and strength per weight ratio. To investigate the feasibility in production of airfoil section sandwich structure, NACA 0016 airfoil section with three-dimensional honeycomb core was constructed and also fabricated using SLM. Findings -According to the result, the three-dimensional honeycomb has elastic modulus of 63.18 MPa and compressive strength of 1.1 MPa, whereas strength per weight ratio is approximately 5.0 ϫ 103 Nm/kg. The FE result presented good agreement to the mechanical testing result. The geometric parameter of the three-dimensional honeycomb structure influences the stiffness, especially the beam thickness, i.e. increase of beam thickness obviously produces the stiffer structure. In addition, the sandwich structure of airfoil was also successfully manufactured. Originality/value -This work demonstrated the production of sandwich structure of airfoil using SLM for aeronautical engineering. This investigation has shown the potential applications of the three-dimensional structure, e.g. aircraft interior compartment components and structure of unmanned aerial vehicles.

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Section: Introductionmentioning

confidence: 99%

Fabrication of three-dimensional honeycomb structure for aeronautical applications using selective laser melting: a preliminary investigation

Chantarapanich

Laohaprapanon

Wisutmethangoon

et al. 2014

Rapid Prototyping Journal

View full text Add to dashboard Cite

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“…So, decreasing the weight of the structure of airplanes has become a main preoccupation for all aircraft constructors, from the biggest commercial airplanes [1,2] (to reduce running costs) to small private airplanes [3,4]. Therefore, composite sandwich structures are largely used in applications requiring high strength and stiffness-to-weight ratios, such as in the aeronautical domain [3][4][5][6]. For more unusual applications, such as ultra-light solar aircraft [7][8][9], competition solar cars, or satellite solar panels, the weight of the structures has to be pared to the absolute limit in order to save every gram.…”

Section: Introductionmentioning

confidence: 99%

Ultra-light asymmetric photovoltaic sandwich structures

Rion

Leterrier

Månson

et al. 2009

Composites Part A: Applied Science and Manufacturing

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a b s t r a c tThis work evaluated the possibility of using silicon solar cells as load-carrying elements in composite sandwich structures. Such an ultra-light multifunctional structure is a new concept enabling weight, and thus energy, to be saved in high-tech applications such as solar cars, solar planes or satellites. Composite sandwich structures with a weight of $800 g/m 2 were developed, based on one 140 lm thick skin made of 0/90°carbon fiber-reinforced plastic (CFRP), one skin made of 130 lm thick mono-crystalline silicon solar cells, thin stress transfer ribbons between the cells, and a 29 kg/m 3 honeycomb core. Particular attention was paid to investigating the strength of the solar cells under bending and tensile loads, and studying the influence of sandwich processing on their failure statistics. Two prototype multi-cell modules were produced to validate the concept. The asymmetric sandwich structure showed balanced mechanical strength; i.e. the solar cells, reinforcing ribbons, and 0/90°CFRP skin were each of comparable strength, thus confirming the potential of this concept for producing stiff and ultra-lightweight solar panels.

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“…These properties allow improved performance and reduction in weight, and are therefore of great interest in aeronautical applications [1][2][3][4], and in all applications where weight saving is a priority. The sandwich structures comprise skins adhesively bonded to a core.…”

Section: Introductionmentioning

confidence: 99%

Prediction of the adhesive fillet size for skin to honeycomb core bonding in ultra-light sandwich structures

Rion

Leterrier

Månson

2008

Composites Part A: Applied Science and Manufacturing

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a b s t r a c tThe formation of resin fillet between honeycomb core cell walls and skin in light sandwich structures was studied to gain a better understanding of the bonding process. A method was developed for tailoring the amount of adhesive between 8 and 80 g/m 2 . The size of the adhesive menisci and the contact angles between the adhesive and the skin and the core materials were measured. A model was developed to predict the size of the menisci. Their shape was driven by the surface energy of skin and honeycomb materials. When adhesive films were used for bonding, up to 50% of the adhesive did not form the menisci whereas 100% did when the newly developed adhesive deposition method on honeycomb was used, which allowed better bonding with lower weight.

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Manufacturing of three dimensional sandwich parts by direct thermoforming

Cited by 28 publications

References 11 publications

Fabrication of three-dimensional honeycomb structure for aeronautical applications using selective laser melting: a preliminary investigation

Fabrication of three-dimensional honeycomb structure for aeronautical applications using selective laser melting: a preliminary investigation

Ultra-light asymmetric photovoltaic sandwich structures

Prediction of the adhesive fillet size for skin to honeycomb core bonding in ultra-light sandwich structures

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