Mechanical characterisation and crashworthiness performance of additively manufactured polymer-based honeycomb structures under in-plane quasi-static loading

Isaac, Chukwuemeke William; Sokołowski, Andrzej; Duddeck, Fabian; Adamiak, Marcin; Pakieła, Wojciech; Aremu, Adedeji

doi:10.1080/17452759.2023.2273296

Cited by 10 publications

(4 citation statements)

References 56 publications

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“…The constituent material adopted for 3D printing was PLA with desirable mechanical properties, and the printing quality of PLA was consistent and acceptable. Hence, the PLA is widely used in additive manufacturing techniques [ 38 , 39 ]. According to the requirements of the Raise 3D Pro3 printer, before transferring the geometric model of the GHHH to the Raise 3D Pro3 printer, a CAD model of the GHHH established using SolidWorks 2023 software should be partitioned into slices using slicing software (ideaMaker 4.3.3).…”

Section: Experimental and Numerical Methodsmentioning

confidence: 99%

In-Plane Elastic Properties of 3D-Printed Graded Hierarchical Hexagonal Honeycombs

Tao,

Zhao,

Shi

et al. 2024

Polymers

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In this study, the graded hierarchical hexagonal honeycomb (GHHH) integrating gradient design and hierarchical design was fabricated using the 3D-printing technique, and its in-plane elastic properties were investigated theoretically, experimentally, and numerically. Theoretical solutions were developed based on the Euler beam theory to predict the effective elastic modulus and Poisson’s ratio of GHHH, and theoretical values were in good agreement with the experimental and numerical results. The effect of gradient design and hierarchical design on the in-plane elastic properties of GHHH was also analyzed and compared. Results showed that the hierarchical design has a more significant effect on Poisson’s ratio and adjusting the internal forces of GHHH compared with the gradient design. In addition, it was found that GHHH exhibited higher stiffness compared with regular hexagonal honeycomb (RHH), graded hexagonal honeycomb (GHH), and vertex-based hierarchical hexagonal honeycomb (VHHH) under the constraint of the same relative density, respectively. Specifically, the effective elastic modulus of GHHH can be enhanced by 119.82% compared to that of RHH. This research will help to reveal the effect of integrating hierarchical design and gradient design on the in-plane elastic properties of honeycombs.

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Section: Experimental and Numerical Methodsmentioning

confidence: 99%

In-Plane Elastic Properties of 3D-Printed Graded Hierarchical Hexagonal Honeycombs

Tao,

Zhao,

Shi

et al. 2024

Polymers

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“…On the other hand, 3D printing technology offers lightweight potential, customised structural parts, ease in producing complex structures, a reduction in material waste, and relatively low production costs. However, the printing techniques used in additive manufacturing have the drawback of yielding parts with a reduced mechanical strength and crushing performance compared to those produced with subtractive manufacturing methods [150]. Moreover, innovative improved methods, like 4D printing technology, were recently proposed to create smart adaptive structures, which are characterized by their reusability, minimal maintenance, and high energy absorption capacity [151][152][153].…”

Section: Stacking Sequencementioning

confidence: 99%

Natural Fibre and Hybrid Composite Thin-Walled Structures for Automotive Crashworthiness: A Review

Capretti,

Del Bianco,

Giammaria

et al. 2024

Materials

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Natural fibres, valued for their low density, cost-effectiveness, high strength-to-weight ratio, and efficient energy absorption, are increasingly emerging as alternatives to synthetic materials in green composites. Although they cannot fully replace synthetic counterparts, like carbon, in structural applications due to their inferior mechanical performance, combining them through hybridization presents a potential solution. This approach promotes a balance between environmental benefits and mechanical efficiency. Recently, the transportation sector has shifted its focus towards delivering lightweight and crashworthy composite structures to improve vehicle performance, address safety concerns, and minimise environmental impact through the use of eco-friendly materials. The crashworthiness of energy absorbers, typically thin-walled structures, is influenced by several factors, including their material and geometric design. This paper presents a comprehensive overview of recent studies focused on the crashworthiness of fibre-reinforced, thin-walled composites under axial crushing. It explores different aspects, such as their materials, cross-sections, stacking sequences, triggering or filling mechanisms, and the effect of loading rate speed. Emphasis is placed on natural-fibre-based materials, including a comparative analysis of synthetic ones and their hybridization. The primary objective is to review the progress of solutions using green composites as energy absorbers in the automotive industry, considering their lightweight design, crashworthiness, and environmental sustainability.

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“…The mechanical properties of these structures are a key factor in the development and manufacture of efficient sandwich structures. Certain factors, including the fabrication techniques for the structure, the kind of structural design, and the type of materials used, can significantly alter the mechanical behavior of sandwich panel with cellular core 9,10 . In order to effectively utilize the AM method for sandwich structures, it is critical to comprehensively assess these factors and systematically perform rigorous evaluations of mechanical behavior, as highlighted in previous research 11 …”

Section: Introductionmentioning

confidence: 99%

“…Isaac et al investigated the effects of different base materials on the deformation modes and overall fracture toughness of additively manufactured polymer‐based honeycomb structures under in‐plane quasi‐static loading. They found that the choice of core material influenced the overall fracture performance, with certain polymer fiber‐reinforced honeycomb structures outperforming the pure polymer‐based ones in terms of specific energy absorption 9 . In addition, Dou et al conducted a comparative study on the in‐plane compression properties of 3D‐printed continuous carbon fiber‐reinforced composite honeycombs and aluminum combination honeycomb structures.…”

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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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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Mechanical characterisation and crashworthiness performance of additively manufactured polymer-based honeycomb structures under in-plane quasi-static loading

Cited by 10 publications

References 56 publications

In-Plane Elastic Properties of 3D-Printed Graded Hierarchical Hexagonal Honeycombs

In-Plane Elastic Properties of 3D-Printed Graded Hierarchical Hexagonal Honeycombs

Natural Fibre and Hybrid Composite Thin-Walled Structures for Automotive Crashworthiness: A Review

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

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