Structural behavior of 3D-printed sandwich beams with strut-based lattice core: Experimental and numerical study

Ghannadpour, S.A.M.; mahmoudi, mohammad javad; Nedjad, K. Hossein

doi:10.1016/j.compstruct.2021.115113

Cited by 51 publications

(14 citation statements)

References 71 publications

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“…The second or multiple secondary strengthening peaks appeared after the first load peak in the curve. The literature also verified this phenomenon [28,29,31]. After local densification, it resulted from the local strengthening effect in the overall lattice structure.…”

Section: Resultsmentioning

confidence: 73%

“…Although there have been some reports on the geometric optimization design of lattice structures subjected to three-point bending, most focused on improving the lattice structures themselves. They did not try to remove redundant structures on the whole to achieve further weight reduction [ 28 , 29 ]. We used the solid isotropic material with penalization (SIMP) algorithm to optimize the design space.…”

Section: Optimization Design Of a Further-lightened Heterogeneous Lat...mentioning

confidence: 99%

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Solid Stress-Distribution-Oriented Design and Topology Optimization of 3D-Printed Heterogeneous Lattice Structures with Light Weight and High Specific Rigidity

Shen

2022

Polymers

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Lightweight structural design is greatly valued in the aviation, aerospace, and automotive industries. Three-dimensional (3D) printing techniques provide viable and popular technical pathways for the rapid design and manufacturing of lightweight lattice structures. Unlike the conventional design idea of a geometrically homogenized lattice structure, this work provides a design method for structurally heterogeneous lattice according to the spatial stress state of 3D-printed parts. Following the quasi-static stress numerical simulations of solid components, finite element mesh units were inconsistently replaced by lattice units with different specific rigidities corresponding to the localized stress levels. Relying on the topology optimization further lightened the lattice structure under quasi-static stress after removing some parts with extremely low stress from the overall structure. As an embodiment of this design idea, face-centered cubic (FCC) lattice units with different strut diameters were employed to non-uniformly and adaptively fill a solid part under localized loading. The topological optimization was conducted on the solid part globally. Then, the topologically optimized solid and the heterogeneous lattice structure were subjected to the geometric Boolean operation. Stereolithographic 3D printing was utilized to fabricate the homogeneous and heterogeneous lattice structural parts for comparative tests of three-point bending. Three evaluation indicators were defined for the standardized assessment of the geometrically complex lattice structures for the performance evaluation. This demonstrated that the heterogeneous lattice part exhibited better comprehensive mechanical performance than the uniform lattice. This work proved the feasibility of this new perspective on 3D-printed lightweight structure design and topology optimization.

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Section: Resultsmentioning

confidence: 73%

Section: Optimization Design Of a Further-lightened Heterogeneous Lat...mentioning

confidence: 99%

Solid Stress-Distribution-Oriented Design and Topology Optimization of 3D-Printed Heterogeneous Lattice Structures with Light Weight and High Specific Rigidity

Shen

2022

Polymers

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“…Ghannadpour et al 10 numerically and experimentally investigated the structural behavior of 3D printed sandwich beams with strut-based lattice core by introducing 10 strut-based topologies. According to their results, star and diamond topologies had maximum flexural and compression strength, and grid and re-entrant Honeycomb structures had minimum flexural and compression strength, respectively.…”

Section: Introductionmentioning

confidence: 99%

Compressive and bending behavior of foam-filled Kevlar fiber composite sandwich panel with novel lozenge core: A numerical and experimental study

Nosratbakhsh

Azadi

Maddah

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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The present research has addressed the flexural and compressive strength of Kevlar fiber composite sandwich panels with novel lattice core, experimentally and numerically. The composite sandwich panels and corrugated cores have been made using the vacuum-assisted resin transfer molding method. Afterward, compressive and three-point bending loads were applied to the composite sandwich panels to determine mechanical performance during structural deformation. Scanning electron microscopy has been conducted on the specimens to evaluate the Kevlar-fiber distribution. In order to evaluate the experimental results, the corresponding testing process has been numerically simulated through finite element analysis. It has been figured out that the simulated model can predict the force–displacement response of the considered sandwich panels under bending and compressive loads. Finally, the effect of polyurethane foam on the composite sandwich panel's mechanical strength and energy absorption capacity has been investigated.

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“…2,9,[17][18][19]26,29,[31][32][33][34] For example, lattices fabricated in ceramic materials with cubic and diamond structures provide high stiffness under compressive and bending loadings and may have the potential to be the best choice as cores in the sandwich panels. 37 Lattice structures are difficult to obtain through conventional manufacturing, so they are obtained by means of additive procedures. Additive manufacturing (AM) is a process of sequential joining of material layers from 3D model data, in a layer-by-layer sequence as opposed to subtractive manufacturing methodologies.…”

Section: Introductionmentioning

confidence: 99%

“…2,9,17–19,26,29,31–34 For example, lattices fabricated in ceramic materials with cubic and diamond structures provide high stiffness under compressive and bending loadings and may have the potential to be the best choice as cores in the sandwich panels. 37…”

Section: Introductionmentioning

confidence: 99%

Cellular lattice cores of sandwich panels fabricated by additive manufacturing: Effect of dimensions and relative density on mechanical behaviour

Pereira

Alves

Reis

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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Sandwich panels have a wide field of applications from aerospace to automotive industries. These panels are formed by a core and two layers, having the geometry of the core an important role in its mechanical properties. While the most common cores have hexagonal honeycomb structures, there is a recent trend to replace them with other cellular structures based on truss or lattice arrangements. Previous studies on modified atomic-based lattices reached the conclusion that modified body and face-centred parallelepiped, with vertical struts, denoted by the body- and face-centred parallelepiped with struts in z-axis, provided higher stiffness and absorbed energy with low weight, compared with the conventional design. These promising findings have motivated a further comprehensive investigation of this type of structure. The aim of the present study is to get the body- and face-centred parallelepiped with struts in z-axis structure that provides the highest stiffness and absorbed energy, in comparison with a previous work of the current authors, by changing its dimensions and relative density. To accomplish this purpose body- and face-centred parallelepiped with struts in z-axis lattices with three relative densities, namely, 0.25, 0.30 and 0.35 and with truss radii of 0.8, 0.92 and 1.1 mm were designed, respectively. Samples were printed by additive manufacturing of polylactic acid. The two face sheets (skins) and the core of the panel were manufactured altogether. The mechanical behaviour of the sandwich panels was assessed by three-point bending tests both experimentally and in numerical simulations with finite element analysis. A good correlation between experiments and numerical results was achieved. Simulation results revealed that the highest values of strength, stiffness and absorbed energy were obtained for the combination of the lowest relative density with the highest truss radius. A failure analysis revealed two failure modes, namely, cohesive failure and face sheet failure. Results indicate that the dimensions of the struts and the relative density affect the mechanical performance and the failure mode of the panels.

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Structural behavior of 3D-printed sandwich beams with strut-based lattice core: Experimental and numerical study

Cited by 51 publications

References 71 publications

Solid Stress-Distribution-Oriented Design and Topology Optimization of 3D-Printed Heterogeneous Lattice Structures with Light Weight and High Specific Rigidity

Solid Stress-Distribution-Oriented Design and Topology Optimization of 3D-Printed Heterogeneous Lattice Structures with Light Weight and High Specific Rigidity

Compressive and bending behavior of foam-filled Kevlar fiber composite sandwich panel with novel lozenge core: A numerical and experimental study

Cellular lattice cores of sandwich panels fabricated by additive manufacturing: Effect of dimensions and relative density on mechanical behaviour

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