A wire-woven cellular metal: Part-II, Evaluation by experiments and numerical simulations

Wire-woven bulk Kagome (WBK) is a new truss-type cellular metal fabricated by systematic assembly of helical wires in six directions. In Part-I of this work, analytic solutions for equivalent material properties, such as yield stress and elastic modulus of WBK under compression and shear were derived. The load capacities of a WBK-cored sandwich panel under bending were predicted for various failure modes, and optimal designs of the WBK-cored sandwich panel were determined. In this work, the overall performance of a WBK-cored sandwich panel under shear and bending loads were evaluated in more detail by experiment and finite element (FE) simulation. Using comparisons with our experimental and numerical results, we show that the simple analytic solutions obtained in Part-I gave effective and accurate solutions. Hence, the model optimally designed on the basis of the analytic solutions gave the expected results. Furthermore, the WBK-cored sandwich panel showed excellent performance in terms of load capacity, energy absorption, and deformation stability after the maximum load point.     

In-plane compression response of wire-woven metal cored sandwich panels

This article presents the buckling behaviors of two types of WBK (Wire-woven Bulk Kagome) cored sandwich panels subjected to in-plane compression. Classical theories are introduced, and the experimental and numerical results are presented. The effects of several design parameters are analyzed. For both types, the peak loads were governed by macroplastic buckling. Low shear modulus and strength of the WBK core substantially influenced the buckling behaviors of the sandwich panels before and after their peaks. A small initial deflection greatly decreased the resistance against buckling of the sandwich panels with thinner cores, as confirmed by a two-stage FEA (Finite Element Analysis) and the analytic solution accounting for eccentricity.     

Three-point bending of sandwich beams with aluminum foam-filled corrugated cores

Sandwich panels having metallic corrugated cores had distinctly different attributes from those having metal foam cores, the former with high specific stiffness/strength and the latter with superior specific energy absorption capacity. To explore the attribute diversity, all-metallic hybrid-cored sandwich constructions with aluminum foam blocks inserted into the interstices of steel corrugated plates were fabricated and tested under three-point bending. Analytical predictions of the bending stiffness, initial failure load, peak load, and failure modes were obtained and compared with those measured. Good agreement between analysis and experiment was achieved. Failure maps were also constructed to reveal the mechanisms of initial failure. Foam insertions altered not only the failure mode of the corrugated sandwich but also increased dramatically its bending resistance. All-metallic sandwich constructions with foam-filled corrugated cores hold great potential as novel lightweight structural materials for a wide range of structural and crushing/impulsive loading applications.     

Stiffness and strength of oil palm wood core sandwich panel under center point bending

This paper presents a study of the bending's stiffness and strength of oil palm wood (OPW) core sandwich panel overlaid with rubberwood veneer under center point bending. Parameters including density and grain orientation of OPW core, rubberwood veneer thickness and span length were investigated. An experimental evaluation of some mechanical properties of OPW and the bending stiffness and strength of the sandwich beams was performed. Linear elastic beam theory was used to predict the bending performance of the panels. Results show that the linear elastic beam theory with the uses of the power law expressions of Young's moduli and shear strength of the OPW as a function of density derived within this study, adequately predicted the stiffness and bending strength of the sandwich beams. Higher OPW core density increased stiffness and strength of the beam. Failures by face fracture and core shear were observed which the latter tended to occur at low OPW core density, relatively thick veneer face and short span length. Grain orientation of OPW core little influenced stiffness and strength of the sandwich board. Finally, the stiffness and failure load equations of the OPW sandwich board were proposed for practical uses of this product.     

Local effects across core junctions in sandwich panels

Sandwich beams and panels with symmetric faces and cores of varying stiffness are investigated. The paper presents a theoretical and experimental study of the local effects that occur in the vicinity of intersections between cores of different stiffness in such sandwich panels. These local effects manifest themselves by a significant rise of the bending stresses in the faces in the vicinity of the core junctions. Closed-form estimates of the stress/strain fields induced by local effects are presented for sandwich beams and panels loaded in cylindrical bending. The accuracy of the derived closed-form estimates is verified experimentally for the case of a sandwich beam in three-point bending.     

Mechanical behavior of carbon fiber reinforced polymer composite sandwich panels with 2-D lattice truss cores

Composite sandwich structures with lattice truss cores are attracting more and more attention due to their superior specific strength/stiffness and multi-functional applications. In the present study, the carbon fiber reinforced polymer (CFRP) composite sandwich panels with 2-D lattice truss core are manufactured based on the hot-pressing method using unidirectional carbon/epoxy prepregs. The facesheets are interconnected with lattice truss members by means of that both ends of the lattice truss members are embedded into the facesheets, without the bonding procedure commonly adopted by sandwich panels. The mechanical properties of the 2-D lattice truss sandwich panels are investigated under out-of-plane compression, shear and three-point bending tests. Delamination of the facesheets is observed in shear and bending tests while node failure mode does not occur. The tests demonstrate that delamination of the facesheet is the primary failure mode of this sandwich structure other than the debonding between the facesheets and core for conventional sandwiches.     

A wire-woven cellular metal: Part-I, optimal design for applications as sandwich core

Wire-woven Bulk Kagome (WBK) is a new truss type cellular metal fabricated by systematic assembling of helical wires in six directions. WBK looks promising with respect to morphology, fabrication cost, and raw materials. In this paper, first, the geometry and the effect of the geometry such as the curved shape of the struts, which compose the truss structure of WBK, are elaborated. Then, analytic solutions for the material properties of WBK and the maximum loads withstood by a WBK-cored sandwich panel under bending are derived. Design optimization is carried out in two ways: one is based on the weight of the sandwich panel, and the other is based on the slenderness ratio of the WBK core. The performance of the WBK is evaluated and compared with those of other periodic cellular metals. With designs fully optimized with respect to the first way mentioned, the WBK-cored panel outperformed the octet counter part. With a specified constraint on the core thickness, the WBK truss core panel performed as well as a honeycomb cored panel.     

Experimental analysis of behavior and damage of sandwich composite materials in three-point bending. Part 1. Static tests and stiffness degradation at failure studies

The analysis of stiffness and the identification of rupture mechanisms during and after static tests of sandwich panels and their components have been investigated. The sandwich panels, having cross-ply laminates skins made of glass fibre and epoxy resin were manufactured by vacuum moulding and subjected to three-point bending tests. Two polyvinyl chloride cores of similar type but with differing densities were investigated. The effect of core density and its thickness on the behavior and the damage was highlighted. In terms of stiffness and load at failure, the sandwich structure has better mechanical characteristics compared to its components. __________ Translated from Problemy Prochnosti, No. 2, pp. 88–98, March–April, 2007.     

钢板夹泡沫铝组合板抗弯性能研究

试验设计了6块钢板夹泡沫铝组合板,其中无侧板组合板与有侧板组合板各为3块,侧板材料与面板相同,泡沫铝芯层厚度分别为40 mm、60 mm和90 mm。对组合板进行抗弯试验,绘制了组合板跨中荷载-位移（P-δ）曲线,记录了组合板变形失效过程。基于Gibson模型最大承载力公式建立了无侧板组合板的失效模式图。推导了有侧板组合板最大承载力计算公式,建立了失效模式图。结果表明:泡沫铝芯层厚度越大,组合板承载力越高,加载刚度越大。建立的失效模式图可以较好预测组合板的失效模式。与无侧板组合板相比,仅增加侧板,可以显著提高组合板的承载能力和加载刚度,有效限制泡沫铝开裂后裂缝的进一步开展。通常无侧板组合板每种失效模式仅独立对应失效模式图中一块区域,而有侧板组合板失效模式图被划分为四块区域,且表皮屈服失效模式独立对应两块区域。     

Compression and bending performances of carbon fiber reinforced lattice-core sandwich composites

To restrict debonding, carbon fiber reinforced lattice-core sandwich composites with compliant skins were designed and manufactured. Compression behaviors of the lattice composites and sandwich columns with different skin thicknesses were tested. Bending performances of the sandwich panels were explored by three-point bending experiments. Two typical failure mechanisms of the lattice-core sandwich structures, delaminating and local buckling were revealed by the experiments. Failure criteria were suggested and gave consistent analytical predictions. For panels with stiff skins, delamination is the dominant failure style. Cell dimensions, fracture toughness of the adhesives and the strength of the sandwich skin decide the critical load capacity of the lattice-core sandwich structure. The mono-cell buckling and the succeeding local buckling are dominant for the sandwich structures with more compliant skin sheets. Debonding is restricted within one cell in bending and two cells in compression for lattice-core sandwich panels with compliant face sheets and softer lattice cores.     

Characteristics of joining inserts for composite sandwich panels

Composite sandwich constructions are widely employed in various light weight structures, because composite sandwich panels have high specific stiffness and high specific bending strength compared to solid panels. Since sandwich panels are basically unsuited to carry localized loads, the sandwich structure should provide joining inserts to transfer the localized loads to other structures.In this work, the load transfer characteristics of the partial type insert for composite sandwich panels were investigated experimentally with respect to the insert shape. The static and dynamic pull out tests of the composite sandwich panels composed of an aluminum honeycomb core, two laminates of carbon fiber/epoxy composite and aluminum insert, were performed. From the experiments, the effect of the insert shape on the mechanical characteristics of composite sandwich panels was evaluated.     

Mechanical behavior of sandwich panels with hollow Al–Si tubes core construction

A new type of lightweight sandwich panels consisting of vertically aligned hollow Al–Si alloy tubes as core construction and carbon fiber composite face sheets was designed. The hollow Al–Si alloy tubes were fabricated using precision casting and were bonded to the face sheets using an epoxy adhesive. The out-of-plane compression (i.e. core crushing), in-plane compression, and three-point bending response of the panels were tested until failure. The hollow Ai–Si alloy tubes core configuration show superior specific strength under crushing compared to common metallic and stochastic foam cores. Under in-plane compression and three-point bending, the buckling of face sheets and debonding of hollow cores from the face sheets were observed. Simple analytical relationships based on the concepts of mechanics of materials were provided for the compression tests, which estimate the sandwich panels’ strength with high fidelity. For three-point bending, detailed finite element analysis was used to model the response and initial failure of the sandwich panels.     

Experimental analysis of behavior and damage of sandwich composite materials in three-point bending. Part 2. Fatigue test results and damage mechanisms

The analysis of stiffness degradation and the identification of damage mechanisms during and after fatigue tests of sandwich panels with PVC foam cores have been performed. The sandwich panels with cross-ply laminates skins made of glass fiber and epoxy resin were manufactured by vacuum moulding and subjected to three-point bending tests. Two PVC cores of similar type but with differing densities were investigated. The effect of core density and thickness on the damage behavior was highlighted. Using the cyclic life criterion, fatigue curves were plotted according to two models and compared with those of the literature. It has been demonstrated that the sandwich SD 2, with the higher core density, withstands a higher load and possesses greater rigidity in static tests, combined with an enhanced fatigue resistance, when compared to sandwich SD 1 which has a lower core density. Translated from Problemy Prochnosti, No. 3, pp. 32–44, May–June, 2009.     

玻璃纤维增强树脂基复合材料夹芯板-钢板连接接头的弯曲性能

以PVC泡沫或Balsa轻木为芯材的玻璃纤维增强树脂基复合材料（GRP）夹芯板目前广泛应用于船舶与海洋工程结构中。论文设计不同参数的GRP夹芯板-钢板混合接头模型,进行四点弯曲加载下的静力及疲劳试验研究,同时运用ABAQUS软件结合MSC.fatigue软件对接头的静态及疲劳弯曲失效进行数值模拟,分析了接头的弯曲强度、刚度和失效模式,并研究了接头填充区材料及长度、钢板嵌入填充区长度等参数对接头弯曲性能的影响。结果表明：弯曲载荷作用下接头破坏发生在连接结合部,失效模式则因填充区的不同设计而不同;对提高接头的弯曲性能较为明显的设计参数包括将钢板延伸到接头填充区或者选择Balsa轻木替代PVC泡沫芯材;对于受到疲劳弯曲载荷的接头模型,在较大疲劳载荷水平下,所有试件在未达到10⁶次循环时均发生了疲劳破坏;而在相对较小的疲劳载荷水平下,经过10⁶次循环后所有试件全部完好,并且接头的剩余强度与疲劳试验前的静强度相近,表明小载荷水平下接头的疲劳次数对其承载能力无影响。     

Enhancing the resistance of composite sandwich panels to localized forces for civil infrastructure and transportation applications

This paper presents the details of an experimental and numerical study that was conducted to evaluate different methods of increasing the punching resistance of glass fiber reinforced polymer (GFRP) composite sandwich panels with balsa wood cores. A total of four large-scale panels were subjected to concentrated loads in a two-way bending configuration. Different techniques of locally stiffening the panels were investigated including bonding a steel coupling plate to the loaded surface of the panels and embedding steel tubes within the panel core. The experimental program was supplemented by a finite element study to evaluate the location, magnitude, and extent of stress concentrations in the panels. The experimental program demonstrated that the failure modes of the stiffened panels shifted from local punching to delamination of the loaded GFRP skin which initiated at the discontinuities of the panel stiffness. The finite element analysis indicated that the delamination failure was due to stress concentrations which formed at these critical locations. The local stiffening of the panel approximately tripled the concentrated load carrying capacity of the panels. The research findings suggest that, through careful design and detailing, composite sandwich panels can be used to resist large-magnitude concentrated loads such as those found in civil infrastructure and heavy freight transportation applications.     

基于缝隙特征的蜂窝夹层结构刚度损失评估及应用

高精度蜂窝夹层结构反射面板由经过开缝应力释放工艺处理的表层铝板和铝蜂窝芯胶接而成, 为了研究缝隙所引起的夹层结构刚度损失, 基于对实验数据的统计分析, 考虑缝隙面积和分布等对刚度的影响, 定义了缝隙对刚度的影响系数与刚度的损失系数并建立了二者之间的关系, 提出了基于缝隙特征的蜂窝夹层结构刚度损失的评估方法。实验分析结果表明, 缝隙对夹层结构刚度造成的损失达到一定程度后明显减缓, 刚度最大损失可限定在40%。针对表板带有缝隙的夹层结构的数值分析, 依据夹层结构刚度等效原则, 利用刚度损失与缝隙影响系数之间的关系, 可将带有缝隙的表板等效为厚度减薄的连续表板, 对于模拟带有缝隙的夹层结构具有一定的应用价值。     

Optimum Design of Composite Sandwich Structures Subjected to Combined Torsion and Bending Loads

This research is motivated by the increase use of composite sandwich structures in a wide range of industries such as automotive, aerospace and civil infrastructure. To maximise stiffness at minimum weight, the paper develops a minimum weight optimization method for sandwich structure under combined torsion and bending loads. We first extend the minimum-weight design of sandwich structures under bending load to the case of torsional deformation and then present optimum solutions for the combined requirements of both bending and torsional stiffness. Three design cases are identified for a sandwich structure required to meet multiple design constraints of torsion and bending stiffness. The optimum solutions for all three cases are derived. To illustrate the newly developed optimum design solutions, numerical examples are presented for sandwich structures made of either isotropic face skins or orthotropic composite face skins.     

Characterisation and Assessment of Load Response, Failure and Fatigue Phenomena in Sandwich Structures Induced by Localised Effects: A Review

Abstract:  The objective of the paper is to provide an overview of the mechanical effects, which determine the occurrence and severity of localised bending effects in sandwich structures, and to provide a survey of the available structural sandwich models, with special emphasis on their ability to describe local bending effects. The presentation includes a brief survey of the various structural models, including classical, 'first-order shear', 'high-order' and continuum mechanics-based models. Moreover, the paper focuses on and addresses the experimental characterisation and assessment of local effects in sandwich structures based on realistic engineering practice, examples including sandwich panels with core materials of different stiffness (core junctions), sandwich plates with inserts and junctions between sandwich panels of different curvature. The issues of general load response (global and local) as well as failure and fatigue of such sandwich structures subjected to out-of-plane and in-plane loads are discussed in some detail, with the inclusion of recent theoretical and experimental results.     

High Temperature Residual Properties of Carbon Fiber Composite Sandwich Panel with Pyramidal Truss Cores

A study on the mechanical property degradation of carbon fiber composite sandwich panel with pyramidal truss cores by high temperature exposure is performed. Analytical formulae for the residual bending strength of composite sandwich panel after thermal exposure are presented for possible competing failure modes. The composite sandwich panels were fabricated from unidirectional carbon/epoxy prepreg, and were exposed to different temperatures for different time. The bending properties of the exposed specimens were measured by three-point bending tests. Then the effect of high temperature exposure on the bending properties and damage mechanism were analyzed. The results have shown that the residual bending strength of composite sandwich panels decreased with increasing exposure temperature and time, which was caused by the degradation of the matrix property and fiber-matrix interface property at high temperature. The effect of thermal exposure on failure mode of composite sandwich panel was observed as well. The measured failure loads showed good agreement with the analytical predictions. It is expected that this study can provide useful information on the design and application of carbon fiber composite sandwich panel at high temperature.     

Multifunctional periodic cellular metals

Periodic cellular metals with honeycomb and corrugated topologies are widely used for the cores of light weight sandwich panel structures. Honeycombs have closed cell pores and are well suited for thermal protection while also providing efficient load support. Corrugated core structures provide less efficient and highly anisotropic load support, but enable cross flow heat exchange opportunities because their pores are continuous in one direction. Recent advances in topology design and fabrication have led to the emergence of lattice truss structures with open cell structures. These three classes of periodic cellular metals can now be fabricated from a wide variety of structural alloys. Many topologies are found to provide adequate stiffness and strength for structural load support when configured as the cores of sandwich panels. Sandwich panels with core relative densities of 2-10% and cell sizes in the millimetre range are being assessed for use as multifunctional structures. The open, three-dimensional interconnected pore networks of lattice truss topologies provide opportunities for simultaneously supporting high stresses while also enabling cross flow heat exchange. These highly compressible structures also provide opportunities for the mitigation of high intensity dynamic loads created by impacts and shock waves in air or water. By filling the voids with polymers and hard ceramics, these structures have also been found to offer significant resistance to penetration by projectiles.