Design of sandwich structures for concentrated loading

While sandwich construction offers well-known advantages for high stiffness with light weight, the problem of designing the sandwich structure to withstand localized loading, such as from accidental impact, remains an important problem. This problem is more difficult with lower stiffness cores, such as expanded foam. In the present study, experiments have been carried out on foam core sandwich beams with carbon/epoxy faces, under conditions of concentrated loading. The variables considered were the density of the foam and the relative thickness of the core. The common failure modes of sandwich structures were observed, including core failure in compression and shear, delamination, and fiber failure in the faces. These failure modes were systematically related to the test variables by means of a detailed stress analysis of the specimen, and a consideration of the failure properties of the constituent materials. The loading is characterized by localized high stress and strain concentrations that are not predicted in first-order shear deformation sandwich beam theory. The three-dimensional elasticity solution of Pagano was used to obtain the stress distributions. The strength prediction requires a detailed consideration of the localized nature of the loading, including the effects of strain gradients in the faces. The results show that failure modes and load levels can be predicted for sandwich structures under concentrated loading, but that accurate predictions require a consideration of the details of the concentrated loading. The results have a direct application in predicting the ability of sandwich structures to withstand localized loading such as from accidental impact.     

Compression, flexure and shear properties of a sandwich composite containing defects

The mechanical properties of a sandwich composite containing interfacial cracks or impact damage are compared when loaded in edgewise compression, flexure or shear. The composite is made from glass fibre reinforced polymer (GFRP) laminate skins over a core of foamed poly vinyl chloride (PVC), and this sandwich material is used in some naval minehunting ships. The properties are reduced with increasing interfacial crack or impact damage length, but only when the defects cause a change in the failure mode, which is dependent on the load state. The principal failure modes under the different load states are compared. The properties are also dependent on the severity of impact damage, with low energy damage to the skin having a smaller effect on stiffness and strength than high energy impacts which damage both the skin and foam core. The implications of these findings on the structural integrity of a minehunting ship made from GFRP/PVC foam sandwich composite is discussed.     

Experimental,Theoretical and Numerical Investigation of the Flexural Behaviour of the Composite Sandwich Panels with PVC Foam Core

This study presents the main results of an experimental, theoretical and numerical investigation on the flexural behaviour and failure mode of composite sandwich panels primarily developed for marine applications. The face sheets of the sandwich panels are made up of glass fibre reinforced polymer (GFRP), while polyvinylchloride (PVC) foam was used as core material. Four-point bending test was carried out to investigate the flexural behaviour of the sandwich panel under quasi static load. The finite element (FE) analysis taking into account the cohesive nature of the skin-core interaction as well as the geometry and materials nonlinearity was performed, while a classical beam theory was used to estimate the flexural response. Although the FE results accurately represented the initial and post yield flexural response, the theoretical one restricted to the initial response of the sandwich panel due to the linearity assumptions. Core shear failure associate with skin-core debonding close to the loading points was the dominant failure mode observed experimentally and validated numerically and theoretically.     

Experimental and numerical evaluation of the mechanical behaviour of GFRP sandwich panels

This work deals with the analysis of the mechanical behaviour of a class of sandwich structures widely employed in marine constructions, constituted by fiber-glass laminate skins over PVC foam or polyester mat cores. In detail, a systematic experimental study and numerical simulations have shown that the theoretical prediction of the strength and the actual failure mechanism of these sandwich structures can be affected by significant errors, specially in the presence of prevalent shear loading. Moreover, because of the low shear stiffness and the elastic constants mismatch of the skins and core material, failure modes and strength are strongly influenced by eventual stresses orthogonal to the middle plane of the sandwich. In particular, for the sandwich structures with a PVC foam core, such a stress interaction leads to early skin–core delamination failure, whereas for those with a polyester core it leads to core shear-cohesive failure. By means of accurate non-linear simulations, accurate failure criteria, that can be used at the design stage in the presence of complex loading, have also been developed.     

Experimental determination of torsion and shear properties of sandwich panels and laminated composites by the plate twist test

A recently developed sandwich plate twist test is employed here for determination of the transverse shear modulus of the core and twist stiffness (D₆₆) of a sandwich panel consisting of a soft (H45 PVC foam) core and glass/vinylester face sheets. The shear modulus of the H45 PVC foam core extracted from the twist test was in good agreement with shear modulus obtained from ASTM plate shear testing of the foam core. D₆₆ values obtained from the sandwich twist test were in good agreement with predictions from classical laminated plate theory. In addition, the twist test was used to determine the in-plane shear modulus of glass/vinylester laminates isolated and as face sheets in sandwich panels with a stiff (plywood) core. The in-plane shear modulus of the face sheets, isolated and as part of a sandwich panel, was in good agreement with shear modulus determined using the Iosipescu shear test. The results point to the potential of the twist test to determine both in-plane and out-of-plane shear moduli of the constituents of a sandwich structure, as well as D₆₆.     

The influence of core properties on the perforation resistance of sandwich structures – An experimental study

The aim of this study is to investigate the perforation resistance of a range of foam-based sandwich structures. Nine foams, based on a crosslinked PVC, a linear PVC and PET, have been combined with thin glass fibre reinforced plastic skins to produce a range of lightweight sandwich structures, Initially, the mechanical properties of the different foams are characterised. Here, a new test geometry is used to evaluate the toughness characteristics and strengths of the foams under shear loading, a condition similar to that encountered during the impact perforation event.The influence of the plastic collapse stress of the foam in determining the failure thresholds of the front and rear composite skins is established. Here, an existing model has been used to successfully predict failure of the top surface composite skin in the sandwich structures. In addition, the force associated with perforating the lightweight core has been shown to be strongly dependent on the shear strength of the polymer foam. Finally, the perforation resistance of the sandwich structure has been shown to be closely linked to the Mode II work of fracture of the foam material. Here a unique relationship has been established between these two parameters, with all of the experimental points lying on one curve.     

复合材料双向波纹夹层结构力学性能

为改进传统单向波纹夹层结构横向力学性能较差的缺点,设计了一种新型复合材料双向波纹夹层结构。考虑复合材料双向夹层结构制备困难,研究了整套真空辅助成型工艺(VARI)工艺制备方案,实现双向波纹夹层结构的高效制备,以满足工程应用的需要。对制备出的复合材料双向波纹夹层结构与单向波纹夹层结构分别进行面外压缩、弯曲和剪切实验,分析了双向波纹夹层结构在不同载荷下的破坏模式及其失效机制,计算了该结构在不同荷载条件下的强度和模量,并将其与单向波纹夹层结构进行对比分析。结果表明,在压缩荷载作用下,玻璃纤维/环氧树脂芯子为主要承载部分,结构的失效主要体现在芯子的屈曲、断裂和分层;在弯曲荷载的作用下,由于纤维的抗压强度远小于抗拉强度,所以压头下方的上面板最先达到破坏荷载,结构的弯曲失效形式主要为上面板的断裂和脱粘;结构的剪切失效主要以泡沫与面板的脱粘和压溃为主,芯子和面板未见明显的破坏现象;与单向波纹夹层结构相比,双向波纹夹层结构力学性能显著提升。      

Impact and post impact behavior of composite sandwich panels

Assessing the residual mechanical properties of a sandwich structure is an important part of any impact study and determines how the structure can withstand post impact loading. The damage tolerance of a composite sandwich structure composed of woven carbon/epoxy facesheets and a PVC foam core was investigated. Sandwich panels were impacted with a falling mass from increasing heights until damage was induced. Impact damage consisted of delamination and permanent indentation in the impacted facesheets. The Compression After Impact (CAI) strength of sandwich columns sectioned from these panels was then compared with the strength of an undamaged column. Although not visually apparent, the facesheet delamination damage was found to be quite detrimental to the load bearing capacity of the sandwich panel, underscoring the need for reliable damage detection techniques for composite sandwich structures.     

玻璃纤维立体织物增强环氧树脂泡沫夹层复合材料的制备及力学性能

为了进一步提高泡沫夹层复合材料的承载能力和综合性能,实现其在轨道交通及汽车等工业领域的应用,开展了玻璃纤维立体织物增强环氧树脂泡沫(GF-Fabric/EP)复合材料的制备及其力学性能的研究。制备GF-Fabric/EP复合材料及其夹层结构,探索了GF-Fabric/EP复合材料及其夹层结构的失效行为,以揭示立体织物的增强机制。结果表明：立体织物的引入可显著改善GF-Fabric/EP复合材料的强度、刚度及破坏应变;但在不同承载条件下,各纱线发挥承载作用和效果不同。面板、芯材各自的性能、尺寸及面/芯界面性能均是影响GF-Fabric/EP夹层复合材料力学性能及失效特征的重要因素。以三点加载下的弯曲性能为例,针对不同的GF-Fabric/EP夹层复合材料,需调整跨厚比和试样尺寸并获得理想的失效特征,方可对其弯曲性能或层间剪切性能进行有效、合理的评价。     

Face/core interface fracture characterization of mixed mode bending sandwich specimens

Debonding of the core from the face sheets is a critical failure mode in sandwich structures. This paper presents an experimental study on face/core debond fracture of foam core sandwich specimens under a wide range of mixed mode loading conditions. Sandwich beams with E‐glass fibre face sheets and PVC H45, H100 and H250 foam core materials were evaluated. A methodology to perform precracking on fracture specimens in order to achieve a sharp and representative crack front is outlined. The mixed mode loading was controlled in the mixed mode bending (MMB) test rig by changing the loading application point (lever arm distance). Finite element analysis was performed to determine the mode‐mixity at the crack tip. The results showed that the face/core interface fracture toughness increased with increased mode II loading. Post failure analysis of the fractured specimens revealed that the crack path depends on the mode‐mixity at the crack tip, face sheet properties and core density.     

The Effect of Load and Geometry on the Failure Modes of Sandwich Beams

Facing compressive failure, facing wrinkling and core shear failure are the most commonly encountered failure modes in sandwich beams with facings made of composite materials. The occurrence and sequence of these failure modes depends on the geometrical dimensions, the form of loading and type of support of the beam. In this paper the above three failure modes in sandwich beams with facings made of carbon/epoxy composites and cores made of aluminum honeycomb and two types of foam have been investigated. Two types of beams, the simply supported and the cantilever have been considered. Loading included concentrated, uniform and triangular. It was found that in beams with foam core facing wrinkling and core shear failure occur, whereas in beams with honeycomb core facing compressive failure and core shear crimping take place. Results were obtained for the dependence of failure mode on the geometry of the beam and the type of loading. The critical beam spans for failure mode transition from core shear to wrinkling failure were established. It was found that initiation of a particular failure mode depends on the properties of the facing and core materials, the geometrical configuration, the type of support and loading of sandwich beams.     

钢板夹泡沫铝组合板抗爆性能研究

鉴于泡沫铝材料优异的吸能特性和夹层结构在强度、刚度上的优势,提出了分层结构为钢板-泡沫铝芯层-钢板的抗爆组合板。对厚度为10 cm、7 cm和5 cm的组合板进行了5组不同装药量的爆炸试验,考察了各板在不同装药量爆炸条件下的变形及破坏情况,并对变形破坏过程进行了理论分析。研究表明:组合板承受爆炸冲击荷载时,通过局部压缩变形和整体弯曲变形吸收能量。钢板相同时,适当增大泡沫铝芯层厚度,增强面板与芯层间连接,可提高该组合板的抗爆性能,防止组合板发生剥离,减小其承受爆炸冲击荷载时产生的变形。     

Transient response of a submerged cylindrical foam core sandwich panel subjected to shock loading

Predicting the dynamic response of submerged vehicles subjected to hydrostatic pressure and underwater shock loading is of great interest to many structural designers and engineers for improving material and configuration design in recent years. In this paper, the finite element method is used to evaluate the dynamic response of a submerged cylindrical foam core sandwich panel subjected to shock loading. The sandwich panel consists of a foam core surrounded by fiber-reinforced laminates. The effect of fluid–structure coupling is included in the finite element analysis whereas the fluid is assumed to be compressible and inviscid. Time histories of circumferential stress for different composite plies are presented in graphical form and the effects of core type on circumferential stress and velocity of stand-off point are also investigated. Additionally, the distribution of pressure in fluid domain and the deformation of cylindrical foam core sandwich panel are estimated. To the best of the authors’ knowledge, the specialized literature addressing the dynamic response of submerged cylindrical foam core sandwich panel to underwater shock loading is rather scanty. This work is likely to fill a gap in the specialized literature on this topic.     

缝纫泡沫夹层结构弯曲性能研究

本文对缝纫泡沫夹层复合材料进行了理论分析和三点弯曲实验研究.讨论了缝纫夹芯剪切模量的计算方法和计算公式.实验表明缝纫提高了泡沫夹层板三点弯曲破坏载荷.针对实验结果研究了材料性能和试件几何的关系,给出了缝纫泡沫夹层板破坏模式的判别公式并基于经典夹层梁理论建立了初始破坏载荷预估方法,预估值和实验值符合较好.     

Compressive failure of carbon-foam sandwich composites with holes and/or partial delamination

Compression failure of sandwich composites made of fibrous carbon-epoxy skins and foam core was investigated using an experimental study. The sandwich specimens had holes and/or partial delamination between the skin and core, and they were subjected to compressive edge loading. Different core thicknesses of sandwich specimens were considered, and hole sizes and locations were varied to examine their effects on the compression failure. The study also included compression of delaminated specimens. In order to better understand the failure mechanism, a numerical study was also conducted. Major modes of failure were core shearing, delamination and skin fracture. Depending on the given parameter, the failure mode was different. The study examined the transition of the failure mode from one kind to another depending on the variation in the parameters such as delamination and hole size and location.     

The effect of core thickness on the flexural behaviour of aluminium foam sandwich structures

The effect of core thickness on the deformation mechanism of an aluminium foam core/thermoplastic composite facing sandwich structure under 4-point bending was investigated. Full field strain analysis and visual observations show a number of failure mechanisms between the different core thicknesses. High strain concentrations were observed in each sample thickness corresponding to the particular region of failure. The thinner samples exhibited skin wrinkling and fracture, and some core cracking and crushing while the thicker samples failed due to core indentation. Increasing the skin thickness eliminated the incidence of core indentation. Instead, significant core shear cracking was observed.     

Buckling,collapse and failure analysis of FRP sandwich panels

Rectangular orthotropic fiber-reinforced plastic (FRP) sandwich panels were tested for buckling in uni-axial compression. The panels, with 0.32 cm (0.125 in.) face sheets and a 1.27 cm (0.5 in.) core of either balsa or linear poly(vinyl chloride) (PVC) foam, were tested in two sizes: 154×77 cm² (72×36 in.²) and 102×77 cm² (48×36 in.²). The sandwich panels were fabricated using the vacuum-assisted resin transfer molding process. The two short edges of the sandwich panels were clamped, while the two long edges were simply supported for testing. The clamped panel ends were potted into a steel frame. The experimental elastic buckling loads were then measured using strain gauges fixed to both sides of the panels. A total of 12 panels were tested under uni-axial compression. Bifurcation in the load versus engineering strain curve was noted in all cases. For all six sandwich panels tested using balsa core, the type of failure was easily identified as face sheet delamination followed by core shear failure. For all six PVC foam core sandwich panels tested, the type of failure consisted of core shear failure with little or no face sheet delamination. In the failed balsa core panels there was little or no evidence of balsa remaining on the FRP face sheet, however, in the PVC foam core panels there were ample amounts of foam left on the FRP face sheet. It was concluded that although the buckling loads for the foam core panels were not as high as those for the balsa core panels, PVC foam core bonding to the FRP face sheets was superior to balsa core bonding.     

Failure initiation and propagation characteristics of honeycomb sandwich composites

The energy absorbed during the failure of a variety of structural shapes is influenced by material, geometry and the failure mode. Failure initiation and propagation of the honeycomb sandwich under loading involves not only non-linear behavior of the constituent materials, but also complex interactions between various failure mechanisms. Therefore, there is a need for an improved understanding of the material characteristics and energy absorption modes to facilitate the design of sandwich performance. In the present study, failure initiation and propagation characteristics of sandwich beams and panels subjected to quasi-static and impact loadings were investigated. Experimental studies involved a series of penetration and perforation tests on 2D beam and 3D panel configurations using a truncated cone impactor with impact velocities up to 10 m/s. Preliminary tests were also performed on the sandwich beams subjected to the three-point bending. Load-carrying, energy-absorbing characteristics and failure mechanisms under quasi-static and impact loading were determined. Dominant deformation modes involved upper skin compression failure in the vicinity of the indenter, core crushing and lower skin tensile failure.