Finite element modelling of core thickness effects in aluminium foam/composite sandwich structures under flexural loading

This paper models the flexural behaviour of a composite sandwich structure with an aluminium foam core using the finite element (FE) code LS-DYNA. Two core thicknesses, 5 and 20 mm, were investigated. The FE results were compared with results from previous experimental work that measured full-field strain directly from the sample during testing. The deformation and failure behaviour predicted by the FE model compared well with the behaviour observed experimentally. The strain predicted by the FE model also agreed reasonably well with the distribution and magnitude of strain obtained experimentally. However, the FE model predicted lower peak load, which is most likely due to a size effect exhibited by aluminium foam. A simple modification of the FE model input parameters for the foam core subsequently produced good agreement between the model and experimental results.