Experimental and Numerical Analysis of the Shear Properties of Honeycomb Cores Produced Using Additive Technologies

An approach to the experimental and computational study of the shear properties of honeycomb cores (HC) produced using Fused Deposition Modeling (FDM) technology is proposed. The experimental approach is based on a new sample type for testing HCs for shear. This sample contains two HCs and three steel plates. Shear tests are carried out in the TiraTest 2300 universal tensile testing machine. The HCs are made of ULTEM 9085 and PLA with FDM technology, which is implemented in the 3D Fortus 900 system. The tests resulted in obtaining the shear properties of the HCs by averaging the stress-strain curves of five samples. As follows from the analysis of the experimental results, brittle destruction of an HC is observed. Before its destruction, the value of shear deformation for samples made of PLA was 0.0134, and for samples made of ULTEM, 0.0257. The experimental analysis was accompanied by numerical finite element (FE) modeling of shear experiments, taking into account the deformation of the equipment. With the FE modeling of the experiments, to describe the behavior of the samples, it is necessary to take into account the influence, on the measurements of the shear properties, of the equipment and the deformation of each honeycomb cell. The deformation of three plates was taken into account; the elastic properties of the adhesive joint were not taken into account. A computer model of the deformation of the HCs with equipment was built using ANSYS Design Modeler. With FE modeling, only the elastic behavior of the HCs was considered.

DETERMINATION OF MECHANICAL PROPERTIES OF COMPOSITE SANDWICH PANEL WITH ALUMINIUM HONEYCOMB CORE

This paper deal with comparison of mechanical properties of composite sandwich panel with aluminium honeycomb core which is determined by experimental measurement, analytic calculation and numerical simulation. The goal was to compared four composite sandwich panels. The composite sandwich panels were made of two different aluminium honeycomb cores with density 32 and 72 kg.m-3 and two different layup of skin with 4 and 5 layers. The comparison was performed on a three-point bend test with support span 400 mm. This paper confirms the possibility of a very precise design of a composite sandwich panel with an aluminium honeycomb core using analytical calculation and numerical simulation.

Vibration and Flutter of a Honeycomb Sandwich Plate with Zero Poisson’s Ratio

A honeycomb is a kind of excellent lightweight structure and a honeycomb sandwich plate with zero Poisson’s ratio (ZPR) core is used widely in morphing structures. In this paper, a sandwich plate composed of a honeycomb core with zero Poisson’s ratio is analyzed for free vibrations and flutter under supersonic airflows. The equivalent elastic parametric formulas of the honeycomb core for zero Poisson’s ratio are proposed. The models are compared for their natural frequencies by theoretical and finite element methods respectively, which verifies the validity of the equivalent elastic parametric formulas and the model for the honeycomb sandwich plate with zero Poisson’s ratio. The influence of the geometric parameters of the honeycomb plate on the vibration frequencies is obtained. Three kinds of honeycomb cores, namely, regular hexagon, auxetic and hybrid with zero Poisson’s ratio, are compared through natural frequencies of the sandwich plate. It is found that the frequency of the zero Poisson’s ratio honeycomb sandwich plate is the second one when the other parameters are the same. The flutter of the honeycomb plate is analyzed by using the first order piston theory under supersonic flows. The critical flutter velocity of the plate is obtained, and the influence of geometric parameters of the honeycomb plate on the critical flutter velocities is obtained.

High fidelity modeling tools for engine liner design and screening of advanced concepts

With aircraft engines trending toward ultra-high bypass ratios, resulting in lower fan pressure ratios, lower fan RPM, and therefore lower blade pass frequency, the aircraft engine liner design space has been dramatically altered. This result is also due to the associated reduction in both the available acoustic treatment area (axial extent) as well as thickness (liner depth). As a consequence, there is current need for novel acoustic liner technologies that are able to meet multiple physical constraints and simultaneously provide enhanced noise attenuation capabilities. In addition, recent advances in additive manufacturing have enabled the consideration of complex liner backing structures that would traditionally be limited to honeycomb cores. This paper provides an overview of engine liner modeling and a description of the key physical mechanisms, with some emphasis on the use of low to high-fidelity tools such as empirical models and commercially available software such as COMSOL, Actran, and PowerFLOW. It is shown that the higher fidelity tools are a critical enabler for the evaluation and construction of future complex liner structures. A systematic study is conducted to predict the acoustic performance of traditional single degree of freedom liners and comparisons are made to experimental data. The effects of grazing flow and bias flow are briefly addressed. Finally, a more advanced structure, a metamaterial, is modeled and the acoustic performance is discussed.

Dynamic cushioning energy absorption of paper composite sandwich structures with corrugation and honeycomb cores under drop impact

The paper composite sandwich structure with corrugation and honeycomb cores has been widely used in civil and national defense industries, and the cushioning energy absorption characteristic is a key indicator to evaluate the performance of this composite structure. Therefore, this paper is focus on the influences of honeycomb thickness on the shock acceleration response and deformation characteristics to analyze cushioning energy absorption performance of the composite structure by various experimental tests. The experimental result shows that, the paper corrugation layer firstly comes into crushed, and then the paper honeycomb layer is crushed. Additionally, the large honeycomb thickness may cause the secondary collapse of paper honeycomb layer. Under the same impact energy or impact mass, the cushioning energy absorption of the single-sided composite sandwich structure is better than that of the double-sided structure with the same honeycomb thickness. However, the impact resistance of the double-sided composite structure is better than that of the single-sided structure. For the paper composite sandwich structures with the honeycomb thicknesses 10, 15, 20 and 25 mm, the increase of honeycomb thickness would decrease the cushioning energy absorption of the whole structure under the drop impact with low energy. However, under the drop impact with high energy, the influence of honeycomb thickness on cushioning energy absorption is contrary. For the paper composite sandwich structure, the specific energy absorption, unit volume energy absorption, and stroke efficiency for the honeycomb thicknesses 10, 15, 20 and 25 mm are higher than those for the honeycomb thickness 70 mm. Therefore, the low honeycomb thickness is more advantageous for the cushioning energy absorption of paper composite sandwich structure.

Non-probabilistic models for in-plane elastic properties of cellular hexagonal honeycomb cores involving imprecise parameters

Inherent imprecisions present in the basic parameters of cellular honeycomb cores, such as the cell angle, the material properties, and the geometric parameters, need to be considered in the analysis and design to meet the high-performance requirements. In this paper, imprecisions associated with the basic parameters of honeycomb cores are considered. Non-probabilistic models for the in-plane elastic properties of hexagonal honeycomb cores are developed in which the imprecisely defined input and response parameters are represented by only their mean values and variations without the requirement of knowing the probability density distributions of the imprecise parameters as is required for probabilistic methods. Thus, the proposed models predict not only the nominal values of the in-plane elastic properties but also their variations from the respective mean values. The applicability of the proposed models is demonstrated by considering the analysis of the in-plane elastic properties of a honeycomb core made of aluminum 5052-H-32 in which the core material properties are defined by their mean values and variations. The results show that realistic variations of the in-plane elastic properties are obtained using the proposed non-probabilistic models. The sensitivity of the in-plane elastic properties to the imprecisions present in each basic parameter is also investigated.