KONGU ENGINEERING COLLEGE

PERUNDURAI

DEPARTMENT OF MECHANICAL ENGINEERING

PRE FINAL YEAR

PAPER PRESENTATION
(COMPOSITE MATERIALS)

STUDY ON THE THREE DIMENSIONAL MODELLING OF

HONEYCOMB SANDWICH STRUCTURES

SUBMITTED BY
S.DHANAPAL
B.KALILULLARAHIM
mechrahim@gmail.co
m sdhanapalmech@gmail.com
ABSTRACT
Honeycomb sandwich structures are widely used in aerospace industries due to its
high buckling resistance and strength to weight ratio. The accurate as finite element
approximation of this structure namely model with shell element, 3-D model with brick
element, etc. Layered element modeling is most widely accepted and used heavily in the
industry. The deficiency of this modeling lies in incorporating damages like delamination,
and inclusion of boundary conditions for thick sandwich structures. 3-D model has a
better edge over these problems. At the same time 3-D model is computationally resource
sensitive. This paper studies the efficacy of 3-D modeling of honeycomb sandwich
structures to capture the real behavior. Case study is conducted on metallic sandwich
plate using layered element modeling and 3-D shell element modeling. Results are
compared with the theoretical results. Conclusion is made on the effectiveness of 3-D
shell element modeling in terms of accuracy and efficiency.

1.0 INTRODUCTION
.
Composites are materials created by combining dissimilar materials with a view
to improve the properties or to create materials with desired properties. Sandwich
Construction is one of the derived forms of composites. This chapter discusses the
Classification of composites, sandwich construction, failure modes , NDT etc
1.1 CLASSIFICATION OF COMPOSITES
The microstructure of the composites provides a convenient basis of classifying
Them for purpose of study, processing and analysis. Two materials can be combined only
by two basic ways (i) by inserting one material into the other or (ii) by bonding they layer
by layer. The former type of composition is called multiphase composition. And the later
type is multi-layered composition. The phase composition is generally at Microscopic
level and the layered composition is at macroscopic level.

Fig 1.1 Classification of composites

Both multiphase composites and multilayered composites can further be divided

Into two subcategories as shown in the fig.1.1. Among above said types of composites,
Here we discuss a particular type of sandwich composite called honeycomb sandwich
Structure in the following pages.

1.2 HONEYCOMB SANDWICH (HCS) STRUCTURES

Honeycomb sandwich structure is the simplest type of sandwich; consist of two
Thin, stiff, strong sheets of dense material separated by a thick layer of low-density
Material, which may be much less stiff and strong (fig 1.2). As a crude guide to the
Proportions, an efficient sandwich is obtained when the weight of the core is roughly
Equal to the combined weight of the faces. Obviously the bending stiffness of this
Arrangement is very much greater than that of a single solid plate of the same total
Weight made of the same material as the face.

Fig 1.2 Honeycomb sandwich structure

1.1.1 Components of sandwich structures
The basic components of a sandwich panel are:
i) A pair of thin, strong facings to carry the axial, bending and in-plane shear
Loading.
ii) A thick, lightweight core to separate the facings to carry the loads from one
Facing to the other and carry transverse shear loads.
iii) Adhesive layer, which is capable of transmitting shear loads to and from the core.
The face material in a sandwich is required to provide the bending and in plane
Shear stiffness to carry the edgewise and bending loads as well as the in plane shear
Loading.
The core has several vital functions [32]; it must be stiff enough in the
directionPerpendicular to the faces to ensure that they remain the correct distance apart. It
must be stiff enough in shear to ensure that when the panel is bent, the faces do not slide
overeach other. If this last condition is not fulfilled the faces merely become as two
independent beams or panels and the sandwich effect is lost. The core must also be stiff
enough to keep the faces nearly that: otherwise it is possible for a face to buckle locally
(Wrinkle) under the influence of compressive stress in its own plane. The core must
satisfy all these requirements and it is also important that the adhesive should not be
sufficiently flexible to permit substantial relative movement of the faces and the core.
1.3 Types of sandwich structures
The sandwich structures may be of metallic or non-metallic skin and core Combinations
like Aluminum, Nomex, Fiberglass, Kraft paper, etc. Core of the Sandwich construction
supports the face sheets, increases the torsional and bending Stiffness and carries most of
the transverse shear load. Generally sandwich construction Uses foam or solid core,
honeycomb core, web core, corrugated or truss core. The Material property, cell
size/shape and thickness of the core have significant
Contributions to the stiffness of the panel. The sandwich structures are classified based
On construction of core with face sheet as:
(i) Foam core sandwich structures
(ii) Regular honeycomb sandwich structure
 (iii) Corrugated shape sandwich structures
The types and core cell shapes of the sandwich structures are shown in fig 1.3.
Core preparation and manufacturing of sandwich structures
There are five basic ways of making honeycomb sandwich structures. They are
a. Adhesive bonding
b. Resistance welding
c. Brazing
d. Diffusion bonding
e. Thermal fusion.
These methods are based on how the nodes are attached. Resistance welding,
Brazing and diffusion bonding are used only on cores that have to withstand high
Temperatures or several environmental conditions. Thermal diffusion method is used for
some thermoplastic materials with their nodes heated so that they are partially melt and
are pressed together. All these methods are not commonly used since they are very
Expensive. The most common (about 95%) manufacturing process is adhesive bonding.

Fig 1.3 Type of sandwich structures and cell shapes

There are two methods used to convert sheet metal into honeycomb core: (a)
Expansion process and (b) corrugation process. Almost all of the adhesive bonded cores
are made of the expansion process.

1.4 Advantages of HCS structures

a. Optimum strength to weight: The distributed support offered to the facings by
the HC core permits the facing to attain the full tensile and compressive capability
Without buckling.
b. Optimum stiffness to weight: This feature of bonded construction is
uncontested. Optimum material utilization for stiffness is achieved by forcing the bending
load carrying components to the surface of the structure with an extremely light weight
Core material.
c. Maximum fatigue resistance: Bonded as opposed to mechanically fastened
systems have a proven record against fatigue failure. The continuous attachment of the
core to the facing eliminates the tendency for stresses to concentrate around mechanical
Fasteners thus minimizing fatigue damage.
d. Smooth/Flat surfaces: The manufacturing techniques used to cut honeycomb
core produce extremely flat surfaces. The resulting surface is extremely smooth and flat.
e. Impact Resistance: Generally the non-metallic components produce optimum
impact resistance. Facing and core materials combinations may be selected to develop the
required degree of impact strength and dent resistance.
f. Thermal and Acoustic Versatility: The availability of both metallic and non-
metallic facings and core provide the designer with the capability to design for a
maximum or minimum heat transfer rate. For extremely low rate requirements the
honeycomb core may be filled with foam prior to bonding.
g. Design Versatility: The fact that a honeycomb system is a composite of three
basic materials provides the designer with a wide range of variables to meet design
Objectives.
h. Crack growth and fracture toughness characteristics are better compared to
solid laminates.
1.5 Applications of HCS structures
Missile / Launch Vehicles / Space craft
o Tankages o Structural shells o Solar panels
o Shipping containers o Inter-tank structures o Heat shields
o Inter-stages o Equipment deck plates o Antennas
o Fins & control surfaces
Aircraft
o Control surface o Helicopter blades o Fan and ducts
o Control tabs o Wing panels o Engine cowlings
o Bulkheads o Fairings
Electronics and communication / Buildings
o Curtain walls o Pre-fabricated shelter o Partition doors
o Antenna reflectors o Electronic packaging o Radomes
Miscellaneous
o Desktops o Boat cargo containers o Railway wagons
o Scaffoldings o House trailor flooring o Sports goods

1.6 DAMAGES AND THEIR EFFECT IN HCS STRUCTURE

In HCS structure, the damage mainly arises at the interface of face and core. The
Sources of damage in the HCS structure are: adhesive bond failure, local crushing of
Core, intra-cell buckling, face wrinkling etc. A number of buckling failure modes [2] can
Occur depending on the relative strength and stiffness of the face, core and adhesive
Strength. Failure modes of metallic HCS-panels are as shown in table 1.1.
Adhesive bond failure
Adhesive bond failure is generally exhibited in three types of failure; face to
Core debonding, core fillet bond failure and core node bond failure. These are described
In fig 1.4. Degradation of the bond strength through exposure to moisture and free water
Will decrease the strength of these bonds. Sandwich panels are generally designed so
That the core fails in shear before the face to core bond or fillet bond fails. Reduction in
Bond strength may change the failure mode and cause premature failure of the panel.

Fig 1.4 Failure types of adhesive bonds in sandwich panels

Correctly designed sandwich-panels will resist the types of failures seen in
Service. Typically the failures take the form of the face or panel skin separating from the
Core. During repair, failures generally occur during panel heating when internal pressure
exceeds the degraded face to core bond strength. This situation can occur when moisture
trapped in the core boils and bond strength is reduced at elevated temperature.
Adhesive degradation may affect the face-to-core bond, fillet bonds and the core
node bonds. Degradation of the face-to-core bond or fillet bonds may lead to shear
crimpling and face wrinkling of the panel. Degradation of the node bonds may affect the
core shear modulus and thus affect the shear buckling, crimpling and face wrinkling
resistance of sandwich panels. Also, it may reduce the general buckling stability of the
panels. Degradation in the adhesive bond would also reduce the flat-wise tension
strength of the face-to-core bond.

Table 1.1 Buckling modes of honeycomb sandwich panel [2]

 It is not surprising that adhesive degradation would lead to the types of failures
and during maintenance in sandwich-panels. Reduction in the face-to-core or fillet bond
strength, particularly in combination with some form of void or disbond, may cause
wrinkling or crimpling of the panel which in combination with low core shear strength
and panel-buckling instability may lead to separation of the face from the core.

There are four basic design principles that should be observed while designing a
Sandwich-panel [2]. They are:
1. The facings need to be thick enough to withstand the chosen design
compressive stress.
2. The core needs to be sufficiently thick and with a sufficiently high shear
modulus so that buckling of the sandwich-panel will not occur at the design compression
load.
3. The modulus of elasticity of the core needs to be sufficiently high and the flat
wise tensile and compressive strength of the panel needs to be sufficiently high as
to prevent wrinkling of either facing.
4. The cell size needs to be sufficiently small so that dimpling of either facing into
the core cell will not occur.
Also, the terminating edge of the sandwich construction is designed such that it
has sufficient strength and stiffness to withstand the applied edge loads, and distribute
those edge loads into the sandwich construction as uniformly as practicable.
1.7 Non destructive testing (NDT) methods
The following NDT methods [33, 34] are used in HCS structures to locate,
determine the size and classify the type of damage:
1. X-ray radiography
2. Thermal neutron radiography
3. Ultrasonic inspection
4. Shearography and
5. Coin-tap test
1.8 CONCLUTION
In this research work, a three dimensional finite elemental model of
honeycomb sandwich structure is developed for simulation of delaminated and intact
honeycomb sandwich panel. The model is developed using commercial code ANSYS
software and validated with theoretical and experimental results. The model is updated
with damage (delamination), modal and transient analyses are conducted to find out the
damage signature and their dynamic response. The said model is suitable for damage
simulation studies for structural health monitoring application.
1.9 REFERENCES

[1]. A review of Structural Health monitoring Literature, 1996-2001, Los Alamos

National Laboratory Report, LA-13976-MS, 2003.
[2]. S Whitehead, M McDonald and R A Bartholomeusz, Loading, degradation
and repair of F-111 bonded honeycomb sandwich panels Preliminary Study, DSTO
Aeronautical and Maritime Research Laboratory, Australia.
[3]. S Adalarasu, Guided waves for flaw detection in sheets and tubes,
Proceedings of national aerospace manufacturing seminar, NAMS2005, 2005
[4]. Seth S Kessler and S Mark Spearing, Damage detection in built-up
composite structures using lamb wave methods, Massachusetts Institute of Technology,
Cambridge, USA.
[5]. Hao Jiang, Douglas E Adams, and Kumar Jata, Material damage modelling
and detection in a homogeneous thin metallic sheet and sandwich panel using passive
acoustic transmission, Structural Health Monitoring, Vol.5(4):0373-15, 373-387,
2006.