The sound transmission loss characteristics of plywood based sandwich panels were investigated. Measurements were made of the sound transmission loss of a range of materials and used as a baseline for comparison while a sound transmission loss optimisation method was developed. A unique test rig was built and calibrated to determine selected mechanical properties of materials of interest. The results of sound transmission loss and material properties measurements were used to select an appropriate prediction model, which was then used in conjunction with a mathematical optimisation model to determine combinations of materials and panel parameters which result in improved sound transmission loss. An effort was made to reproduce these predictions in experimental testing by constructing several prototype panels.

Sandwich panels using fibre-reinforced composite skins and low-density cores are being increasingly used in the aerospace industry due to their superior specific strength and stiffness, and increased design flexibility over traditional metallic and composite structures. However, it is well-known that sandwich panels are highly vulnerable to the effects of impact damage, with even low-energy impacts potentially causing very severe reductions in the in-plane compressive strength of these structures. The objective of this project was to produce a faithful and reliable numerical model for the simulation of the compression-after-impact strength of composite sandwich panels. An in-depth literature review revealed that delamination within the skins of a sandwich panel is a damage mechanism that has gone almost entirely neglected in previous efforts at modelling this problem, despite the proven significance of this mechanism in the failure of impact damaged sandwich panels in compression. Consequently, the use of the cohesive zone model for delamination initiation and propagation is the key unique feature of this model, with Hashin s criteria being used for intra-laminar damage formation, and a simple plasticity response capturing core crushing. An experimental study is performed to produce a thorough dataset for model validation, featuring differing levels of damage induced via quasi-static indentation, and novel asymmetric panels with skins of unequal thickness (the thinner skin being on the unimpacted side). The experimental study revealed that the use of a thinner distal (undamaged) skin could improve the strength of mildly damaged sandwich panels over undamaged sandwich panels using the same asymmetric configuration. It is believed that this effect is due to the movement of the neutral plane of the sandwich panel caused by the reduction in the stability of the damaged skin through stiffness reduction and geometric imperfections. This removes the eccentricity of the compressive loading that exists in the undamaged asymmetric panels, which has mismatched axial stiffness between the indented skin and the thinner distal skin, and thus a noticeably lower ultimate strength than the undamaged symmetric panels. The sandwich model is developed using pre-existing experimental and material data, and trialled for a variety of different skin lay-ups, core thicknesses and indenter sizes. The numerical model generally agreed well with the ultimate stress found in the experiments for these different configurations, but is quite poor at estimating the magnitude of the damage induced by the indentation. When used to model the experimental study, the model gave generally good, conservative estimates for the residual compressive strength of both the symmetric and asymmetric panels. The tendency of the asymmetric panels to become stronger with mild damage was not captured by the model per se, with the numerical results instead showing an insensitivity to damage in the asymmetric panels, which was not shared by the symmetric panels. However, the numerical model did exhibit erroneous strain-stress responses for both panel configurations, particularly for the undamaged and mildly damaged cases. Investigations revealed that this erroneous behaviour was caused by inconsistency in the material data, which had been collected partially via experimentation and partly from literature sources. Overall, the model developed here represents a promising advancement over previous efforts, but further development is required to provide accurate damage states.

Sandwich panels serve many purposes in engineering applications. Additive manufacturing opened the door for easy fabrication of the sandwich panels with different core structures. In this study, additive manufacturing technique, experiments, and numerical analysis are combined to evaluate the mechanical properties of sandwich panels with different cellular core structures. The sandwich panels having honeycomb, re-entrant honeycomb, diamond, square core topologies are printed with the vat photopolymerization technique. Uniaxial compression testing is performed to determine the compressive modulus, strength, and specific strength of these lightweight panels. Elasto-plastic finite element analysis having good similarities with the experimental results provided a preview of the stress distribution of the sandwich panels under applied loading. The imaging of the tested samples showed the fractured regions of the cellular cores. Dynamic mechanical analysis of the panels provided scope to compare the performance of panels and solid materials with the variation of temperature. Sandwich panels with the diamond structure exhibit better compressive properties and specific strength while the re-entrant structure offers high energy absorption capacity. The sandwich structures provided better thermo-mechanical properties than the solid material. The findings of this study offer insights into the mechanical properties of sandwich panels printed with vat photopolymerization technique which can benefit a wide range of engineering applications.

Precast concrete sandwich panels are a structural system consisting of concrete layers with insulation layers in between. The concrete layers are connected through the insulation with specially designed connectors. For engineers to properly design and analyze the strength characteristics of sandwich panels and their connectors, the engineers need to obtain recommendations from the individual connector manufacturers, which can be a very rigorous process. This project tested eight full scale precast concrete sandwich panels with two concrete layers on either side of an insulation layer with connectors concentrated at either end of each panel. The objectives of this project were to evaluate the interaction between the two concrete layers and how well the connectors transferred forces between the layers (percent of composite action) and to validate simplified methods of predicting properties of the panels by comparing the predicted panel properties to the results of the testing series. Additionally, this study evaluated the panel’s different thicknesses and lengths and compared their results.

An efficient interaction formula and a semi-analytical method are developed for calculating the ultimate strength of steel-elastomer sandwich panels under combined in-plane compression and lateral pressure. By using the Galerkin method and extending the semi-analytical method to clamped sandwich panels, the governing equations of sandwich panels have been solved by the Galerkin method. The material nonlinearity is treated by iteration and a three-dimensional mesh. For the load case of pure lateral pressure, the ultimate strength from the semi-analytical method is similar to that from hinge line theory and finite element analysis (FEA). However, the semi-analytical method requires about as much computation as FEA, and it is therefore not suitable for design. Finite element modeling and nonlinear analysis are performed to calculate the ultimate strength of sandwich panels under combined load. The results agree with experimental results. This verifies the accuracy of the current finite element model. The verified finite element model is used to obtain the results for a large set of sandwich panels with various dimensions and load combinations. The FEA results for pure lateral pressure load cases are used to derive a correction factor for the hinge line formula. Statistical analysis confirms that the generalized hinge line formula gives accurate values of ultimate strength of sandwich panels under pure lateral pressure. Except for the pressure-only FEA data points, the other FEA data points are corrected so as not to count the in-plane load carried by the elastomer core. Based on the corrected FEA data points, a general expression is developed for an interaction equation. The resulting equation has a bias of -0.003 and a standard deviation of 0.029. Since the radius of the interaction curve is close to 1, this standard deviation is of the order of 3%, which shows that the ultimate strength given by the equation is very close to the FEA results. The interaction equation is so simple that the ultimate strength of clamped sandwich panels under combined in-plane compression and lateral pressure can be easily calculated. / Ph. D.

In aerospace applications, use of laminates made of composite materials as face sheets in sandwich panels are on the rise. These composite laminates have low transverse shear and transverse normal moduli compared to the in-plane moduli. It is also seen that the corresponding transverse strength values are very low compared to the in-plane strength leading to delaminations. Further, in sandwich structures, the core is subjected to significant transverse shear stresses. Therefore the interlaminar stresses (i.e., transverse shear and normal) can govern the design of sandwich structures. As a consequence, the first step in achieving efficient designs is to develop the ability to reliably estimate interlaminar stresses. Stress analysis of the composite sandwich structures can be carried out using 3-D finite elements for each layer. Owing to the enormous computational time and resource requirements for such a model, this process of analysis is rendered inefficient. On the other hand, existing plate/shell finite elements, when appropriately chosen, can help quickly predict the 2-D displacements with reasonable accuracy. However, their ability to calculate the thickness-wise distributions of interlaminar shear and normal stresses and 3-D displacements remains as a research goal. Frequently, incremental refinements are offered over existing solutions. In this scenario, an asymptotically correct dimensional reduction from 3-D to 2-D, if possible, would serve to benchmark any ongoing research. The employment of a mathematical technique called the Variational Asymptotic Method (VAM) ensures the asymptotical correctness for this purpose. In plates and sandwich structures, it is typically possible to identify (purely from the defined material distributions and geometry) certain parameters as small compared to others. These characteristics are invoked by VAM to derive an asymptotically correct theory. Hence, the 3-D problem of plates is automatically decomposed into two separate problems (namely 1-D+2-D), which then exchange relevant information between each other in both ways. The through-the-thickness analysis of the plate, which is a 1-D analysis, provides asymptotic closed form solutions for the 2-D stiffness as well as the recovery relations (3-D warping field and displacements in terms of standard plate variables). This is followed by a 2-D plate analysis using the results of the 1-D analysis. Finally, the recovery relations regenerate all the required 3-D results. Thus, this method of developing reduced models involves neither ad hoc kinematic assumptions nor any need for shear correction factors as post-processing or curve-fitting measures. The results are most general and can be made as accurate as desired, while the procedure is computationally efficient. In the present work, an asymptotically correct plate theory is formulated for composite sandwich structures. In developing this theory, in addition to the small parameters (such as small strains, small thickness-to-wavelength ratios etc.,) pertaining to the general plate theory, additional small parameters characterizing (and specific to) sandwich structures (viz., smallness of the thickness of facial layers com-pared to that of the core and smallness of elastic material stiffness of the core in relation to that of the facesheets) are used in the formulation. The present approach also satisfies the interlaminar displacement continuity and transverse equilibrium requirements as demanded by the exact 3-D formulation. Based on the derived theory, numerical codes are developed in-house. The results are obtained for a typical sandwich panel subjected to mechanical loading. The 3-D displacements, inter-laminar normal and shear stress distributions are obtained. The results are compared with 3-D elasticity solutions as well as with the results obtained using 3-D finite elements in MSC NASTRAN®. The results show good agreement in spite of the major reduction in computational effort. The formulation is then extended for thermo-elastic deformations of a sandwich panel. This thesis is organized chronologically in terms of the objectives accomplished during the current research. The thesis is organized into six chapters. A brief organization of the thesis is presented below. Chapter-1 briefly reviews the motivation for the stress analysis of sandwich structures with composite facesheets. It provides a literature survey on the stress analysis of composite laminates and sandwich plate structures. The drawbacks of the existing anlaytical approaches as opposed to that of the VAM are brought out. Finally, it concludes by listing the main contributions of this research. Chapter-2 is dedicated to an overview of the 3-D elasticity formulation of composite sandwich structures. It starts with the 3-D description of a material point on a structural plate in the undeformed and deformed configurations. Further, the development of the associated 3-D strain field is also described. It ends with the formulation of the potential energy of the sandwich plate structure. Chapter-3 develops the asymptotically correct theory for composite sandwich plate structure. The mathematical description of VAM and the procedure involved in developing the dimensionally reduciable structural models from 3-D elasticity functional is first described. The 1-D through-the-thickness analysis procedure followed in developing the 2-D plate model of the composite sandwich structure is then presented. Finally, the recovery relations (which are one of the important results from 1-D through-the-thickness analysis) to extract 3-D responses of the structure are obtained. The developed formulation is applied to various problems listed in chapter 4. The first section of this chapter presents the validation study of the present formulation with available 3-D elasticity solutions. Here, composite sandwich plates for various length to depth ratios are correlated with available 3-D elasticity solutions as given in [23]. Lastly, the distributions of 3-D strains, stresses and displacements along the thickness for various loadings of a typical sandwich plate structure are correlated with corresponding solutions using well established 3-D finite elements of MSC NASTRAN® commerical FE software. The developed and validated formulation of composite sandwich structure for mechanical loading is extended for thermo-elastic deformations. The first sections of this chapter describes the seamless inclusion of thermo-elastic strains into the 3-D elasticity formulation. This is followed by the 1-D through-the-thickness analysis in developing the 2-D plate model. Finally, it concludes with the validation of the present formulation for a very general thermal loading (having variation in all the three co-ordinate axes) by correlating the results from the present theory with that of the corresponding solutions of 3-D finite elements of MSC NASTRAN® FE commercial software. Chapter-6 summarises the conclusions of this thesis and recommendations for future work.

A demanda por estruturas mais leves implica num ganho em economia, porém o aumento de esbeltez da estrutura pode tornar ela susceptível a instabilidade frente a tensões compressivas estáticas ou dinâmicas. A instabilidade acontece em várias escalas da estrutura analisada e pode interagir com outras formas de colapso como a propagação instável de fissuras, problema governado pela mecânica da fratura, pela plastificacão do material, ou por uma combinação dos efeitos citados. Neste contexto, no presente trabalho, se explora a capacidade do método dos elementos discretizados por barras (LDEM) na simulação de problemas de instabilidade estática e dinâmica devido as tensões de compressão. Este método permite simular o sólido como um arranjo de barras com rigidez equivalente ao contínuo que se quer representar. Leis constitutivas não lineares permitem modelar ruptura de forma simples. A equação de movimento resultante da discretização permite formular uma equação de movimento desacoplada que pode ser integrada no domínio do tempo com um método explícito (Método das Diferencias Finitas Centrais). O fato das barras serem rotuladas nos seus extremos e a solução do problema ser obtida de forma incremental permite capturar problemas com não linearidade geométrica, entre eles a instabilidade estrutural frente a tensões compressivas. Como último exemplo se realiza a análise de um painel sanduiche por flexão em três pontos, que é composto por um núcleo de poliuretano, com duas lâminas externas de material compósito, neste caso a instabilidade estrutural está associada a flambagem da camada da lâmina comprimida. Finalmente a potencialidade da metodologia de análise utilizada é discutida. / The demand for lighter structures implies a gain in economy, but the increase in slenderness of the structure may make it susceptible to instability against static or dynamic compressive stresses. Instability occurs at various scales of the analyzed structure and may interact with other forms of collapse such as unstable crack propagation, problem governed by fracture mechanics, plastification of the material, or a combination of the cited effects. In this context, in the present work, we explore the ability of the discrete elements methods by bars (LDEM) in the simulation of problems of static and dynamic instability due to the compression stresses. This method allows to simulate the solid as an arrangement of bars with rigidity equivalent to the continuum that one wants to represent. Constitutive non-linear laws allow simple modeling of rupture. The equation of motion resulting from the discretization allows us to formulate a decoupled motion equation that can be integrated in the time domain with an explicit method (Central Finite Differences Method). The fact that the bars are labeled at their ends and the solution of the problem is obtained in an incremental way allows to capture problems with geometric non-linearity, among them the structural instability against compressive tensions. The last example, the analysis of a sandwich panel by three-point bending, which is composed of a polyurethane core, with two external blades of composite material, in this case the structural instability is associated with buckling of the layer of the compressed blade . Finally, the potential of the analysis methodology is discussed.

Structures and material combinations, tailored for multiple purposes, are within the reach of vehicle manufacturers. Besides reducing the environmental impact of the transportation sector these multi-functional structures can reduce costs, such as development, manufacturing and maintenance, and at the same time offer improved comfort to the passengers. This thesis sets out to develop multi-functional design algorithms and evaluate concepts for future composite high speed train car bodies with the objective of optimising the amount of mass needed to fulfil all functions of the structure. In a first step complete composite car bodies were developed, optimised and evaluated based on global stiffness requirements and load cases. The knowledge gained in this step was used as requirements for the strength and stiffness of panels during the continued development of the multi-functional optimisation which, besides strength and stiffness, later also considers sound transmission, thermal insulation, geometric restrictions, manufacturability and fire safety. To be able to include fire safety in the analysis, a method for simulating the high temperature response of layered composite structures was needed, and developed. Significant weight reductions are proven when utilising carbon fibre in the load carrying structure of the vehicle, on component level as high as 60%. Structures can be made significantly thinner when using the algorithms developed in this thesis and wall thickness is reduced by 5-6 cm. Analysis carried out and extensive literature surveys also suggest significant cost savings in manufacturing, maintenance and use-phase, even thou the raw material cost can be significantly higher as compared to the conventional steel or aluminium alternatives. Results from drive cycle simulations showed that the benefit, with respect to reduced energy consumption, is in the range of 0.5-0.8% per reduced weight percentage, comparable to both automotive and air applications. The algorithms and methods established in this thesis can be directly applied for the development and analysis of future high speed train car bodies. / <p>QC 20130521</p>

The structural vibration damping behaviour of plates and beams can be improved by the application of viscoelastic passive damping materials. Unconstrained layer damping treatments applied to metal plate systems were studied experimentally. Design and modelling of novel fibre reinforced constrained layer damping materials was performed, and implementation of these composite damping materials into laminated composite sandwich constructions commonly used as structural elements within large composite marine vessels was explored. These studies established effective methods for examining, designing and applying damping materials to metal and composite marine structures. Two test fixtures were designed and constructed to facilitate testing of viscoelastic material damping properties to ISO 6721-3 and ASTM E756. Values of material damping made in accordance with ASTM E756 over a range of temperatures were compared to values produced by a Dynamic Mechanical Analyser (DMA). Glass transition temperatures and peak damping values were found to agree well, although results deviated significantly at temperatures above the glass transition temperature. The relative influence of damping layer thickness, ambient temperature, edge conditions, plate dimensions and substrate material on the system damping performance of metal plates treated with an unconstrained viscoelastic layer was investigated experimentally. This investigation found that substrate material had the greatest influence on system damping performance, followed by damping layer thickness and plate size. Plate edge conditions were found to have little influence on the measured system damping performance. These results were dependent on the values of each variable used in the study. Modal damping behaviour of a novel fibre reinforced composite constrained layer damping material was investigated using finite element analysis and experimental methods. The material consisted of two carbon fibre reinforced polymer (CFRP) layers surrounding a viscoelastic core. Opposing complex sinusoidal fibre patterns in the CFRP face sheets were used to achieve stress-coupling by way of orthotropic anisotopy about the core. A finite element model was developed in MATLAB to determine the modal damping, displacement, stress, and strain behaviour of these complex patterned fibre constrained layer damping (CPF-CLD) materials. This model was validated using experimental results produced by modal damping measurements on CPF-CLD beam test specimens. Studies of multiple fibre pattern arrangements found that fibre pattern properties and the resulting localised material property distributions influenced modal damping performance. Inclusion of CPF-CLD materials in laminated composite sandwich geometries commonly used in marine hull and bulkhead constructions was studied experimentally. Composite sandwich beam test specimens were fabricated using materials and techniques frequently used in industry. It was found that the greatest increases in modal damping performance were achieved when the CPF-CLD materials were applied to bulkhead geometries, and were inserted within the sandwich structure, rather than being attached to the surface.

Honeycomb core sandwich panels are widely used in the aeronautic industry due to their excellent flexural stiffness to weight ratio. Generally, classical homogenized model is used to model honeycomb core sandwiches in order to have an efficient but not expensive numerical modeling. However, previous works have shown that, while the homogenized models could correctly represent the membrane waves' behavior of sandwiches in a large frequency range, they could not give satisfying simulation results for the flexural waves' behavior in the high frequency range (HF). In fact, the honeycomb core layer plays an important role in the propagation of the flexural waves, so that when the involved wavelengths become close to the characteristic lengths of honeycomb cells, the cellular microstructure starts interacting strongly with the waves and its effect should no longer be neglected, which is unfortunately not the case of the homogenized models. In the present work, we are interested in improving the theoretical and numerical analysis of HF elastic waves' propagation in honeycomb core sandwich panels by a numerical approach based on the Bloch wave theorem, which allows taking into account the periodic characteristics of the honeycomb core. In fact, by decomposing non-periodic wave solutions into their periodic Bloch wave basis modes, numerical models are defined on a basic cell and solved in a efficient way, and provide a better description and so a better understanding of the interaction between HF wave propagation phenomena and the periodic structures. Our numerical approach is developed and validated in the cases of one-dimensional periodic beam structures, of two-dimensional periodic hexagonal and rectangular beam structures and of honeycomb core sandwich plates. By solving the eigenvalue problem of the Bloch wave modes in one primitive cell of the periodic structure for all the wave vectors located in the corresponding first Brillouin zone in the phase space, the dispersion relation between the wave vector and the eigenvalue is calculated. The analysis of the dispersion relation provides important results such as: the frequency bandgaps and the anisotropic and dispersive characteristics of periodic structures, the comparison between the first Bloch wave modes to those of the classical equivalent homogenized models and the existence of the retro-propagating Bloch wave modes with a negative group velocity.