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.

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.

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.

Over the past century, the automobile has become an integral part of modern industrializedsociety. Consumer demands, regulatory legislation, and the corporate need togenerate a profit, have been the most influential factors in driving forward the evolutionof the automobile. As the comfort, safety, and reliability of the automobile haveincreased, so has its complexity, and most definitely its mass.The work within this thesis addresses the twofold problem of economy and ecologywith respect to sustainable development of automobiles. Specifically, the conflictingproblems of reducing weight, and maintaining or improving noise, vibration, andharshness behaviour are addressed. Potential solutions to these problems must also beexecutable at the same, or preferably lower production costs. The hypothesis is that byreplacing acoustic treatments, aesthetic details, and complex systems of structural componentsboth on the interior and exterior of the vehicle with a single multi-functionalbody panel, functionality can be retained at a reduced mass (i.e. reduced consumptionof raw materials) and reduced fiscal cost.A case study is performed focusing on the roof structure of a production vehicle. Fullvehicle and component level acoustic testing is performed to acquire acoustic functionalrequirements. Vibro-mechanical testing at the component level is performedto acquire structural functional requirements complimentary to those in the vehiclesdesign specifications. Finite element modelling and analysis is employed to createa model representative of the as-tested component and evaluate its acoustic and mechanicalbehaviour numerically. Results of numerical simulations are compared withthe measured results for both acoustic and mechanical response in order to verify themodel and firmly establish a set of acoustic and mechanical constraints for future work.A new, multi-layered, multi-functional sandwich panel concept is proposed which replacesthe outer sheet metal, damping treatments, transverse beams, and interior trimof the existing structure. The new panel is weight optimized to a set of structural constraintsand its acoustic properties are evaluated. Results show a significant reductionin mass compared to the existing system with no degradation of the acoustic environment.A discussion of the results is presented, as is a suggestion for future research.

No description available.

A better understanding of the effect of impact damage on composite structures is necessary to give the engineer an ability to design safe, efficient structures. Current composite structures suffer severe strength reduction under compressive loading conditions, due to even light damage, such as from low velocity impact. A review is undertaken to access the current state-of-development in the areas of experimental testing, and analysis methods. A set of experiments on Nomex honeycomb core sandwich panels, with thin woven fiberglass cloth facesheets, is described, which includes detailed instrumentation and unique observation techniques. These techniques include high speed video photography of compression after impact (CAI) failure, as well as, digital image correlation (DIC) for full-field deformation measurements. The effect of nominal core density on the observed failure mode is described. A finite element model (FEM) is developed to simulate the experiments performed in the current study. The purpose of this simulation is to predict the experimental test results, and to conrm the experimental test conclusions. A newly-developed, commercial implementation of the Multicontinuum Failure Theory (MCT) for progressive failure analysis (PFA) in composite laminates, Helius:MCT, is included in this model. The inclusion of PFA in the present model gives it the new, unique ability to account for multiple failure modes. In addition, significant impact damage detail is included in the model as a result of a large amount of easily available experimental test data. A sensitivity study is used to assess the effect of each damage detail on overall analysis results. Mesh convergence of the new FEM is also discussed. Analysis results are compared to the experimental results for each of the 32 CAI sandwich panel specimens tested to failure. The failure of each specimen is accurately predicted in a high-fidelity, physics-based simulation and the results highlight key improvements in the understanding of honeycomb core sandwich panel CAI failure. Finally, a parametric study highlights the strength benefits compared to mass penalty for various core densities. / Ph. D.

Sandwich Panels with cellular cores are widely used in the aerospace industry for their higher stiffness to mass, strength to mass ratio, and excellent energy absorption capability. Even though, sandwich panels are considered state of the art for lightweight aerospace structures, the requirement to further reduce the mass exists due to the direct impact of mass on mission costs. Traditional manufacturing techniques have limited the shape of the cores to be either hexagonal or rectangular, but, with rapid advancements in additive manufacturing, other core shapes can now be explored. This research aims to identify and evaluate the mechanical performance of two-dimensional cores having standard wall geometry, which provide higher specific stiffness than honeycomb cores. Triangular cores were identified to have higher specific in-plane moduli and equivalent specific out-of-plane and transverse shear moduli. To consider practical use of the triangular cores, elastic and elastic-plastic structural analysis was performed to evaluate the stiffness, strength, failure, and energy absorption characteristics of both the core and sandwich panels. The comparison made between triangular cores and hexagonal cores having the same cell size and relative density showed that triangular cores outperform hexagonal cores in elastic range and for applications where in-plane loading is dominant. Triangular cores also have excellent in-plane energy absorption capabilities at higher densities. / Master of Science / Sandwich panels with cellular cores are widely used in aerospace structures to reduce weight, which helps increase payload and improve fuel efficiency. They also have the ability to absorb energy during accidental impacts. Sandwich construction typically consists of two thin facesheets separated by a lightweight core and, is analogous to I-beams used in civil structures. Most commonly used core is the hexagonal honeycomb core inspired by beehives. While sandwich panels constructed using honeycomb cores are considered the state-of-the-art for lightweight aerospace structures, there is a need to further reduce the mass due to the direct impact on mission costs. This research aims to explore other core shapes that provide better stiffness to mass ratio than the hexagonal core. Among the two-dimensional cores explored, the triangular shaped core was identified to have higher stiffness than the hexagonal core of the same size and weight. To consider practical use of triangular cores, mechanical performance and failure behavior of sandwich panels constructed using triangular core sandwich panels was compared to hexagonal core sandwich panels. It was concluded that the triangular panels provided higher stiffness for the same mass and was more resistant to failure when axially loaded. Triangular cores also have excellent in-plane energy absorption capabilities at higher densities.

Les panneaux sandwichs sont des éléments de structure omniprésents au quotidien. Leur efficacité structurelle n'est plus à démontrer. Elle est même un élément déterminant dans le marché qui leur est associé. Ce mémoire de doctorat s'intéresse à un nouveau type d 'âme de panneau sandwich qui pourrait être amené à supplanter le nid d'abeilles dans certaines applications, le module à chevrons. L'objectif est donc de pouvoir faire une estimation précise du comportement de ces nouvelles âmes. Cependant le gain en efficacité structurelle des panneaux sandwichs se paye par une augmentation considérable de la complexité de leur comportement mécanique. C'est en particulier le cas de la raideur à l'effort tranchant qui est déterminante pour estimer l'efficacité d'une âme de panneau sandwich. Ainsi, ce travail nous a amené à reconsidérer en profondeur les méthodes pour calculer le comportement à l'effort tranchant des plaques en général. Il nous a conduit à proposer une nouvelle théorie des plaques ainsi qu'une méthode d'homogénéisation associée dans le cas périodique. Cette théorie peut être considérée comme l'extension de la théorie bien connue de Reissner-Mindlin au cas des plaques hétérogènes. Elle ne peut cependant pas être réduite au mod èle de Reissner-Mindlin dans le cas général. Dans le cas particulier des panneaux sandwichs incluant le module à chevrons, l'application de cette méthode d'homogénéisation permet de mettre en évidence un phénomène de distorsion des peaux qui affecte de façon notable la raideur à l'effort tranchant de ces panneaux / Sandwich panels are widespread in everyday life. Their structural efficiency is well-known and is a central criterion in possible applications. This Ph.D. thesis is dedicated to the study of a new sandwich panel core which might replace honeycomb in some applications: the chevron pattern. In order to compare this new core to other ones, an accurate knowledge of its mechanical behavior is necessary. However, the price for structural efficiency is a more complex mechanical behavior. This is the case for the shear forces stiffness which is critical when comparing sandwich panels cores. Thus, in this work we reconsider in details and in the general case how to derive plates behavior under shear forces. A new plate theory is suggested as well as the related homogenization scheme for periodic plates. This plate theory is the extension of the well-known Reissner-Mindlin plate theory in the case of heterogeneous plates. However, it cannot be reduced to a Reissner-Mindlin plate theory in the general case. In the special case of sandwich panels including the chevron pattern, applying the homogenization scheme brings out a skins distorsion phenomenon which affects a lot their shear forces stiffness