Lattice materials are used as the core of sandwich panels to construct light and strong structures. This thesis focuses on metallic sandwich structures and has two main objectives: (i) explore how a surface treatment can improve the strength of a lattice material and (ii) investigate the collapse response of two competing prismatic sandwich cores employed in ship hulls. First, the finite element method is used to examine the effect of carburisation and strain hardening upon the compressive response of a pyramidal lattice made from hollow tubes or solid struts. The carburisation surface treatment increases the yield strength of the material, but its effects on pyramidal lattices are not known. Here, it is demonstrated that carburisation increases the plastic buckling strength of the lattice and reduces the slenderness ratio at which the transition from plastic to elastic buckling occurs. The predictions also showed that strain hardening increases the compressive strength of stocky lattices with a slenderness ratio inferior to ten, but without affecting the collapse mode of the lattice. Second, the quasi-static three-point bending responses of simply supported and clamped sandwich beams with a corrugated core or a Y-frame core are compared via experiments and finite element simulations. The role of the face-sheets is assessed by considering beams with (i) front-and-back faces present and (ii) front face present, but back face absent. These two beam designs are used to represent single hull and double hull ship structures, and they are compared on an equal mass basis by doubling the thickness of the front face when the back face is absent. Beams with a corrugated core are found to be slightly stronger than those with a Y-frame core, and two collapse mechanisms are identified depending upon beam span. Short beams collapse by indentation and for this collapse mechanism, beams without a back face outperform those with front-and back faces present. In contrast, longbeams fail by Brazier plastic buckling and for this collapse mechanism, the presence of a back face strengthens the beam. Third, drop weight tests with an impact velocity of 5 m/s are performed on simply supported and clamped sandwich beams with a corrugated core or a Y-frame core. These tests are conducted to mimic the response of a sandwich hull in a ship collision. The responses measured at 5 m/s are found to be slightly stronger than those measured quasi-statically. The measurements are in reasonable agreement with finite element predictions. In addition, the finite element method is used to investigate whether the collapse mechanism at 5 m/s is different from the one obtained quasi-statically. The predictions indicate that sandwich beams that collapse quasi-statically by indentation also fail by indentation at 5 m/s. In contrast, the simulations for beams that fail quasi-statically by Brazier plastic buckling show that they collapse by indentation at 5 m/s. Finally, the dynamic indentation response of sandwich panels with a corrugated core or a Y-frame core is simulated using the finite element method. The panels are indented at a constant velocity ranging from quasi-static loading to 100 m/s, and two indenters are considered: a flat-bottomed indenter and a cylindrical roller. For indentation velocities representative of a ship collision, i.e. below 10 m/s, the predictions indicate that the force applied to the front face of the panel is approximately equal to the force transmitted to the back face. Even at such low indentation velocities, inertia stabilisation effects increase the dynamic initial peak load above its quasi-static value. This strengthening effect is more important for the corrugated core than for the Y-frame core. For velocities greater than 10 m/s, the force applied to the front face exceeds the force transmitted to the back face due to wave propagation effects. The results are also found to be very sensitive to the size of the flat-bottomed indenter; increasing its width enhances both inertia stabilisation and wave propagation effects. In contrast, increasing the roller diameter has a smaller effect on the dynamic indentation response. Lastly, it is demonstrated that material strain-rate sensitivity has a small effect on the dynamic indentation response of both corrugated and Y-frame sandwich panels.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / In this paper, a three-dimensional numerical solution for the bending study of laminated composite doubly-curved shells is presented. The partial differential equations are solved analytically by the Navier summation for the midsurface variables; this method is only valid for shells with constant curvature where boundary conditions are considered simply supported. The partial differential equations present different coefficients, which depend on the thickness coordinates. A semi-analytical solution and the so-called Differential Quadrature Method are used to calculate an approximated derivative of a certain function by a weighted summation of the function evaluated in a certain grin domain. Each layer is discretized by a grid point distribution such as: Chebyshev-Gauss-Lobatto, Legendre, Ding and Uniform. As part of the formulation, the inter-laminar continuity conditions of displacements and transverse shear stresses between the interfaces of two layers are imposed. The proper traction conditions at the top and bottom of the shell due to applied transverse loadings are also considered. The present results are compared with other 3D solutions available in the literature, classical 2D models, Layer-wise models, etc. Comparison of the results show that the present formulation correctly predicts through-the-thickness distributions for stresses and displacements while maintaining a low computational cost. / Consejo Nacional de Ciencia, Tecnología e Innovación Tecnológica

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Les structures sandwichs dissymétriques sont un cas particulier de la famille des structures sandwichs. Elles présentent une peau dite travaillante qui est chargée en membrane. Celle-ci est stabilisée par une âme en nid d'abeille Nomex et une contre-peau dite peau stabilisatrice. Cette configuration génère un comportement non linéaire géométrique. Plusieurs thèories analytiques des poutres et plaques sandwichs dissymétriques ont été élaborées basées sur le minimum de l'énergie potentielle ou le principe des puissances virtuelles associées à une méthode de discrétisation de Ritz. Ces théories intégrent de plus la modélisation a priori ou a posteriori de la compression de l'âme. Parallélement un montage d'essai sous sollicitations combinées compression/cisaillement a été développé et des essais multiaxiaux ont été réalisés sur éprouvettes neuves et impactées. Une comparaison théorie/expérience est aussi réalisée.

Sandwich structures constitute basic components of advanced supersonic/hypersonic flight and launch vehicles. These advanced flight vehicles operate in hostile environments consisting of high temperature, moisture, and pressure fields. As a result, these structures are exposed to large lateral pressures, large compressive edge loads, and high temperature gradients which can create large stresses and strains within the structure and can produce the instability of the structure. This creates the need for a better understanding of the behavior of these structures under these complex loading conditions. Moreover, a better understanding of the load carrying capacity of sandwich structures constitutes an essential step towards a more rational design and exploitation of these constructions. In order to address these issues, a comprehensive geometrically non-linear theory of doubly curved sandwich structures constructed of anisotropic laminated face sheets with an orthotropic core under various loadings for simply supported edge conditions is developed. The effects of the radii of curvature, initial geometric imperfections, pressure, uniaxial compressive edge loads, biaxial edge loading consisting of compressive/tensile edge loads, and thermal loads will be analyzed. The effect of the structural tailoring of the facesheets upon the load carrying capacity of the structure under these various loading conditions are analyzed. In addition, the movability/immovability of the unloaded edges and the end-shortening are examined. To pursue this study, two different formulations of the theory are developed. One of these formulations is referred to as the mixed formulation, While the second formulation is referred to as the displacement formulation. Several results are presented encompassing buckling, postbuckling, and stress/strain analysis in conjunction with the application of the structural tailoring technique. The great effects of this technique are explored. Moreover, comparisons with the available theoretical and experimental results are presented and good agreements are reported. / Ph. D.

Honeycomb core sandwich structures are an integral part of many of today's aerospace structures. When subjected to high-speed flight, thermal loading can induce significant stresses. The need for thermal properties to perform thermal stress analyses in these structures is the motivation behind this research. The thermal property estimation approach used here involves the minimization of a least-squares function containing both measured and calculated values. In addition, an applied heat flux is necessary at one boundary for the simultaneous estimation of thermal properties. The specific objectives are to develop a thermal model to describe honeycomb core sandwich structures, optimize experimental designs for use in parameter estimation, develop a finite element-based parameter estimation algorithm, and estimate the pertinent thermal properties of the structure. A combined conductive/radiative heat transfer model was used for the analysis of the structure. Due to the composition of the structure, it was determined that a one-dimensional model would be sufficient. This model was used in both parameter estimation and experimental design. Experimental design involves finding input variables for an experiment such that the response of the system contains the highest possible amount of information on the parameters of interest which characterize the response. In this study, the design was performed by using a combination of two methods. The first involved maximizing the temperature derivatives with respect to unknown thermal properties. The second involved a scaled confidence interval approach. The experimental parameters optimized were heating time and total experiment time. A finite element program was used to perform transient temperature calculations because of the flexibility it has to analyze complex structures. Parameters estimated in this study exhibited a great deal of correlation, or interaction. This showed the need for a constrained parameter estimation algorithm. A penalty function method was developed for this purpose. The last part of this study involved the actual estimation of thermal properties. An experimental apparatus was designed and built to record the transient temperature response of the test sample. A four-sheet SPF/DB sandwich was used as the test sample. Thermal properties were estimated using four combinations of sensors and boundary conditions. It was found that in one case parameters could be simultaneously estimated despite the presence of correlation. These estimated parameters were shown to produce reasonably small errors when used in transient temperature calculations. It was also shown that large temperature gradients produce estimates with smaller confidence intervals. The importance of maintaining accurately known boundary conditions was also demonstrated. / Master of Science

Due to high specific strength and stiffness as well as outstanding energy-absorption characteristics, sandwich structures are extensively used in aircraft, aerospace, automobile, and marine industries. With the objective of finding lightweight blast-resistant sandwich structures for protecting infrastructure, we have found, for a fixed areal mass density, one- or two-core doubly-curved sandwich shell's (plate's) geometries and materials and fiber angles of unidirectional fiber-reinforced face sheets for it to have the maximum first failure load under quasistatic (blast) loads. The analyses employ a third-order shear and normal deformable plate/shell theory (TSNDT), the finite element method (FEM), a stress recovery scheme (SRS), the Tsai-Wu failure criterion and the Nest-Site selection (NeSS) optimization algorithm, and assume the materials to be linearly elastic. For a sandwich shell under the spatially varying static pressure on the top surface, the optimal non-symmetric one-core (two-core) design improves the first failure load by approximately 33% (27%) and 50% (36%) from the corresponding optimal symmetric design with clamped and simply-supported edges, respectively. For a sandwich plate under blast loads, it is found that the optimal one-core design is symmetric about the mid-surface with thick face sheets, and the optimal two-core design has a thin middle face sheet and thick top and bottom face sheets. Furthermore, the transverse shear stresses (in-plane transverse axial stresses) primarily cause the first failure in a core (face sheet). For the computed optimal design under a blast load, we also determined the collapse load by using the progressive failure analysis that degrades all elasticities of the failed material point to very small values. The collapse load of the clamped (simply-supported) sandwich structure is approximately 15%–30% (0%–17%) higher than its first failure load. Incompressible materials such as rubbers, polymers, and soft tissues that can only undergo volume preserving deformations have numerous applications in engineering and biomedical fields. Their vibration characteristics are important for using them as wave reflectors at interfaces with a fiber-reinforced sheet. In this work we have numerically analyzed free vibrations of plates made of a linearly elastic incompressible rubber-like material (Poison's ratio = 0.5) by using a TSNDT for incompressible materials and the mixed FEM. The displacements at nodes of a 9-noded quadrilateral element and the hydrostatic pressure at four interior nodes are taken as unknowns. Computed results are found to match well with the corresponding either analytical or numerical ones obtained with the commercial FE software Abaqus and the 3-dimensional linear elasticity theory. The analysis discerns plate's in-plane vibration modes. It is found that a simply supported plate admits more in-plane modes than the corresponding clamped and clamped-free plates. / Doctor of Philosophy / A simple example of a sandwich structure is a chocolate ice cream bar with the chocolate layer replaced by a stiff plate. Another example is the packaging material used to protect electronics during shipping and handling. The intent is to find the composition and the thickness of the "chocolate layer" so that the ice cream bar will not shatter when dropped on the floor. The objective is met by enforcing the chocolate layer with carbon fibers and then finding fiber materials, their alignment, ice cream or core material, and its thickness to resist anticipated loads with a prescribed level of certainty. Thus, a sandwich structure is usually composed of a soft thick core (e.g., foam) bonded to two relatively stiff thin skins (e.g., made of steel, fiber-reinforced composite) called face sheets. They are lightweight, stiff, and effective in absorbing mechanical energy. Consequently, they are often used in aircraft, aerospace, automobile, and marine industries. The load that causes a point in a structure to fail is called its first failure load, and the load that causes it to either crush or crumble is called the ultimate load. Here, for a fixed areal mass density (mass per unit surface area), we maximize the first failure load of a sandwich shell (plate) under static (dynamic) loads by determining its geometric dimensions, materials and fiber angles in the face sheets, and the number (one or two) of cores. It is found that, for a non-uniformly distributed static pressure applied on the central region of a sandwich shell's top surface, an optimal design that has different materials for the top and the bottom face sheets improves the first failure load by nearly 30%-50% from that of the optimally designed structure with identical face sheets. For the structure optimally designed for the first failure blast load, the ultimate failure load with all of its edges clamped (simply supported) is about 15%-30% (0%-17%) higher than its first failure load. This work should help engineers reduce weight of sandwich structures without sacrificing their integrity and save on materials and cost. Rubberlike materials, polymers, and soft tissues are incompressible since their volume remains constant when they are deformed. Plates made of incompressible materials have a wide range of applications in everyday life, e.g., we hear because of vibrations of the ear drum. Thus, accurately predicting their dynamic behavior is important. A first step usually is determining natural frequencies, i.e., the number of cycles of oscillations per second (e.g., a human heart beats at about 1 cycle/sec) completed by the structure in the absence of any externally applied force. Here, we numerically find natural frequencies and mode shapes of rubber-like material rectangular plates with different supporting conditions at the edges. We employ a plate theory that reduces a 3-dimensional (3-D) problem to a 2-D one and the finite element method. The problem is challenging because the incompressibility constraint requires finding the hydrostatic pressure as a part of the problem solution. We show that the methodology developed here provides results that match well with the corresponding either analytical or numerical solutions of the 3-D linear elasticity equations. The methodology is applicable to analyzing the dynamic response of composite structures with layers of incompressible materials embedded in it.

Edgewise crushing responses of composite aluminum honeycomb sandwich structures were predicted using finite element analysis (FEA) software LS-DYNA by modeling the honeycomb as a material with anisotropic properties. The goal of the project was to develop a process for modeling the sandwich structure to rapidly iterate possible solutions for a safer workstation train table. Current workstation tables are too rigid and may cause injury or death in a head-on collision. Experimental compression tests were used to calibrate the aluminum honeycomb core with material type 26 (MAT 26, honeycomb). A published composite tensile test was used to validate the use of material type 22 (MAT 22, composite damage) for laminates. Finally, a model was made to recreate the results of a published compression test of an aluminum honeycomb sandwich structure with aluminum sheet metal face sheets to confirm contact types. With each component of the model verified separately, three plain weave composite aluminum honeycomb sandwich structures were modeled, one with [0/90] composite sheets completely bonded to the core, one with [0/90] composite sheets partially bonded to the core, and one with [±45] composite sheets partially bonded to the core. The failure modes for each sandwich structure were previously shown through research and the elastic region of the response was checked for accuracy using a simple beam theory. The analysis suggests that incorporating unbonded zones into the sandwich structure will change the failure mode from general buckling to face wrinkling, which effectively lowers the failure strength while not sacrificing energy absorption throughout loading. The analysis also indicates that using an angled ply orientation will lower the initial stiffness and the failure load. Future work is recommended such as performing compression tests with composite aluminum honeycomb sandwich structures and integrating delamination failure modes into the model using cohesive elements.

<p>In the industry, all passenger vehicles are treated with damping materials to reduce structure-borne sound. Though these damping materials are effective to attenuate structure-borne sound, they have little or no effect on the air-borne sound transmission.The lack of effective predictive methods for assessing the acoustic effects due to added damping on complex industrial structures leads to excessive use of damping materials.Examples are found in the railway industry where sometimes the damping material applied per carriage is more than one ton. The objective of this thesis is to provide a better understanding of the application of these damping materials in particular when applied to lightweight sandwich panels.</p><p>As product development is carried out in a fast pace today, there is a strong need for validated prediction tools to assist in the design process. Sound transmission loss of sandwich plates with isotropic core materials can be accurately predicted by calculating the wave propagation in the structure. A modified wave propagation approach is used to predict the sound transmission loss of sandwich panels with honeycomb cores. The honeycomb panels are treated as being orthotropic and the wave numbers are calculated for the two principle directions. The orthotropic panel theory is used to predict the sound transmission loss of panels. Visco-elastic damping with a constraining layer is applied to these structures and the effect of these damping treatment on the sound transmission loss is studied. Measurements are performed to validate these predictions.</p><p>Sound radiated from vibrating structures is of great practical importance.The radiation loss factor represents damping associated with the radiation of sound as a result of the vibrating structure and can be a significant contribution for structures around the critical frequency and for composite structures that are very lightly damped. The influence of the radiation loss factor on the sound reduction index of such structures is also studied.</p> / QC 20100519 / ECO2-Multifunctional body Panels

In this thesis, design and analyses of honeycomb structures are investigated. Primary goal is to develop an equivalent orthotropic material model that is a good substitute for the actual honeycomb core. By replacing the actual honeycomb structure with the orthotropic model, during the finite element analyses, substantial advantages can be obtained with regard to ease of modeling and model modification, solution time and hardware resources . To figure out the best equivalent model among the approximate analytical models that can be found in the literature, a comparison is made. First sandwich beams with four different honeycomb cores are modeled in detail and these are accepted as reference models. Then a set of equivalent models with the same dimensions is generated. The material properties of the equivalent models are taken from different studies performed in the literature. Both models are analyzed under the same loading and the boundary conditions. In finite element analyses, ANSYS finite element program is used. The results are compared to find out the best performing equivalent model. After three major analyses loops, decision on the equivalent model is made. The differences between the total reaction forces calculated by the equivalent model and the actual honeycomb model are all found to be within 10%. The equivalent model gives stress results at the macro-scale, and the local stresses and the strains can not be determined. Therefore it is deemed that for stress analysis, equivalent model can be used during the preliminary design phase. However, the equivalent model can be used reliably for deflection analysis, modal analysis, stiffness determination and aero-elastic analysis.