Thesis (PhD) - Swinburne University of Technology, Faculty of Engineering and Industrial Sciences, 2008. / A thesis submitted for the degree of Doctor of Philosophy, Faculty of Engineering and Industrial Sciences, Swinburne University of Technology, 2008. Typescript. Includes bibliographical references (p. 152-158).

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.

This study addresses the flexural performance of sandwich panels composed of a polyurethane foam core and glass fibre-reinforced polymer (GFRP) skins. Panels with and without GFRP ribs connecting the skins have been studied. While the motivation of the study was to develop new insulated cladding panels for buildings, most of the work and findings are also applicable to other potential applications such as flooring, roofing and light-weight decking. The study comprises experimental, numerical, and analytical investigations. The experimental program included three phases. Phase I is a comprehensive material testing program of the polyurethane core and GFRP skins and ribs. In Phase II, six medium size (2500x660x78 mm) panels with different rib configurations were tested in one-way bending. It was shown that flexural strength and stiffness have increased by 50 to 150%, depending on the rib configuration, compared to a panel without ribs. In Phase III, two large-scale (9150x2440x78 mm) panels, representing a cladding system envisioned to be used in the field, were tested under a realistic air pressure and discrete loads, respectively. The deflection under service wind load did not exceed span/360, while the ultimate pressure was about 2.6 times the maximum factored wind pressure in Canada. A numerical study using finite element analysis (FEA) was carried out. The FEA model accounted for the significant material nonlinearities, especially for the polyurethane soft core, and the geometric nonlinearity, which is mainly a reduction in thickness due to core softness. Another independent analytical model was developed based on equilibrium and strain compatibility, accounting for the core excessive shear deformation. The model also captures the localized deformations of the loaded skin, using the principals of beam-on-elastic foundation. Both models were successfully validated using experimental results. Possible failure modes, namely core shear failure, and compression skin crushing or wrinkling were successfully predicted. A parametric study was carried out to explore further the core density, skin thickness, and rib spacing effects. As the core density increased, flexural strength and stiffness increased and shear deformations reduced. Also, increasing skin thickness became more effective as the core density increased. The optimal density was 95-130 kg/m3. Reducing the spacing of ribs enhanced the strength up to a certain level; It then stabilized at a spacing of 2.9 times the panel thickness. / Thesis (Ph.D, Civil Engineering) -- Queen's University, 2010-09-21 16:29:00.315

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.

<p>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.</p>

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.