1 HEXOEL OOMPOSTES

The honeycomb sandw|ch construct|on |s one o the most

va|ued structura| eng|neer|ng |nnovat|ons deve|oped by the
compos|tes |ndustry.
sed extens|ve|y |n aerospace and many other |ndustr|es,
the honeycomb sandw|ch prov|des the o||ow|ng key bene|ts
over convent|ona| mater|a|s:
- very |ow we|ght
- H|gh st|ness
- Durab|||ty
- Product|on cost sav|ngs
Hexce| began deve|op|ng honeycomb over 40 years ago,
and now supp||es a range o h|gh perormance honeycombs,
prepregs and Pedux

||m adhes|ves - a|| |dea||y su|ted to the

manuacture o honeycomb sandw|ch construct|ons. Hexce| |s
a|so the |ead|ng supp||er o ||ghtwe|ght honeycomb sandw|ch
pane|s.
Th|s gu|de exp|a|ns how to des|gn and manuacture
honeycomb sandw|ch pane|s, rom mater|a|s se|ect|on and
ana|ys|s o mechan|ca| propert|es, through to product|on
methods, and |nc|udes bas|c samp|e ca|cu|at|ons or s|mp|e
construct|ons.
More comp|ex ca|cu|at|ons may requ|re computer mode|||ng
wh|ch, a|though ment|oned br|e|y, |s beyond the scope o th|s
pub||cat|on.
December 2000
Pub||cat|on No. AG 075b
Hexce| Peg|stered Trademark
Hexce| Oompos|tes, Duxord
HexWeb
TM
HONEYOOMB SANDWOH DESGN TEOHNOLOGY
HEXOEL OOMPOSTES 2
HexWeb
TM
HONEYOOMB SANDWOH DESGN TEOHNOLOGY
Contents
Page
Oontents 2
Bene|ts o Honeycomb Bandw|ch Oonstruct|ons 3
Mater|a|s Be|ect|on 4 - 5
Des|gn:
How a beam works 6
Fa||ure modes 7 - 8
Des|gn Gu|de||nes 9
Nomenc|ature 10
Bummary o Beam Ooe|c|ents 11
Bamp|e Prob|ems 12
B|mp|y Bupported Beam 12 - 13
B|mp|y Bupported P|ate 14 - 17
End Load|ng Oond|t|ons 18 - 19
Oomputer Mode|||ng 20
Product|on Methods 21 - 22
Edge O|osure Des|gn 23
Hea|th & Baety 24
Append|x l
Mechan|ca| Propert|es o Honeycomb Mater|a|s 25
Append|x ll
Propert|es o Typ|ca| Fac|ng Mater|a|s 26
Append|x lll
Bummary o Formu|ae 27
Further Pead|ng 28
3 HEXOEL OOMPOSTES
F|gure 2 shows the re|at|ve st|ness and we|ght o sandw|ch pane|s compared to so||d pane|s.
BENEFTS OF HONEYOOMB SANDWOH OONSTRUOTONS
The ac|ng sk|ns o a sandw|ch pane| can be compared to the
|anges o an 1-beam, as they carry the bend|ng stresses to
wh|ch the beam |s sub|ected. W|th one ac|ng sk|n |n
compress|on, the other |s |n tens|on. B|m||ar|y the honeycomb
core corresponds to the web o the 1-beam. The core res|sts
the shear |oads, |ncreases the st|ness o the structure by
ho|d|ng the ac|ng sk|ns apart, and |mprov|ng on the 1-beam, |t
g|ves cont|nuous support to the |anges or ac|ng sk|ns to
produce a un|orm|y st|ened pane|. The core-to-sk|n adhes|ve
r|g|d|y |o|ns the sandw|ch components and a||ows them to act
as one un|t w|th a h|gh tors|ona| and bend|ng r|g|d|ty.
F|gure 1 shows the construct|on o a sandw|ch pane| compared to an 1 beam.
Bt|ness 1.0 7.0 37.0
F|exura|
Btrength 1.0 3.5 9.2
We|ght 1.0 1.03 1.06
1-beam Bandw|ch pane|
Adhes|ve
Honeycomb core
Fac|ng sk|n
F|anges
Web
HEXOEL OOMPOSTES 4
HexWeb
TM
HONEYOOMB SANDWOH DESGN TEOHNOLOGY
MATERALS SELEOTON
Honeycomb Sandwich MateriaIs
The honeycomb sandw|ch construct|on can compr|se an
un||m|ted var|ety o mater|a|s and pane| con|gurat|ons. The
compos|te structure prov|des great versat|||ty as a w|de range
o core and ac|ng mater|a| comb|nat|ons can be se|ected. The
o||ow|ng cr|ter|a shou|d be cons|dered |n the rout|ne se|ect|on
o core, ac|ng, and adhes|ve.
StructuraI Considerations
$trength:
Honeycomb cores and some ac|ng mater|a|s are d|rect|ona|
w|th regard to mechan|ca| propert|es and care must be taken
to ensure that the mater|a|s are or|entated |n the pane| to take
the best advantage o th|s attr|bute.
$t///ness:
Bandw|ch structures are requent|y used to max|m|se st|ness
at very |ow we|ghts. Because o the re|at|ve|y |ow shear
modu|us o most core mater|a|s, however, the de|ect|on
ca|cu|at|ons must a||ow or shear de|ect|on o the structure |n
add|t|on to the bend|ng de|ect|ons usua||y cons|dered.
Adhes/ve Per/ormance:
The adhes|ve must r|g|d|y attach the ac|ngs to the core
mater|a| |n order or |oads to be transm|tted rom one ac|ng to
the other. Bu|tab|e adhes|ves |nc|ude h|gh modu|us, h|gh
strength mater|a|s ava||ab|e as ||qu|ds, pastes or dry ||ms. As a
genera| ru|e, a |ow pee|-strength, or re|at|ve|y br|tt|e adhes|ve
shou|d never be used w|th very ||ght sandw|ch structures wh|ch
may be sub|ected to abuse or damage |n storage, hand||ng or
serv|ce.
Econom/c Cons/derat/ons:
Oompos|te sandw|ch pane|s can prov|de a cost eect|ve
so|ut|on. va|ue ana|ys|s shou|d |nc|ude assessment o
product|on and assemb|y costs, and |nsta||at|on costs |nc|ud|ng
support|ng structure.
EnvironmentaI Considerations
7emperature:
As |n any mater|a|s system the therma| env|ronment w||| p|ay an
|mportant ro|e |n the se|ect|on o mater|a|s.
A|| systems are bas|ca||y operat|ona| at Poom Temperature and
mater|a|s are read||y ava||ab|e to g|ve perormance up rom
-55O to 170O.
Mater|a| se|ect|on shou|d a|so take account o ava||ab|e
manuactur|ng ac|||t|es, espec|a||y cure temperature capab|||ty.
F/ammab///ty:
Mater|a|s used |n bonded sandw|ch construct|on are usua||y
c|ass||ed |nto three categor|es:
1) Non-burn|ng - wh|ch means that the product w||| not burn.
2) Be|-ext|ngu|sh|ng - wh|ch means that the mater|a| w||| burn
wh||e he|d |n a |ame but w||| ext|ngu|sh when the |ame |s
removed.
3) F|ammab|e. F|ammab|e mater|a|s are somet|mes urther
de|ned by determ|n|ng the |ame spread rate under
spec||ed cond|t|ons.
Heat 7rans/er:
The transer o heat through a sandw|ch pane| |s dependent
upon the bas|c pr|nc|p|es o convect|on, conduct|on and
rad|at|on. Meta|||c cores w|th meta|||c ac|ngs max|m|se heat
|ow character|st|cs.
Mo/sture/Hum/d/ty:
Bome core and ac|ng mater|a|s oer exce||ent res|stance to
degradat|on due to mo|sture and hum|d|ty.
Adhes/ve $o/vents and Outgass/ng:
Bome adhes|ves g|ve o gases or so|vent vapours dur|ng cure
wh|ch can |nteract w|th res|n systems |n some non-meta|||c
cores, or w|th the node adhes|ve |n some meta|||c
honeycombs. The ent|re bond|ng process must be checked to
ensure that no reduct|on |n mechan|ca| propert|es has
occurred due to |ncompat|b|||ty o the mater|a|s or process
actua||y used. A|| o Hexce|s Pedux

||m adhes|ves are

compat|b|e w|th th|s type o construct|on.
Honeycomb MateriaIs
HexWeb honeycomb |s ava||ab|e |n a w|de range o mater|a|s
|nc|ud|ng:-
A|um|n|um, Nomex (Aram|d), Korex, Kev|ar, F|breg|ass, Oarbon.
For deta||s p|ease consu|t The HexWeb Honeycomb Be|ector
Gu|de and the HexWeb Honeycomb Attr|butes and Propert|es
Manua|.
Be|ected mechan|ca| propert|es or A|um|n|um and Nomex
honeycombs are shown |n Append|x l.
MechanicaI Performance
Honeycomb strength and st|ness (compress|on and shear) |s
proport|ona| to dens|ty. Pe|at|ve perormance o the mater|a|
types |s shown |n compar|son to PvO oam.
Key: A|um|n|um - 3003/AOG, 5052, 5056
Nomex - HPH10, HPH78,
F|breg|ass - HPP
strength stiffness
HRH10 & HRH78
5052, 5056 & HRP
PVC
foam
HRP
5052 & 5056
3003/ACG
PVC
foam
HRH10 &
HRH78
density density
3003/ACG
5 HEXOEL OOMPOSTES
CeII Size
A |arge ce|| s|ze |s the |ower cost opt|on, but |n comb|nat|on
w|th th|n sk|ns may resu|t |n te|egraph|ng, |.e. a 'd|mp|ed' outer
surace o the sandw|ch. A sma|| ce|| s|ze w||| g|ve an |mproved
surace appearance, and prov|des a greater bond|ng area, but
at h|gher cost.
CeII Shape
Norma||y supp||ed w|th hexagona| ce|| shapes, a ew
honeycomb types can be supp||ed w|th rectangu|ar ce|| shapes
(W:L approx|mate|y 2:1), and des|gnated OX.
Skin MateriaIs
The tab|e |n Append|x ll shows propert|es o typ|ca| ac|ng
mater|a|s or sandw|ch pane| construct|on.
Bk|n cons|derat|ons |nc|ude the we|ght targets, poss|b|e
abuses and |oca| (dent|ng) |oads, corros|on or decorat|ve
constra|nts, and costs.
Fac|ng mater|a| th|ckness d|rect|y aects both the sk|n stress
and pane| de|ect|on.
Hexce| Oompos|tes oers a w|de range o prepreg mater|a|s.
Peer to the Prepreg Matr|x Be|ector Gu|de to |dent|y systems
most ||ke|y to su|t your app||cat|on, where |bre re|norced
compos|tes are thought appropr|ate.
Adhesive MateriaIs
For honeycomb sandw|ch bond|ng, the o||ow|ng cr|ter|a are
|mportant:
1. FiIIet Forming
To ach|eve a good attachment to an open ce|| core such as
honeycomb, the adhes|ve shou|d |ow su|c|ent|y to orm a |||et
w|thout runn|ng away rom the sk|n to core |o|nt.
2. Bond Line ControI
Every endeavour shou|d be made to ensure |nt|mate contact
between the parts dur|ng bond|ng, as the adhes|ve needs to |||
any gaps between the bond|ng suraces.
Adhes|ves are oten supp||ed supported by a carr|er c|oth, or
the purpose o he|p|ng them to rema|n |n p|ace where the parts
are squeezed part|cu|ar|y t|ght|y together.
Hexce| Oompos|tes oers a w|de range o ||m adhes|ves.
Peer to the PEDX

F||m Adhes|ve Be|ector Gu|de to |dent|y

the most su|tab|e mater|a| or your app||cat|on.
Hexagona| ce||s g|ve m|n|mum dens|ty or a g|ven amount o
mater|a|.
Pectangu|ar ce||s g|ve eas|er orm|ng |n the W d|rect|on (w|th
|ess ant|c|ast|c curvature than |s exh|b|ted by hexagona| ce||
honeycomb).
OX ce|| size
~ nom|na| hexagona| ce||
s|ze beore expans|on to
rectangu|ar shape.
hexagona| ce|| size
~ measured across |ats
HEXOEL OOMPOSTES 6
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HONEYOOMB SANDWOH DESGN TEOHNOLOGY
SANDWOH DESGN
How a Sandwich Beam Works
Loads
Oons|der a cant||ever beam w|th a |oad app||ed at the ree end.
The app||ed |oad creates a bend|ng moment wh|ch |s a
max|mum at the |xed end, and a shear orce a|ong the |ength
o the beam.
ln a sandw|ch pane| these orces create tens|on |n the upper
sk|n and compress|on |n the |ower sk|n. The core spaces the
ac|ng sk|ns and transers shear between them to make the
compos|te pane| work as a homogeneous structure.
DefIections
The de|ect|on o a sandw|ch pane| |s made up rom bend|ng
and shear components.
The bend|ng de|ect|on |s dependant on the re|at|ve tens||e and
compress|ve modu|| o the sk|n mater|a|s.
The shear de|ect|on |s dependant on the shear modu|us o the
core.
Tota| Def|ection = Bending Def|ection + Shear Def|ection.
nder d|erent sets o app||ed |oads and support|ng
cond|t|ons, the mater|a| stresses and de|ect|ons can be
ca|cu|ated as shown on page 9 onwards.
7 HEXOEL OOMPOSTES
FaiIure modes
Des|gners o sandw|ch pane|s must ensure that a|| potent|a|
a||ure modes are cons|dered |n the|r ana|ys|s. A summary o
the key a||ure modes |s shown be|ow:
1. Strength
The sk|n and core mater|a|s shou|d be ab|e to w|thstand the
tens||e, compress|ve and shear stresses |nduced by the des|gn
|oad.
The sk|n to core adhes|ve must be capab|e o transerr|ng the
shear stresses between sk|n and core.
2. Stiffness
The sandw|ch pane| shou|d have su|c|ent bend|ng and shear
st|ness to prevent excess|ve de|ect|on.
3. PaneI buckIing
The core th|ckness and shear modu|us must be adequate to
prevent the pane| rom buck||ng under end compress|on |oads.
Excess|ve de|ect|on
Bk|n compress|on a||ure
HEXOEL OOMPOSTES 8
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HONEYOOMB SANDWOH DESGN TEOHNOLOGY
4. Shear crimping
The core th|ckness and shear modu|us must be adequate to
prevent the core rom premature|y a|||ng |n shear under end
compress|on |oads.
5. Skin wrinkIing
The compress|ve modu|us o the ac|ng sk|n and the core
compress|on strength must both be h|gh enough to prevent a
sk|n wr|nk||ng a||ure.
6. Intra ceII buckIing
For a g|ven sk|n mater|a|, the core ce|| s|ze must be sma||
enough to prevent |ntra ce|| buck||ng.
7. LocaI compression
The core compress|ve strength must be adequate to res|st
|oca| |oads on the pane| surace.
9 HEXOEL OOMPOSTES
DESGN GUDELNES FOR A HONEYOOMB SANDWOH PANEL
1. Define Ioading conditions
e.g. Po|nt |oad|ng, un|orm d|str|buted |oad, end |oads.
Oare shou|d be taken to cons|der a|| poss|b|e |oad|ng
cond|t|ons. For examp|e, see tab|e page 11, or reer to an
appropr|ate lndustry Btandard or gu|dance.
2. Define paneI type
e.g. Oant||ever, s|mp|y supported.
Th|s |s determ|ned by the type and extent o the pane|
supports. Fu||y bu||t |n support cond|t|ons shou|d on|y be
cons|dered when the support|ng structure has adequate
st|ness to res|st de|ect|on under the app||ed |oads.
3. Define physicaI/space constraints
Th|s shou|d |nc|ude an assessment o the requ|rements
|nc|ud|ng:
- de|ect|on ||m|t
- th|ckness ||m|t
- we|ght ||m|t
- actor o saety
Pre||m|nary mater|a|s se|ect|on shou|d be based on the above
cr|ter|a |n con|unct|on w|th the eatures cons|dered on pages
4 - 5 (and append|ces l and ll).
4. PreIiminary caIcuIations
- Make an assumpt|on about sk|n mater|a|, sk|n th|ckness and
pane| th|ckness. lgnore the core mater|a| at th|s stage.
- Oa|cu|ate st|ness.
- Oa|cu|ate de|ect|on (|gnor|ng shear de|ect|on).
- Oa|cu|ate ac|ng sk|n stress.
- Oa|cu|ate core shear stress.
5. Optimise design
- Mod|y sk|n th|ckness, sk|n mater|a| and pane| th|ckness to
ach|eve acceptab|e perormance.
- Be|ect su|tab|e core to w|thstand shear stress.
6. DetaiIed caIcuIations
- Oa|cu|ate stiffness.
- Oa|cu|ate defIection, |nc|ud|ng shear de|ect|on.
- Oa|cu|ate facing skin stress. .. ..
- Oa|cu|ate core shear stress.
- Oheck or paneI buckIing - where app||cab|e
- Oheck or shear crimping.
- Oheck or skin wrinkIing.
- Oheck or intraceII buckIing.
- Oheck or IocaI compression |oads on core.
NB.
The ormu|ae used or the samp|e prob|ems that o||ow on
pages 12 to 19, use s|mp|||ed terms and g|ve an order o
magn|tude apprec|at|on.
Bee a|so Bummary o Formu|ae |n Append|x lll.
HEXOEL OOMPOSTES 10
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HONEYOOMB SANDWOH DESGN TEOHNOLOGY
a ~ Pane| |ength
A ~ Area o app||ed |oad
b ~ Beam w|dth
D ~ Pane| bend|ng st|ness
E
O
~ Oompress|on modu|us o core
E

~ Modu|us o e|ast|c|ty o ac|ng sk|n

F ~ Max|mum shear orce
G
O
~ Oore shear modu|us - |n d|rect|on o app||ed |oad
G
L
~ Oore shear modu|us - P|bbon d|rect|on
G
W
~ Oore shear modu|us - Transverse d|rect|on
h ~ D|stance between ac|ng sk|n centres
k
b
~ Beam - bend|ng de|ect|on coe|c|ent
k
B
~ Beam - shear de|ect|on coe|c|ent
K
1
~ Pane| parameter (used or s|mp|y supported p|ate)
K
2
~ Pane| parameter (used or s|mp|y supported p|ate)
K
3
~ Pane| parameter (used or s|mp|y supported p|ate)
l ~ Beam span
M ~ Max|mum bend|ng moment
P ~ App||ed |oad
P
b
~ Or|t|ca| buck||ng |oad
q ~ n|orm|y d|str|buted |oad
P ~ Pat|o G
L
/G
W
s ~ Oe|| s|ze
B ~ Pane| shear st|ness
t
O
~ Th|ckness o core
t

~ Th|ckness o ac|ng sk|n

v ~ Pane| parameter (used or s|mp|y supported p|ate)
@ ~ Oa|cu|ated de|ect|on
I
O
~ Oore compress|ve stress
I
OP
~ Or|t|ca| ac|ng sk|n stress
I

~ Oa|cu|ated ac|ng sk|n stress

J
O
~ Bhear stress |n core
~ Po|ssons Pat|o o ace mater|a|
~ Bend|ng correct|on actor or Po|ssons Pat|o eect
NOMENOLATURE
11 HEXOEL OOMPOSTES
MAXlMM MAXlMM BENDlNG BHEAP
BEAM TYPE BHEAP BENDlNG DEFLEOTlON DEFLEOTlON
FOPOE MOMENT OOEFFlOlENT OOEFFlOlENT
F M k
b
k
S
P Pl 5 1
2 8 384 8
P Pl 1 1
2 12 384 8
P Pl 1 1
2 4 48 4
P Pl 1 1
2 8 192 4
P Pl 1 1
2 8 2
P Pl 1 1
3
P Pl 1 1
3 15 3
Summary of beam coefficients
B|mp|e Bupport
P ~ q l b
n|orm Load D|str|but|on
Both Ends F|xed P ~ q l b
n|orm Load D|str|but|on
B|mp|e Bupport
P
Oentra| Load
Both Ends F|xed
P
Oentra| Load
One End F|xed
(Oant||ever)
P ~ q l b
n|orm Load D|str|but|on
One End F|xed
(Oant||ever)
P
Load One End
P ~ q l b
2
Tr|angu|ar Load D|str|but|on
One End F|xed
(Oant||ever)
HEXOEL OOMPOSTES 12
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HONEYOOMB SANDWOH DESGN TEOHNOLOGY
Beam
SAMPLE PROBLEMS BASED ON A STANDARD HEXLTE 220 PANEL
SimpIy Supported Beam
- taking a beam as being defined as having width (b) |ess
than
1
/3 of span (l)
Bending Stiffness
D ~ E

h
2
b
2
Where h ~ t

t
O
Shear Stiffness
B ~ b h G
O
D ~ (70 x 10
9
) (0.5 x 10
-3
) (25.9 x 10
-3
)
2
(0.5)
2
D ~ 5869.6 Nm
2
Configuration and Data:
Facing Skins A|um|n|um 5251 H24
Th|ckness t
1
and t
2
~ 0.50mm
and rom Append|x ll
Y|e|d Btrength ~ 150 MPa
E

Modu|us ~ 70 GPa
Po|ss|ns Pat|o ~ 0.33
Core 5.2 - 1/4 - 3003
Th|ckness t
O
~ 25.4 mm
and rom Append|x l
E
O
Modu|us ~ 1000 MPa
Long|tud|na| shear ~ 2.4 MPa
G
L
Modu|us ~ 440 MPa
Transverse shear ~ 1.5 MPa
G
W
Modu|us ~ 220 MPa
Btab|||zed Oompress|on ~ 4.6 MPa
As the core shear here w||| be taken by the weaker transverse
d|rect|on - take G
O
~ G
W
shear modu|us
B ~ (0.5) (25.9 x 10
-3
) (220 x 10
6
)
B ~ 2849 x 10
3
N
Oons|der|ng a centre po|nt |oaded beam
w|th b ~ 0.5m and l ~ 2m and P ~ 1500N
13 HEXOEL OOMPOSTES
Def|ection
Bend|ng p|us Bhear
@ @@ @@ ~ k
b
Pl
3
k
B
Pl
D B
Where k
b
and k
B
are de|ect|on coe|c|ents rom page 11.
l do|ng pre||m|nary ca|cu|at|ons, |ust work out the bend|ng
de|ect|on.
l opt|m|s|ng des|gn, ca|cu|ate or both bend|ng and shear
components (as shown oppos|te).
Facing Stress
I II II

~ ~~ ~~ M
h t

b
Where M |s Max|mum Bend|ng Moment express|on rom page 11
and h ~ t

t
O
Core Stress
J JJ JJ
O OO OO
~ ~~ ~~ F
hb
Where F |s Max|mum Bhear Force express|on rom page 11
Beam continued
Bend|ng p|us Bhear
@ @@ @@ ~ 1 x 1500 x 2
3
1 x 1500 x 2
48 5869.6 4 2849 x 10
3
@ @@ @@ ~ 0.04259m 0.000263m
Tota| ~ approx 43mm
l excess|ve, then the most e|c|ent way to reduce de|ect|on |s
to |ncrease core th|ckness, and thus |ncrease the sk|n
separat|on and the va|ue o h.
M ~ Pl ~ 1500 x 2 ~ 750 Nm
4 4
I II II

~ 750
(25.9 x 10
-3
) (0.5 x 10
-3
) (0.5)
I II II

~ ~~ ~~ 115.8 MPa
Bo ca|cu|ated stress |s |ess than ace mater|a| typ|ca| y|e|d
strength o 150 MPa, thus g|v|ng a actor o saety.
F ~ P ~ 1500 ~ 750N
2 2
J JJ JJ ~ 750
(25.9 x 10
-3
) (0.5)
J JJ JJ ~ 0.06 MPa
Bo ca|cu|ated shear |s cons|derab|y |ess than core mater|a|
typ|ca| p|ate shear |n the transverse (W) d|rect|on o 1.5 MPa,
g|v|ng a actor o saety, wh|ch cou|d a||ow core dens|ty to be
reduced.
HEXOEL OOMPOSTES 14
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HONEYOOMB SANDWOH DESGN TEOHNOLOGY
SimpIy Supported PIate
- taking a p|ate as being defined as having width (b) greater
than
1
/3 of |ength (a)
Because p|ate theory |s more |nvo|ved than beam theory, some
charts have been prov|ded to g|ve mu|t|p||ers/coe|c|ents or
use w|th p|ates s|mp|y supported on a|| our s|des.
A urther term ( ) |s a|so |ntroduced, to take account o the
Po|ssons Pat|o o the ace sk|n mater|a|s. For the p|ate set up
shown, |s taken as 1- 0 00 00
2
.
NB. For the ear||er beams, and the end |oad cond|t|on|ng to
o||ow, |s assumed to be 1, as any aect rom Po|ssons
Pat|on |s sma|| due to the re|at|ve narrowness o beams.
Determine P|ate Coefficient
b
a
P ~ G
L
G
W
v ~ F FF FF E t

h
2b
2
G
W

From F|g.1 (page 16) K
1
~ 0.0107
From F|g.2 (page 17) K
2
~ 0.102
and or shorter span |ength b
From F|g.3 (page 17) K
3
~ 0.36
Def|ection
@ @@ @@ ~ 2K
1
q b
4

E

h
2
PIate
1000 ~ 0.5
2000
440 ~ 2
220
se P ~ 2.5 |n F|gs. on pages 16 & 17
v ~ F FF FF (70 x 10
9
) (0.5 x 10
-3
) (25.9 x 10
-3
) ~ 0.023
(2) (1
2
) (220 x 10
6
) (1 - 0.33
2
)
Take v ~ 0 |n F|gs. on pages 16 & 17
@ @@ @@ ~ (2) (0.0107) (3 x 10
3
) (1
4
) (1 - 0.33
2
)
(70 x 10
9
) (0.5 x 10
-3
) (25.9 x 10
-3
)
2
@ @@ @@ ~ 0.0024m ~ 2.4mm
15 HEXOEL OOMPOSTES
Facing Stress
I II II

~ K
2
q b
2
ht
Core Shear
J JJ JJ
O
~ K
3
q b
h
Loca| Compression
I II II
O
~ P ~ q x A
A A
I II II

~ (0.102) (3 x 10
3
) (1
2
)
(25.9 x 10
-3
) (0.5 x 10
-3
)
I II II

~ 23.6 MPa
Bo ca|cu|ated stress |s cons|derab|y |ess than sk|n mater|a|
typ|ca| y|e|d strength o 150 MPa, thus g|v|ng a actor o saety.
J JJ JJ
O
~ (0.36) (3 x 10
3
) (1)
(25.9 x 10
-3
)
J JJ JJ
O
~ 0.042 MPa
Bo ca|cu|ated core shear |s cons|derab|y |ess than typ|ca| core
mater|a| shear va|ue o 1.5 MPa, thus g|v|ng a actor o saety.
I II II
O
~ (3 x 10
3
) (2 x 1)
(2 x 1)
I II II
O
~ 0.003 MPa
Bo |oca| compress|on wou|d not be an |ssue, be|ng very sma|| |n
compar|son to typ|ca| core compress|on strength o 4.6 MPa.
PIate continued
HEXOEL OOMPOSTES 16
HexWeb
TM
HONEYOOMB SANDWOH DESGN TEOHNOLOGY
Figure 1 - K
1
for determining maximum def|ection @
Charts providing coefficients for pIates simpIy supported on aII four sides
17 HEXOEL OOMPOSTES
Figure 3 - K
3
for determining maximum core shear stress t
C
Figure 2 - K
2
for determining facing stress I
HEXOEL OOMPOSTES 18
HexWeb
TM
HONEYOOMB SANDWOH DESGN TEOHNOLOGY
END LOAD OONDTONS
Oons|der|ng a un|orm|y d|str|buted end |oad o
q ~ 20kN/m |ength and w|th b ~ 0.5m and l ~ 2m.
Facing Stress
I II II

~ P
2 t

b
assum|ng end |oad |s taken by both sk|ns, and app||ed |oad
P ~ q x b
Pane| Buck|ing
P
b
~ F FF FF D
l
2
F FF FF D
G
O
h b
Tak|ng D rom the beam ca|cu|at|on examp|e.
I II II

~ (20 x 10
3
) (0.5)
(2) (0.5 x 10
-3
) (0.5)
I II II

~ 20 MPa
Th|s |s sae, as |t |s cons|derab|y |ess than sk|n mater|a| typ|ca|
y|e|d strength o 150 MPa.
Oons|der|ng the core shear to be |n the weaker transverse
d|rect|on
Bo G
O
~ G
W
shear modu|us
Then
P
b
~ F FF FF (5869.6)
(2)
2
F FF FF (5869.6)
(220 x 10
6
) (25.9 x 10
-3
) (0.5)
P
b
~ 14,413 N
Bo ca|cu|ated |oad at wh|ch cr|t|ca| buck||ng wou|d occur |s
greater than the end |oad be|ng app||ed (P) o 10,000 N, thus
g|v|ng a actor o saety.
End Loading
q ~ 20kN/m |ength
19 HEXOEL OOMPOSTES
Shear Crimping
P
b
~ t
O
G
O
b
Skin Wrink|ing
I II II
OP
~ 0.5 [G
O
E
O
E

]
1/3
ntrace|| Buck|ing
I II II
OP
~ 2 E

2
s
NB: s ~ ce|| s|ze
Tak|ng G
O
as G
W
P
b
~ (25.4 x 10
-3
) (220 x 10
6
) (0.5)
P
b
~ 2.79 MN
Bo the ca|cu|ated |oad at wh|ch shear cr|mp|ng wou|d occur, |s
cons|derab|y greater than the end |oad be|ng app||ed (P) o
10,000 N, thus g|v|ng a actor o saety.
Tak|ng G
O
as G
W
I II II
OP
~ 0.5 [(220 x 10
6
) (1000 x 10
6
) (70 x 10
9
)]
1/3
I II II
OP
~ 1244 MPa
Bo the stress |eve| at wh|ch sk|n wr|nk||ng wou|d occur, |s we||
beyond the sk|n mater|a| typ|ca| y|e|d strength o 150 MPa, so
sk|n stress |s more cr|t|ca| than sk|n wr|nk||ng.
I II II
OP
~ 2 (70 x 10
9
) (0.5 x 10
-3
)
2
(6.4 x 10
-3
)
I II II
OP
~ 854 MPa
Bo stress |eve| at wh|ch |ntrace|| buck||ng wou|d occur |s we||
beyond the sk|n mater|a| typ|ca| y|e|d strength o 150 MPa, so
sk|n stress |s more cr|t|ca| than |ntrace|| buck||ng.
End Loading continued
HEXOEL OOMPOSTES 20
HexWeb
TM
HONEYOOMB SANDWOH DESGN TEOHNOLOGY
OOMPUTER MODELLNG OF HONEYOOMB SANDWOH PANELS
Beore ana|ys|ng a |arge structure the mode|||ng techn|que
shou|d be checked by mode|||ng a s|mp|e pane| w|th known
resu|ts.
The above s|mp||st|c approach has proven to g|ve reasonab|e
eng|neer|ng so|ut|ons or pract|ca| app||cat|ons.
The actua| orce/stress d|str|but|on w|th|n a honeycomb
sandw|ch structure |s a comp|ex sub|ect, and |s beyond the
scope o th|s pub||cat|on.
For a more soph|st|cated ana|ys|s o a structure, cons|der|ng
the sandw|ch pane| to be sub|ected to a comb|nat|on o orces,
a techn|que such as F|n|te E|ement Ana|ys|s (FEA) m|ght be
used.
ln genera| terms, the shear orces norma| to the pane| w||| be
carr|ed by the honeycomb core. Bend|ng moments and |n-
p|ane orces on the pane| w||| be carr|ed as membrane orces
|n the ac|ng sk|ns.
For many pract|ca| cases, where the span o the pane| |s |arge
compared to |ts th|ckness, the shear de|ect|on w||| be
neg||g|b|e. ln these cases, |t may be poss|b|e to obta|n
reasonab|e resu|ts by mode|||ng the structure us|ng compos|te
she|| e|ements. lt shou|d be noted that the |n-p|ane st|ness o
the honeycomb |s neg||g|b|e compared to that o the ac|ng
sk|ns.
Where a more deta||ed mode| |s requ|red |t |s poss|b|e to
mode| the honeycomb core us|ng so||d 3D e|ements. Attempts
to mode| the |nd|v|dua| ce||s o the honeycomb shou|d be
avo|ded or norma| eng|neer|ng ana|yses.
When de|n|ng the propert|es o honeycomb core the o||ow|ng
po|nts shou|d be taken |nto cons|derat|on:-
E
X
E
Y
0
A very sma|| va|ue may be necessary to avo|d s|ngu|ar|ty.

xy

xz

yz
0
G
xy
0
G
xz
~ G
L
~ shear modu|us |n r|bbon d|rect|on
G
yz
~ G
W
~ shear modu|us |n transverse d|rect|on
E
Z
~ E
O
~ compress|ve modu|us o core mater|a|
21 HEXOEL OOMPOSTES
MANUFAOTURE
Basic Honeycomb Sandwich Production Methods
Honeycomb sandw|ch components may be produced us|ng
three a|ternat|ve we||-estab||shed methods:-
Heated Press, genera||y used or the product|on o |at
board or s|mp|e preormed pane|s.
Vacuum Bag Processing, used or curved and comp|ex
orm pane|s.
Matched Mou|d Processing, used genera||y or batch
product|on o |n|shed pane|s.
Heated Press
ldea||y the pane|s shou|d be assemb|ed ready or cur|ng as a
s|ng|e shot process. Th|s method |s su|tab|e or meta|||c and
prepreg (pre-|mpregnated) ac|ng sk|ns. A|ternat|ve|y prepreg
ac|ng sk|n mater|a|s may be pre-cured by us|ng a press, and
subsequent|y bond|ng w|th a ||m adhes|ve |ayer.
Hexce|s Pedux

range o ||m adhes|ves |s we|| su|ted or these

product|on methods.
lntegra||y bonded |tems such as extruded bar sect|ons and
|nserts may be |nc|uded and |ocated by the honeycomb core
or w|th s|mp|e too||ng.
Honeycomb
Oore Mater|a|
Pedux F||m
Adhes|ve
Fac|ng
Bk|n
Mater|a|
NB. Bome urther |normat|on re|ated to product|on methods,
may be ound |n Hexce| Oompos|tes pub||cat|ons: Pedux
Bond|ng Techno|ogy Pe: PG 034b and Prepreg
Techno|ogy Pe: FG 017 ava||ab|e on request or v|a
www.hexce|compos|tes.com
Oau| or
Layup P|ates
Honeycomb
core
Adhes|ve
Fac|ng
HEXOEL OOMPOSTES 22
HexWeb
TM
HONEYOOMB SANDWOH DESGN TEOHNOLOGY
Match MouId Processing
Th|s method |s most su|ted to the s|ng|e shot cure process
where a key ob|ect|ve |s to ach|eve product|on |tems w|th h|gh
|eve|s o to|erance and surace |n|sh. The heat and pressure
cure cyc|e |n th|s case |s app||ed us|ng a var|ety o methods.
Typ|ca| methods are the use o heated too|s w|th externa|
mechan|ca| pressure or non heated too|s p|aced |n a press or
oven to ach|eve the u|| cyc|e.
s|ng a room temperature cur|ng adhes|ve co|d bond|ng may
be cons|dered | the sandw|ch construct|on |s too |arge to be
processed us|ng the above methods, or | heat|ng equ|pment |s
unav||ab|e.
Adv|ce on spec|a| methods and app||cat|ons, p|us |normat|on
on equ|pment and supp||ers can be obta|ned rom Hexce|
Oompos|tes on request.
Vacuum Bag Processing
The component shou|d be assemb|ed or cure as a s|ng|e shot
process, the necessary conso||dat|on |s obta|ned us|ng a
vacuum. Th|s can be cured |n an oven, and add|t|ona| pressure
can be app||ed | an autoc|ave |s used.
Th|s method |s su|tab|e or |tems w|th prepreg or preormed
compos|te or meta|||c ac|ng sk|ns. When |ex|b|e or ormed
honeycomb core and ||m adhes|ves are used comp|ex |tems
may be produced.
vacuum bag
Honeycomb
Oore Mater|a|
Fac|ng
Bk|n
Mater|a|
Pedux F||m
Adhes|ve
Matched Too|
P P E B B P E
Honeycomb
Oore Mater|a|
Fac|ng
Bk|n
Mater|a|
Pedux F||m
Adhes|ve
Form too|
23 HEXOEL OOMPOSTES
Sandwich PaneI Edge CIosure Design
When des|gn|ng o sandw|ch pane|s |t may be necessary to
cons|der methods o c|os|ng or sea||ng the edges. Exposed
edge areas are a potent|a| weakness |n the des|gn as they may
be suscept|b|e to |oca| |mpact or env|ronmenta| damage.
Edge c|osures may a|so prov|de |oca| re|norcements,
attachment po|nts, or s|mp|y meet aesthet|c requ|rements.
l||ustrated are a number o methods common|y used to c|ose
sandw|ch boards:
Further |normat|on on edge c|osure, board |o|n|ng, abr|cat|on
and |n|sh|ng methods |s ava||ab|e |n the Hexce| Oompos|tes
pub||cat|on "Bandw|ch Board Fabr|cat|on Techno|ogy" Pe:
LT 018, ava||ab|e on request.
Pane| c|osed w|th edge |||er. Bonded Z sect|on
Box extrus|on Bonded sect|on
HEXOEL OOMPOSTES 24
HexWeb
TM
HONEYOOMB SANDWOH DESGN TEOHNOLOGY
The |normat|on conta|ned here|n |s be||eved to be the best ava||ab|e at the t|me o pr|nt|ng but |s g|ven w|thout acceptance o ||ab|||ty, whether
expressed or |mp||ed, or |oss or damage attr|butab|e to re||ance thereon. sers shou|d make the|r own assessment o the techno|ogys su|tab|||ty or
the|r own cond|t|ons o use and, beore mak|ng any comm|tment w|th regard to the |normat|on g|ven, shou|d check that |t has not been superseded.
SAFETY
HandIing Precautions
When abr|cat|ng rom honeycomb sandw|ch board mater|a|s |t |s adv|sab|e to wear d|sposab|e c|ean cotton g|oves throughout the
ent|re operat|on. Th|s he|ps to keep the pane| c|ean, and aords protect|on or the operators hands.
G|ass |bre dust |s an |rr|tant. Avo|d breath|ng the dust generated by cutt|ng operat|ons, and do not rub the eyes w|th hands wh|ch
may be contam|nated w|th the dust.
The usua| precaut|ons shou|d be observed wh||e work|ng w|th synthet|c res|ns.
Product Baety Data Bheets have been prepared or a|| Hexce| Oompos|tes products and are ava||ab|e to company saety o|cers on
request.
25 HEXOEL OOMPOSTES
APPENDX
MechanicaI Properties of Honeycomb MateriaIs - TypicaI VaIues at Room Temperature
PRODUCT CONSTRUCTON COMPRESSON PLATE SHEAR
Dens|ty Oe|| B|ze* ** ** Btab|||zed L D|rect|on W D|rect|on
kg/m
3
mm Btrength Modu|us Btrength Modu|us Btrength Modu|us
(|b/t
3
) (|n) MPa MPa MPa MPa MPa MPa
3003 A|uminium
29 (1.8) 19 (
3
/4) 0.9 165 0.65 110 0.4 55
37 (2.3) 9 (
3
/8) 1.4 240 0.8 190 0.45 90
42 (2.6) 13 (
1
/2) 1.5 275 0.9 220 0.5 100
54 (3.4) 6 (
1
/4) 2.5 540 1.4 260 0.85 130
59 (3.7) 9 (
3
/8) 2.6 630 1.45 280 0.9 140
83 (5.2) 6 (
1
/4) 4.6 1000 2.4 440 1.5 220
5052 A|uminium
37 (2.3) 6 (
1
/4) 1.35 310 0.96 220 0.58 112
50 (3.1) 5 (
3
/16) 2.3 517 1.45 310 0.9 152
54 (3.4) 6 (
1
/4) 2.6 620 1.6 345 1.1 166
72 (4.5) 3 (
1
/8) 4.2 1034 2.3 483 1.5 214
83 (5.2) 6 (
1
/4) 5.2 1310 2.8 565 1.8 245
127 (7.9) 6 (
1
/4) 10.0 2345 4.8 896 2.9 364
130 (8.1) 3 (
1
/8) 11.0 2414 5.0 930 3.0 372
5056 A|uminium
37 (2.3) 6 (
1
/4) 1.8 400 1.2 220 0.7 103
50 (3.1) 3 (
1
/8) 2.4 669 1.7 310 1.1 138
50 (3.1) 5 (
3
/16) 2.8 669 1.8 310 1 138
72 (4.5) 3 (
1
/8) 4.7 1275 3.0 483 1.7 193
HRH10 Nomex (Aramid)
29 (1.8) 3 (
1
/8) 0.9 60 0.5 25 0.35 17.0
32 (2.0) 5 (
3
/16) 1.2 75 0.7 29 0.4 19.0
32 (2.0) 13 (
1
/2) 1.0 75 0.75 30 0.35 19.0
48 (3.0) 3 (
1
/8) 2.4 138 1.25 40 0.73 25.0
48 (3.0) 5 (
3
/16) 2.4 140 1.2 40 0.7 25.0
64 (4.0) 3 (
1
/8) 3.9 190 2.0 63 1.0 35.0
64 (4.0) 6 (
1
/4) 5.0 190 1.55 55 0.86 33.0
80 (5.0) 3 (
1
/8) 5.3 250 2.25 72 1.2 40.0
96 (6.0) 3 (
1
/8) 7.7 400 2.6 85 1.5 50.0
123 (7.9) 3 (
1
/8) 11.5 500 3.0 100 1.9 60.0
144 (9.0) 3 (
1
/8) 15.0 600 3.5 115 1.9 69.0
29 (1.8) 5 OX (
3
/16) 1.0 50 0.4 14 0.4 21.0
48 (3.0) 5 OX (
3
/16) 2.9 120 0.8 20 0.85 35.0
HRH78 Typ|ca| mechan|ca| propert|es are s|m||ar to HPH10, however, the aram|d sheet
manuactur|ng to|erances are w|der thereore m|n|mum va|ues may be reduced.
Other o|| th|cknesses and ce|| s|ze are ava||ab|e: see spec||c data sheet or Be|ector Gu|de, obta|nab|e rom Hexce| Oompos|tes on request.
* ** **P|ease note that the exact ce|| s|zes or HexWeb core are the |mper|a| measurements. The metr|c va|ues are prov|ded or reerence on|y.
HEXOEL OOMPOSTES 26
HexWeb
TM
HONEYOOMB SANDWOH DESGN TEOHNOLOGY
APPENDX
FACNG MATERAL TYPCAL MODULUS OF POSSON'S TYPCAL CURED TYPCAL WEGHT
STRENGTH ELASTCTY RATO PLY THCKNESS PER PLY
Tens|on/Oompress|on Tens|on/Oompress|on 0 mm kg/m
2
MPa GPa
Epoxy D OAPBON
tape (0) 2000 / 1300 130 / 115 0.25 0.125 0.19
60% vo|ume ract|on
Epoxy D GLABB
tape (0) 1100 / 900 43 / 42 0.28 0.125 0.25
55% vo|ume ract|on
Epoxy WOvEN OAPBON
(G793-5HB) 800 / 700 70 / 60 0.05 0.30 0.45
55% vo|ume ract|on
Epoxy WOvEN APAMlD
(285K-4HB 500 / 150 30 / 31 0.20 0.20 0.27
60% vo|ume ract|on
Epoxy WOvEN GLABB
(7781-8HB) 600 / 550 20 / 17 0.13 0.25 0.47
50% vo|ume ract|on
Pheno||c WOvEN GLABB
(7781-8HB) 400 / 360 20 / 17 0.13 0.25 0.47
55% vo|ume ract|on
ALMlNlM A||oy Av. Y|e|d Av. 70 0.33 0.50 1.35
2024 T3 270
5251 H24 150
6061 T6 240
BTEEL carbon Av. Y|e|d Av. 205 0.30 0.5 4.15
1006 285
1017 340
Exter|or PLYWOOD F|r 30 / 35 Av. 9 0.1 12.7 6.3
Tempered
HAPDWOOD Teak 110 / 40 Av. 12 0.1 12.7 8.5
Properties of typicaI facing materiaIs for sandwich paneI construction.
27 HEXOEL OOMPOSTES
BEAM (pages 12 to 13)
Bend|ng Bt|ness ~ D ~ E

h
2
b where h ~ t

t
O
2
Bhear Bt|ness ~ B ~ bhG
O
where G
O
~ G
L
or G
W
De|ect|on ~ @ @@ @@ ~ K
b
Pl
3
(bend|ng) K
B
Pl (shear)
D B
Fac|ng Btress ~ I II II

~ M where M |s rom page 11

h t

b
Oore Btress ~ J JJ JJ
O
~ F where F |s rom page 11
h b
PLATE (pages 14 to 17)
P|ate Ooe|c|ent ~ |) b , ||) P ~ G
L
, |||) v ~ F FF FF E

h
a G
W
2b
2
G
W

De|ect|on ~ @ @@ @@ ~ 2K
1
q b
4

E

h
2
Fac|ng Btress ~ I II II

~ K
2
q b
2
h t
Oore Bhear ~ J JJ JJ
O
~ K
3
q b
h
Loca| Oompress|on ~ I II II
O
~ P ~ q x A (NB: a|so app||cab|e to Beams)
A A
END LOADNG (pages 18 to 19)
Fac|ng Btress ~ I II II

~ P where P ~ q x b | app||cab|e
2 t

b
Pane| Buck||ng ~ P
b
~ F FF FF D where D |s as per beam
l
2
F FF FF D
G
O
h b
Bhear Or|mp|ng ~ P
b
~ t
O
G
O
b
Bk|n Wr|nk||ng ~ I II II
OP
~ 0.5 [G
O
E
O
E

]
1/3
lntra Oe|| Buck||ng ~ I II II
OP
~ 2 E

2
s
The above ormu|ae assume symetr|ca| |tems, w|th th|n ac|ngs o the same sk|n mater|a| and th|ckness, and core re|at|ve|y much
|ess st| than sk|ns.
APPENDX
Summary of FormuIae
HEXOEL OOMPOSTES 28
HexWeb
TM
HONEYOOMB SANDWOH DESGN TEOHNOLOGY
Further reading:
ZENKEPT, D. - An /ntroduct/on to $andw/ch Construct/on
Emas Pub||sh|ng, London (1997)
BlTZEP, T. - Honeycomb 7echno/ogy
Ohapman & Ha||, London (1997)