Design And Analysis Of Aluminium Honeycomb For Building Internal Walls

1. INTRODUCTION

1.1 Introduction of the project work

In mechanical structures where stiffness, strength and weight efficiency are

required there the sandwich construction is commonly employed. In applications such as
satellites, Trains, space craft, Aircraft, boats, trucks etc these sandwich panels are used.
On the basis of performance low density hexagonal honeycombs are preferred as core
material. The sandwich panel is a composition of “strong and stiff” face plates bonded on
upper and lower side with “weak” core material. The facings provide in plane extensional
rigidity and practically all of the overall bending. The basic principle of the sandwich
panel is that the core carries the shear stresses whereas the faceplate carries the bending
stresses.
The sandwich facings performs function that are similar to that of I beam flanges and
core plays a role that is analogous to that of the I beam web. In the sandwich structural
design by the proper choice of geometry and material construction having high ratios of
stiffness-to-weight can be achieved, hence the sandwich is an attractive design concept.
The dynamic responses of honeycombs to impact have been studied in both the out-of-
plane and in-plane regimes. Definitions of specific crushing mechanisms dependent on
impact velocity have also been made, identifying three main crushing behaviors based
upon both the wave trapping velocity and the crit-ical wave speed of the honeycomb
structure . The effects of effective density of honeycomb imperfections and inclusions on
crushing mechanisms have also been researched.The effects of honeycomb cellular
geometry on mechanical per-formance specifically honeycombs with a negative Poisson’s
ratio, often call auxetic, have been limited to the response to static loading conditions.
Topics in this field include targeting of shear compliance and stress parameters through
the modification to the cellular angle and thicknesses. The effect of cell angle on the
specific energy absorption, that is, energy absorbed per unit mass, has been quantified,
but is limited to positive cell angles.

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1.2 Problem Statement

To perform an accurate analysis an engineer must determine such information as

structural loads, geometry, support conditions, and materials properties. The results of
such an analysis typically include deformation, stresses and displacements. This
information is then compared to criteria that indicate the conditions of failure
Need to generate a material for high strength for supporting building wall.
Which occupies a more space in floor area

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1.3 Project Objectives

1. To manufacture a structure with high tensile strength.
2. To use the material on domestic level such as buildings and other possible
applications
3. To increase the strength and stability of the structure.
4. To make the walls light in weight.
5. The process of installation should not be complicated.
6. The manufacturing and fabrication should be available for costumized
requirements.
7. The design of the required material should be flexible so as to increase
customization.

One of the most important advantages to aluminium honeycomb clean room panels is
the fact that it is non-shedding. Unlike aluminium honeycomb panels, if Mineral Fibre,
PIR or PUR panels are pierced or broken it can release spores into the clean room
environment. As a result the clean room may need to be shut down, cleaned extensively,
air system filtered and then revalidated.

Aluminium honeycomb panels have a better resistance to damage due to their high
crush strength and are also easier to repair. They can simply be filled or reskinned
whereas other panels may need to be completely replaced causing further delays and
problems for the clean room.

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1.4 Scope of the project

In general copper honeycomb is available in large volumes. In numerous engineering

and scientific applications in industry for both the porosity and strength copper honey comb
is used. In our present work copper core honey comb sandwich panel bending behaviour
with stainless steel facing under 3-point bending was studied experimentally for various
loads and core heights. To predict the deflection numerical simulation was used. Then the
experimental values and predicted values were compared. Based on that results it is
determined that for lower core height the gradient of deflection curve is high and for higher
value of core height the gradient of deflection curve is low. In the above results the deflected
curve raises with the decrease of core height. These results can be used as input while
designing sandwich panels. A brass honeycomb can also be manufactured using brass
material even though it is of high cost it many advantages and better features than the
existing copper honeycomb. And also in both the copper honeycomb and brass honeycomb
we can calcite the experimental and theoretical values by increasing the load values such as
8KN, 9KN, 10KN and so on. These are the future works that can be implemented from the
existing work
Bending and crushing analysis is done by taking aluminum, titanium and high tensile
steel honeycomb panels and the same analysis can also be extended to composite materials.
An engineering design process is a process used by engineers to help develop
products. This project has the wide range of scope. The capability of this honeycomb
structure is being exploited with new uses and materials being developed regularly. Sheets
of honeycomb can be profiled before covering. This tailors its limited flexibility properties
and with modern laser cutting technology this technique is in the early days of development.
The aluminium honeycomb for instance is available in different aluminium grades
with specific material properties and thus can be applied as required. However, the material
used has a significant effect on the price. The possibility of adapting the grades to required
output is a tremendous advantage in diverse markets. The trend of its usage in the Formula
one is increasing as well as for the aerospace segment for aircraft components.

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2. LITERATURE REVIEW

Sandwich panels are extensively and increasingly used in civil engineering,

aerospace engineering, and shipbuilding industry where weight is an important
design criterion. With the variety of faces and cores, the sandwich panels have wide
applications in many fields such as acoustic and thermal insulation and fire safety.
Therefore, the sandwich panels have been used commercially in exterior walls and
internal partition walls in architectural engineering.

 A lot of work has been done to simulate the behavior of the

sandwich panels using FEA. UlaAlwan, et al studied on the v-
core sandwich panel by idealizing it to a 2D structure. The
results of the 2D structure idealization are verified using FEA
of complete 3D model.

 Ijsbrand J. Van Straalen indicated that most of the FE Models

are based on two dimensional plate and shell models.

 As per SAND.CORe if continuum (solid) elements are used

to model the whole sandwich structure, it is possible to
accurately predict all the modes of deformation, i.e.:

1. Overall bending of the sandwich structure.

2. Bending of the facings.

3. Compression/tension of the core in the through-thicknessdirection.

4. Shear deformations.

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2.1] PenttiKujala, et al performed a numerical simulation to study the fatigue strength

of the joints. For this the 2D FE model was created with symmetric boundary
conditions.(Figure 2.1)

Figure 1 : 2D Idealization

2.2] Valdevit, et al performed numerical simulations using ABAQUS software to assess

the deflections of the corrugated sandwich beam in 3-point bending test. During the
study, 3D model of the test specimen is generated in which the sandwich panel is
modeled using shell elements. The mesh was made denser at the central core. The
results were in good agreement with experimental values. The meshed in the region
around the central platen is shown in the figure 2.2. The rollers were modeled with
reduced integration eight-node solid elements (C3D8R). Contacts between the panel and
the rollers as well as between the panel and the platen were modeled as hard surfaces (no
penetration), with a friction coefficient of 0.1. The rollers were clamped at their centers.
One node of the panel was restrained horizontally. The stress/strain curve measured

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for brazed 304 stainless steel was used to characterize the plastic response.

Figure 2 : Meshed model for the numerical simulation.

Significant reductions in the fluid structure interaction regulated transfer of

impulse occur when sandwich panels with thin (light) front faces are impulsively
loaded in water.

2.3] Haydn N G Wadley, et al used a combined experimental and computational

simulation approach has been used to investigate this phenomenon during the
compression of honeycomb core sandwich panels. Face sheets modeled with solid
elements while core modeled with shell elements.. Square cell honeycomb panels with a
core relative density of 5% have been fabricated from 304 stainless steel (Figure 2.3).

Figure 3:Honeycomb sandwich panel for underwater impact loading

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2.4] Jimenez-Caballero, et al discussed the simulation procedure for corrugated

cardboard boards. Single fluted and double fluted card board panels are modeled and
simulated. Abaqus was used for this purpose (Figure 2.4 a&b). An element selection
criterion was explained with Shell and solid elements can be used for analysis. Simple
model of composite linear thick shells with reduced integration using simplified
continuum-equivalent properties for the fluting is the most efficient solution for single
flute corrugated board.

(a) Single fluted cardboard panel (b) Double fluted cardboard panel

Figure 4: Cardboard panel and its FE model

2.5] Hans Kolsters, et al investigated the possibilities for structural optimization of

laser-welded sandwich panels with an adhesively bonded core and unidirectional
vertical webs. Mathematical Equations for equivalent stiffness and elastic buckling
strength of laser-welded sandwich panels are presented. Method of Moving
Asymptotes (MMA) was used to optimize the sandwich panel design. The face plate
thickness, the core thickness, the web thickness, and the web spacing are considered
as the variables based on which the structure optimization is carried out.

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2.6] Edgars Labans, et al investigated the behavior of plywood sandwich panels

with corrugated core both experimentally and numerically. The numerical simulation
was performed using Ansys. 4 – Noded Shell element was used to model the
corrugated panel (Figure 2.5). Simulation was carried out to predict stress and
deflections in 4-point bending test.

Figure 5: Manufactured cross section of sandwich panel (upper); numerical

2.7] St-Pierre, et al explored the sensitivity of the three-point bending response of a

sandwich beam to the relative placement of material in the core, front face and back
face (Figure 2.12) and numerical simulations were performed to understand the collapse
mechanisms of sandwich beams with Y framed cores. Four noded , linear shell
elements with reduced integration (S4R in Abaqus notation) were used to discretize the
sandwich beams using a mesh size of 0.5 mm. A convergence study showed that
further mesh refinement did not improve significantly the accuracy of

(a) Double hull design (b)Single hull design

Figure 6 : The Y-frame sandwich core

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2.8] Andrew C. Marshal described various testing procedures for bending strength that
are to be performed on the sandwich panels. It shows that shear strength values obtained
using plate shear test methods (Figure 2.15)are quite normally up to 25% below those
obtained when using the flexure method (Figure 2.16).

Figure 7: plate shear test method Figure 8 : flexure method (top:

3-point bending test, bottom: 4-
point bending test)

2.9] Shawn R. McCullough reported the behavior of LASER welded corrugated core
sandwich beams and plates stiffened with concrete. The sheet tested consists of a
corrugated sandwich panel with top and bottom steel facing separated by steel
corrugation. Concrete layer is placed on the top of the sheet utilizing shear connector
to ensure composite action. Structural behavior of these composites was evaluated.
Main applications of these sandwich panels include emergency bridge repair, building
floors, fire walls etc. Beam Theory (for narrow panels) and classical theory of
orthotropic plates used for analyzing the plates by experimental Results are verified for
both 3-Point and 4- Point loading (figure 2.17).

Figure 9: Testconfigurations.

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2.10] St-Pierre performed 3-point bending test in two forms i.e.in (i) simply supported
and (ii) clamped conditions with the prismatic axis of the core aligned to the
longitudinal axis of the beam. Two classes of sandwich beams were fabricated for this
purpose:
i. A beam with front-and-back faces of thickness t and

ii. A beam with only a front face of thickness 2t.

The dimensions of the cores were approximately 1:20 scale models of the cores
used in a ship hull. In addition, the uniaxial tensile response of as-brazed stainless steel
was found to be representative of shipbuilding steel up to strain levels of about 10%.
Sandwich beams with front-and-back faces present collapsed by indentation whereas
structures without a back face collapsed by Brazier plastic buckling.

2.11] Schultz M. R., Worked on the use of fluted core composites. Fluted-core, which
consists of integral angled web members with structural radius fillers spaced between
laminate face sheets, (Figure 2.27).

Figure 10: Fluted core sandwich panels

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3. METHODOLOGY FOR MANUFACTURING

 There are five basic ways of manufacturing honeycomb :

1. Adhesive bonding
2 .Resistance welding
3 .Brazing
4. Diffusion bonding
5 .Thermal fusion

 There are two basic methods of manufacturing honeycomb core by adhesive

bonding.
1.Expansion method
2.Corrugation method

A schematic of expansion process for honeycomb core manufacturing is shown in

figure 7. Metallic sheet is cut into specified dimensions and strips of adhesive are printed
on it. Adhesive is applied in such a way that adhesive prints on adjacent sheets are shifted
by half of the distance between adjacent prints on the same sheet. After solidification and
curing of the adhesive, HOBE block is sliced into required thickness of the core and then
HOBE slice is expanded to form honeycombs.

 Expansion Method

Figure 11 : Expansion method of core manufacturing

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 Corrugation Method

Figure 12 : Corrugation method of core manufacturing

Manufacturing of core by corrugation method is shown in figure 8. In this method

corrugations are produced by pressing metallic sheet between toothed rollers. Corrugated
sheets are then bonded, brazed or resistance welded to form honeycomb core. This
method is generally preferred for high density cores which cannot be expanded due to
thick and strong metallic sheets.

SANDWICH PANEL FABRICATION

The basic components of sandwich panel are core, facings and adhesive. Face
sheets can be metallic or composite prepreg. Prepreg such as fiberglass, Kevlar and CFRP
can be precured and bonded to honeycomb core with adhesive. Resin from the composite
prepreg bonds fiber with core and therefore adhesive is not necessary for composite skins.
The common methods of bonding panels are with the help of autoclaves,vacuum bagging
and presses. Autoclaves and vacuum bagging are generally used for curved parts and
presses for flat panels.

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Figure 13: Sandwich Panel Fabrication

When composite laminate is made in an autoclave generally either 121°C or

177°C cure cycle for 1 hour after heat up rate of 1.1-2.2°C per minute with pressure
around 0.48 MPa is used. Similar cure cycles can be adopted for metallic facings however
amount of pressure to be applied depends on compressive strength of core. Honeycomb
cores cannot withstand any side pressures. Hence care must be taken to use seals on sides
to prevent it from caving inward.

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4. Planning Schedule / Flowchart for completion of project

4.1 Planning

Table no -2 :-

Activity
Jun- Jul- Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr-
Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May
Topic
selection
Literature
review
Collection
Of data
Analysis
Of work
Remedial
measures
Results
And
conclusion
Report
Writing
Planning and Scheduling

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5. REFERENCES

 Buckling of laser-welded sandwich panels: ultimate strength and experiments

Hans Kolsters and Dan Zenkert Department of Aeronautical and Vehicle Engineering,
Royal Institute of Technology (KTH), SE-100 44 Stockholm, Sweden.
 Stiffness analysis of sandwich panels with corrugated plywood and GFRP core E.
Labans & K. Kalnins Riga Technical University, Riga, Latvia K. Zudrags JSC Latvijas
Finieris, Riga, Latvia
 Design of Different Types of Corrugated Board Packages Using Finite Element
Tools M. A. Jiménez-Caballero, I. Conde, B. García, E. Liarte Instituto Tecnológico de
Aragón C/ María de Luna 7-8, 50007 Zaragoza. SPAIN
 Design and Fabrication of Spot Welded Corrugated Panel Under Three Point
Bending by FEM G.Nirupamaa , V.Diwakar Reddya , G.Krishnaiaha * a Department of
Mechanical Engg., Sri Venkateswara University College of Engineering, Tirupati-
517502,Andhra Pradesh, INDIA
 L. St-Pierre N. A. Fleck1 e-mail: naf1@eng.cam.ac.uk V. S. Deshpande
Department of Engineering, University of Cambridge, Trumpington Street, Cambridge,
CP2 1PZ, UK
 International Journal of Solids and Structures In-plane column response of
metallic corrugated core sandwich panels R. Biagi, H. Bart-Smith ⇑ Department of
Mechanical and Aerospace Engineering, University of Virginia, 122 Engineer’s Way,
Charlottesville, VA 22904, USA

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