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Finite Element Analysis ofCellular Foam Core Sandwich Structures

Article  in  Materials today: proceedings · December 2017

DOI: 10.1016/j.matpr.2017.02.103

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Materials Today: Proceedings 4 (2017) 2501–2510 www.materialstoday.com/proceedings

5th International Conference of Materials Processing and Characterization (ICMPC 2016)

Finite Element Analysis ofCellular Foam Core Sandwich

Structures
Rakesh.Potluri.a *,A.Eswara kumarb, M.Naga Rajuc,K.Ravi Prakash Babud
a*
P.G Scholar,Mech. Engg. Dept, PVPSIT, Vijayawada, India.
b
Assitant Prof., Mech. Engg. Dept, K L University, Guntur, India
c
Associate Prof., Mech. Engg. Dept, DIET, Vijayawada, India
d
Associate Prof., Mech. Engg. Dept, K L University, Guntur, India

Abstract

Sandwich structures offer a lot of advantages in many applications beginning from aerospace ranging up to architecture
with means of providing high strength to weight ratio’s, insulation, energy absorption…etc. so there is every reason why we
have to study and understand those structures. Sandwich Composites are made up of two thin but stiff skins called face sheets
whose main purpose is to carry tensile and compressive loads and separated by a light weight core whose purpose to carry shear
loads.The response of the sandwich core structures will be influenced by Core and Face sheet thickness in view of overall
structural stiffness, shear stiffness and core shear. These parameters will also influence the dynamic behavior of the structures.In
this paper Static structural and modal analysis was done on the effect of the core thickness and the face sheet thickness by using
the finite element simulation software(FEM) Ansys Workbench.The influence was studied by designing experiments through the
technique of central composition design (CCD). Matlab code was developed to verify the stress values analytically and to
homogenize the material properties for the core.

©2017 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials
Processing and Characterization (ICMPC 2016).

Keywords:Foam core; Sandwich Structures; Static & Dynamic Analysis;Design of Experiments; Ansys workbench;Matlab;

* Corresponding author. Tel.: +91-9505266522;

E-mail address:y09me042@gmail.com

2214-7853©2017 Elsevier Ltd. All rights reserved.

Selection and peer-review under responsibility of Conference Committee Members of 5th International Conference of Materials Processing and
Characterization (ICMPC 2016).
2502 Rakesh Potluri et al/ Materials Today: Proceedings 4 (2017) 2501–2510

1. Introduction

A sandwich material is a special type of composite material which consists of two thin but stiff, strong
sheets of either composite material or metals which are known as face sheets that are separated by a relatively soft
core materialDifferent types of foams are used cores in creating lightweight structures that are essential to a number
of engineering applications such as ships, aircrafts and different vehicles, blast and ballistic armors, energy
absorbers in vehicles, and insulation purposes. In general, the face sheets are intended members that carries tensile
and compressive loads, whereas the core carriestransverse loads as well as shear loads.Face sheets or skins and core
are bonded together to form a very efficient load bearing Structure. Most of the literature suggested to use a 3 –point
bend tests to characterize the bending mechanisms in these composites. The foam that is selected ere is the
polyurethane (PUR) foam which has a wide range of applications starting from very light non-rigid foam used in
furniture to the very useful products for composite-core applications in aerospace which contains polyurethane rigid
foams.
Mohammed Yaseer omar et al. [1] studied characterizing a metal matrix syntactic foam core sandwich
composite under three-point bending conditions.Crackpropagation through the alumina particles is observed in the
failed specimens instead of interfacial failure. Hesham Tuwair et.al [2]studied about alternative core for GFRP
cores. Three typesThese configurations consisted of high-density polyurethane foam, a bidirectional grid work of
thin, interconnecting, GFRP webs that is in-filled with low-density polyurethane foamand trapezoidal-shaped, low-
density polyurethane foam utilizing GFRP web layers. The results suggested 3rd type core possessed a higher
strength and stiffness than the other two types.Huseyin Erdem Yalkin et.al [3] has experimented on improvement of
the mechanical performance of the foam core sandwich compositesand found sandwich composite panelswhich are
manufactured using only-perforated foam and perforated-stitched foam as the core with multi-axialglass fabrics as
the face sheet materials by vacuum infusion method using epoxy resin and found out that reinforced foam core with
perforation and stitching isa simple and effective method in performance improvement for the sandwich
composites.Ramu I et. al [4] worked on modal analysis of a functionally graded material (FGM) plate to determine
its natural frequencies and mode shapes by using FEM. The code for that was written in mat lab and the mode shape
and Kochekseraii et al. [5] showed in his work that the commercial FEA software is an effective practical solver for
the calculation of physical field in the representative volume elements(RVE) composites and foams.Feldhusen et. al.
[6] used the finite element analysissoftware in order to predict the failure of sandwich structures and exnatural
frequencies of rectangular FGM plate were found at different boundary conditions and the effect of volume fraction
index, the effects of power law index on the FGM plate natural frequency and mode shapes were studied. Sadegh
Babaii perimentally performed properties validations on that and proved that the fea softwares can predict the failure
accurately.Nattakan Soykeabkaew et.al[7] have presented are view paper on the methods being followed improve
microstructure, mechanical and thermal of starch-based foams.

2. Problem Modelling

2.1. Problem objective

The objective of the present work is to understand the response of Sandwich Structuresby varying the face
sheet(Ft)and core thickness(Ct) in view of static structural and modal analysis.For this purpose, the concept of
parameter correlation and D.O.E were used. spearman ‘s rank order correlation procedure was used in parameter
correlationto find the most important output parameters to be considered through plotting of parameter co-relation
charts,from which the parameters most influenced were core shear, stiffness, equivalentstress and
naturalfrequencies. Then five experiments were created using CCD techniqueand generated a response surface
charts through which we can predict the different output values and graphs were drawn to give the variation of the
output parameters w.r.to the input parameters.

2.2. Geometry

The Model of the sandwich structure was designed in ANSYS workbench. The structure was modeled to
perform a three- point bend test according to the ASTM C393(2011) test method which helps to determine the
 Rakesh Potluri et. al/ Materials Today: Proceedings 4 (2017) 2501–2510 2503

properties of sandwich beams is taken as the base model shown in fig 1a. The structure usually contains the face
sheets, core and adhesive layers which join the core with the face sheets shown in fig.1b. Here the adhesive layers
are modeled as the bonded contact in between the face sheets and the core as this type of modelling serves the main
purpose of the adhesive layer. So core and the face sheets remain in full contact throughout the analysis.

Face Sheets

Core

Fig 1a: Geometry of the foam core sandwich structureFig 1b: Geometry of sandwich structure in exploded view

2.3. Finite Element Meshing

It is the process of converting the geometrical entities to finite element entities and 8 noded brick element is
used for all components of the sandwich structure [14]. In Ansys it is called solid 185.Fine meshing is done to take
care about the stress transfer taking place between very thick core material and the very thin face sheets as shown in
fig.2

Fig 2: Meshing view of the sandwich structure

2.4. Loads & Boundary conditions

The structure has been sliced into 3 parts to create the line contact as such like in the original experiment (Three-
point bend test). Displacement constraints were applied which mimics simply supported beam conditions and top
face was loaded with force in the static structural analysis shown in fig3& fig4. Then the sandwich structure was
taken as a cantilever beam, so that we could more reliably predict the change in the basic modal frequencies shown
in fig.4
2504 Rakesh Potluri et al/ Materials Today: Proceedings 4 (2017) 2501–2510

Force

Simply
Supported
Condition

Fig 3: Loads & Boundary conditions for static analysis Fig 4: Loads & Boundary conditions for modal analysis

Fig 5: 3-Point Bending Test of Sandwich

2.5. Material properties

Table 1. Material Properties used for skin and core

Material E (MPa) ν G (MPa) ρ (Kg/m3)

Young’s Modulus Poisson’s Shear Density
Ratio Modulus

Steel 20,6000 0.29 75,500 7,800

Aluminum 7100 0.33 2669 2770
PUR 14 0.3 5,373 75

The material properties which are used in the analysis of the sandwich structure are presented in the table:1
where the aluminum and the steel are the materials used as the face sheet materials and the PUR material is used for
the core material.
The behavior of cellular materials and their characterization and prediction of most mechanical properties were
empirically derived from experimental results (Formula 1) and this work was done by Gibson and Ashby. The
formulae shown can be used for the homogenization of the foam core properties when a particular material is used
as the core. Here for the core we have assume it as open foam core containing an array of cubic cells. Since foams
 Rakesh Potluri et. al/ Materials Today: Proceedings 4 (2017) 2501–2510 2505

are available in a wide range of densities, thicknesses, the firstdesign problem is to choose the right thickness.
Ifproper material data tables are not available, thefollowing formula could be employed to determinethe unknown
parameters for design calculations. The material parameters calculation was done using a code designed in Matlab.

𝐸𝑐 = 𝐶𝐸 𝜌𝑘 , 𝐺𝑐 = 𝐶𝐺 𝜌𝑙 , 𝜎𝑐 = 𝐶𝜎 𝜌𝑚 And 𝜏𝑐 = 𝐶𝜏 𝜌𝑛 (1)
C = geometric constant for proportionality

2.6. Analytical validation

There are standard procedures for calculating the deflection and stresses available in literature which can be used
to verify the finite element model as well. With the help all the formulations we had taken from the literature [7,8]
we developed a computer code in the form of application which runs inside mat lab and gives out all that values
which are required.
Table.2 shows a type of beam support for which the bending and shear coefficient calculation formulaswere shown
which are going to be used in main formulas which are used in the code. Other types of beams may include, both
ends fixed, cantilever.etc. [8]

Table 2. Calculating Bending and Shear Coefficients for simply supported beam
Beam Type Maximum Shear Maximum Bending Moment Bending Deflection Shear Deflection
Force (F) (M) Coefficient (kb) Coefficient (ks)

Simple Support 𝑃 𝑃𝑙 5 1
2 2 384 8

3. Results & Observation:

3.1. Parameter Correlation study

The samples selection was done based on the technique of Latin Hyper Cube sampling where the sample
points will be selected at random from the given design space and care is taken such that no two input parameters
share the same sampling value. This is done to build a better correlation matrix with higher accuracy. Then the
correlation was calculated by the spearman’s rank correlation methodology and the relationship between the
parameters were established. The formula for the spearman ‘s rank correlation is given as:
6 ∑ 𝑑𝑖 2
𝜌=1− 𝑛3 −𝑛
(2)

Where di = difference between paired ranks, n = no of samples

we have taken about 100 samples in order interpolate the relation between the change in the skin thickness to the
change in the parameters like stress, total deformation, stiffness, mass, natural Frequencies... etc. and have prepared
a correlation matrix for this case. Then again sameprocedure is repeated for the studying the effect of change in the
core thickness and the correlation matrices have been shown below in fig 6. From the fig 6 it can help to predict the
2506 Rakesh Potluri et al/ Materials Today: Proceedings 4 (2017) 2501–2510

Fig 6: Correlation core linear Matrix for thickness relationship between our input & output parameters wither they
are directly or inversely related to each other and how strong the relationship is there. If the color is red, then it a
direct relationship exists and if its blue inverse relation exists between the input and output parameters and the
correlation factor specifies how strong is the relationship.

3.2. Design of Experiments

These design points were taken by the design of experiments procedure using the central composition
design method. A Central Composite Design (CCD) is a five-level fractional factorial design that is suitable for
calibrating the quadratic response of a model. A CCD consists of a single center point, 2*N axis points located at the
–a and +a positions on each axis of the selected input parameter, 2^ (N-f) factorial points which are located at the -1
and +1 positions along the diagonals of the input parameterspace will be selected. Five experiments were designed
and the variation of the parameters were observed. Thegoodness of fit table and graph shows how well the
interpolated values for the input values which are not generated in D.O.E scenario.fig.7 shows a goodness of fit table
and fig.8 shows a goodness of fit graph for the core thickness variation with aluminium face sheets and PUR core.
Then a response surface is generated and the values of the different output parameters are interpreted and the
variation can be conformed with a higher confidence. A parameters parallel chart shows the variation of different
output parameters w.r.to input parameters for the cases generated in D.O.E which is shown in fig.9.

Fig 7: Goodness of fit table for Core thickness Fig 8: Goodness of fit chart for Core thickness
 Rakesh Potluri et. al/ Materials Today: Proceedings 4 (2017) 2501–2510 2507

Fig 9: Parameters Parallel Chart for D.O.E scenarios

The graphs were plotted in excel for all the cases i.e. 1st case is effect of change of core thickness, 2nd case
is effect of change of core thickness.

3.3. Static Analysis

Ct Vs Equiavalent Stress Ct Vs Shear Stress

1200 25
1000
Equiavalent Stress (MPa)

20
Shear Stress (MPa)

800
15
600
400 10
200
5
0
50 55 60 65 70 0
50 55 60 65 70
aluminium steel Core thickness(mm)
Aluminium steel Core thickness (mm)

Fig 10: Core Thickness Vs Equivalent Stress Fig 11: Core Thickness Vs Shear Stress
2508 Rakesh Potluri et al/ Materials Today: Proceedings 4 (2017) 2501–2510

Ct Vs Stiffness Ft Vs Equivalent stress

1500
250

Equivalent Stress (Mpa)

200
Stiffness (N/mm)

1000
150

100 500

50
0
0 0.5 0.55 0.6 0.65 0.7
0.5 10.5 20.5 30.5 aluminium steel Face Thickness (mm)
aluminium steel Core thickness (mm)
Fig 12: Core Thickness Vs Stiffness Fig 13: Face sheet Thickness Vs Equivalent Stress

Ft Vs Shear stress Ft Vs Stiffness

30 300
Shear Stress (Mpa)

Stiffness (N/mm)
20 200

10 100

0 0
0.5 0.55 0.6 0.65 0.7 0.5 10.5 20.5 30.5
aluminium steel Face thickness (mm) aluminium steel Face thickness (mm)

Fig 14: Face sheet Thickness Vs Shear stress Fig 15: Face sheet Thickness Vs Stiffness

From the above figures 10, 11, 12, 13, 14 & 15, we can observe that with the increase in the core thickness
there is a decrease in the core shear as well as the overall shear stress that is experienced by the sandwich structure.
The equivalent von –misses stress decrease with the increase in the core thickness. The stiffness of the sandwich is
also increasing with the increase in the thickness which means the deformation due to the load is decreasing. The
same type of behavior has been also observed in terms of the increase in the skin thickness. But the increase in the
skin thickness if observed the mass will be increased very drastically, but if the thickness of the core is increased the
increase in the weight of the structure is negligible and one of the main failure mode which is due to the excessive
increase in the core shear will be avoided but this will be a problem in case if there is thickness constraint over the
design.

3.4. Dynamic Analysis

Fig. 16 shows the modes shapes of the first 3 natural frequencies of sandwich structure for the base model.
From the figures 17&18 it is observed that as the skin thickness increases,the frequencies 1,2 increases & remaining
4 frequencies decreases.With the increase in core thickness, frequencies 1,3,4,5,6 increases & frequency 2
decreases.This is mainly due to the variation in the mass and stiffness which occur with the change in thickness of
core & skin.
 Rakesh Potluri et. al/ Materials Today: Proceedings 4 (2017) 2501–2510 2509

Mode 1 Mode 2 Mode 3

21.257 49.742 76.118

Fig 16:First 3 mode shape contours of the sandwich structure

300
250
250
200
Frequency(Hz)

200
Frequency (Hz)

150
150

100 100

50 50

0 0
52 57 62 0.53 0.58 0.63
1 2 3 1 2 3
4 5 6 Ct Thickness (mm) 4 5 6 Ft Thickness(mm)

Fig 17: Core Thickness Vs Frequency Fig 18: Face sheet Thickness Vs Frequency

4. Conclusion

Successful modelling and analysis was performed and the results were plotted and observations were made from
which the following conclusions have been taken.From the above observationsit is concluded that the core thickness
and skin thickness has inverse relation with equivalent maximum stress, shear stress, deformation. The stiffness of
the sandwich structure is directly impacted by both Core and skin thickness. Mass and elastic strain has no major
changes due to the Core thickness but the skin thickness is directly proportional to mass and inversely proportional
to elastic strain of the sandwich structure.The main failure in the sandwich structure is the core shear failure. So
from the above it can be concluded that for designing a low weight and high stiff sandwich construction with metal
skins and foam core, optimize the core thickness& foam structure,by keeping the skin thickness to minimum amount
can lead to better results in terms of stiffness because the core is playing the major role. From the modal analysis it
is concluded that the frequencies 1,2 increases & remaining 4 frequencies decreases with the increase in skin
thickness due a higher stiffness in mode 1,2. With the increase in core thickness, frequencies 1,3,4,5,6 increases &
frequency 2 decreases due to the reason that mode 2 has lower stiffness.
2510 Rakesh Potluri et al/ Materials Today: Proceedings 4 (2017) 2501–2510

5. References

[1] Mohammed Yaseer Omar“Syntactic foam core metal matrix sandwich composite under bending conditions” Materials and Design 86 (2015)
536-544
[2] Hesham Tuwair et.al., “Evaluation of sandwich panels with various polyurethane foam-cores and ribs” Accepted Manuscript to be published
in Composites Part B
[3]Huseyin Erdem Yalkin, Bulent Murat Icten, Tuba AlpyildizEnhanced mechanical performance of foam core sandwich composites with
through the thickness reinforced core” Composites Part B 79 (2015) 383 - 391
[4] Ramu I, Mohanty S.C. “Modal analysis of Functionally Graded Material Plates using Finite Element Method” Procedia Materials Science 6
(2014) 460 – 467
[5] Sadegh Babaii Kochekseraii “Effectiveconductivityofmatrix composites andfoammaterialsbyself-consistent field method using commercial
FEA software” International Journal of Engineering Science 000 (2015) 1–6
[6] FELDHUSEN, J. et al Numerical Modelling and Experimental Investigation of the Failure Modes of the Cellular Foam Sandwich Structures.
- Journal of Metals, Materials and Minerals, Vol.18 No.2 pp.111-115, 2008.
[7] Nattakan Soykeabkaew, Chuleeporn Thanomsilp, Orawan Suwantong “A review: starch-based composite foams” Accepted manuscript to be
published in Composites: Part A
[8] Tom Blitzer “Honeycomb Technology First edition 1997” published by Chapman &Hali in 1997
[9] Cheol-Won Kong, Gi-Won Nam, Young-Soon Jang & Yeong-Moo Yi (2014), Experimental strength of composite sandwich panels with
cores made of aluminium honeycomb and foam, Advanced Composite Materials, 23:1, 43-52.
[10] A. Valenza, V. Fiore & L. Calabrese (2010): Three-Point Flexural Behaviour of GFRP Sandwich Composites: A Failure Map, Advanced
Composite Materials, 19:1, 79-90.
[11] Design of sandwich structures – a dissertation submitted for Ph.D. By Petra’s (Cambridge university) – December 1998.
[12] Rakesh Potluri “Comparative Study on Pressure Vessels Made from Laminated Composite Material (COPV) with the Pressure Vessels
Made with Sandwich Core Composite Material” Journal of Material Science and Mechanical Engineering (JMSME) Volume 2, Number 3;
April-June,2015 pp 203-207
[13] Rakesh Potluri, Krishna Kanth Ketha “Comparison between GFRP and CFRP Composite Power Take-off Shaft in Helicopters for
Prescribed Torque and Geometrical Constraints” Journal of Material Science and Mechanical Engineering (JMSME) Volume 2, Number 3;
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[14] Eswara Kumar A, Balakrishna Murthy V, Chandra Mohan R. “Effect of Shim Percentage on Non-Linear Static Behavior of Flex Seal of
Rocket Nozzle” Materials Today: Proceedings 2 (2015) 1427 – 1434
[15] Bapi Raju. v, Balakrishna Murthy. v, Swetha Srinivas. j, '' Non-linear analysis of composite beam", International journal of Advanced
Materials Manufacturing & Characterization, vol 3,2013
[16] Priti Sonasale “An Approach to Optimize Mig Welding Parameters by Using Design of Experiments” International journal of Advanced
Materials Manufacturing & Characterization Vol 5 Issue 1 (2015)

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