scum amis FR CER RIOR ROC CR SCI IC RIO REAR ARR RH A SIMPLE METHOD TO PREPARE FE MODELS OF HONEYCOMB SANDWICH PANELS by K, Badari Narayana, K.S. Ramanath and D.H. Bonde, ISRO-Satellite Centre, Bangalore, India INTRODUCTION Honeycomb sandwich panels are extensively used in the aerospace industry for their superior stiffness and strength-to-weight ratios. The general-purpose finite element software systems available today provide a variety of sandwich/composite layered clements for the analysis of these structural components. Often, as it may be necessary to perform a quick analysis to reflect the design changes without sacrificing the overall efficiency, an equivalent plate/shell idealization is preferred to sandwich idealization. This also allows the simplification of data preparation (which, in tum, helps in reducing the manual errors) and facilitates an easy transfer of data between various software packages. The detail of the necessary mathematical expressions to simplify finite element modelling of sandwich panels to a plate/shell idealization are given in our earlier articles (1] and [2]. For the sake of completeness and clarity, the important expressions are given in Appendix A. The main focus of this paper is to highlight the advantages of such simplified models in the analysis of ‘practical problems’. The functional behaviour of a honeycomb sandwich construction is very similar to that of a conventional ‘’ beam; with the face sheets of the panel providing the required in-plane and bending rigidity and the hon- eycomb core providing the necessary resistance to the shear loads. In order to utilize plate/shell idealization in place of sandwich elements, appropriate values for Young’s modulus - Ee , thickness - te and density - Rhoe are used for the plate/shell element. These properties can be derived by simulating a) in-plane (stretching), (b) Bending (flexure), and c) In-plane and out-of-plane (transverse) shear stiffness charac- teristics of sandwich and the equivalent plate/shell idealization THE BASIC MODELLING APPROACH ‘The stiffness of a thin sandwich face sheet with a light core can be obtained using the constitutive equations. The in-plane stiffiness of the core is neglected. For the face sheet, the transverse shear stiffiness is quite large (highly rigid), compared to the in-plane properties. Then, the membrane (A), membrane-bending coupling (B), bending (D) and transverse shear (K) stiffnesses of a thin wall sandwich structure is obtained using laminate theory [3] as (0). (a5) (0) Fon “San * Bon ~ Son ae fon ‘and =a (2) (i) 4 62 _ (0) Pon Fm 7 2 Om + en (1) 26 (2) (2) wo (7) pt. and kK, Bo te FINITE ELEMENT NENS 195 ISSUE ND.6 (DECEMBER) Page 30where (ty +t, +t, ) 72 a (r) WHY L cay!) ty) + an) tg°"1) 9 (r= 0,1,2) By are the transverse shear modulus of the core material. If the face sheets are from the same material and have the same thickness, Sant a Can?) ande=h/ 2. One can eliminate all the coupling between A and D by setting B,,, coefficients to zero, cont (Exe: Eye Gye San. Gye, Fal Jc Safe te Equivalent shell Honeycomb sandwich Figure 1 Notation and material property specifications of sandwich laminate and equivalent shel] Following the notation of the sandwich and equivalent plate constructions shown in Figure 1, and using the relations given in Equation (1), the expressions for the in-plane, bending and shear stiffness for a sandwich with isotropic or composite facing idealized as equivalent layers, are obtained as: [1,2] (2) In-plane stifhess per unit width Zep tp = EL ty Q) b) Bending stiffness per unit width (t+ 7-2 levy t i 3 Ep te (tot tes 2 Oe Ww) = Bt 7 @G) ¢) Transverse shear stiffness per unit width 2 - G ltt tp) st = 6 t. / 1.2 (4) Where, Eg : modulus of elasticity of face sheet material, ty : facesheet thickness, t, 1 Core thickness, G_ : Core shear modulus, and v_: Poisson’s ratio of the facesheet thaterial FINITE ELEMENT NEWS 1995 ISSUE NO.6 (DECEMBER) Page 31The two face sheets are assumed to be of equal thickness (tp) and they are thin compared to the core thickness (t.) . In Equation (3), the factor 1.2 is used to represent the parabolic stress distribution over the cross sectional area of the solid section, Expressions given in Equations (3) and (4) are generally valid for te/ty ratio larger than 10, NUMERICAL EXAMPLES “The simple theoretical expressions are derived in references [1,2] __ to prepare finite element models of honeycomb sandwich constructions. Two different models are developed, depending upon the facesheet constructions, a) the orthotropic and b) the isotropic models. These models are basically obtained from Equations (2) to (4) and are given in Equations (Al) to (A5) of Appendix A. The general purpose finite clement software, NISA [4], is used to illustrate the utility of these simplified models for solving practical problems. The following sections present the numerical results for a) A simply supported square plate under uniform transverse loads for maximum deflection and normal modes; b) Thermal distortion analysis of a reflector antenna; and ¢) Normal mode analysis of a typical spacecraft structure. a) Simply supported square plate ‘The configuration and boundary conditions of a three-layered simply supported orthotropic sandwich plate under uniform loading is shown in Figure 2. Due to double symmetry of the problem, one quarter of the geometry is analysed for central deflections and normal modes. Table 1 gives the geometry, material properties of the sandwich constructions (MODEL-1) and the properties of isotropic (MODEL-2) and orthotropic (MODEL-3) models / obtained using expressions given in Appendix A. - ¢. The results of static analysis are compared with available reference solution [5]. The model using orthotropic idealization gives accurate results, which correlates very well with reference [4] and sandwich idealization given by Model-1. Whereas, the model with isotropic shell idealization under- estimates the deflection. This discrepancy is at- tributed to the higher value of in-plane shear moduli and the orthotropic ratio of the facesheet (Efe, = 2.5). The same problem is further analysed for natural frequencies. The corresponding results are also given in Table 2, As can be seen from Table 2. the deviation in the frequencies predicted by th thotropic model and that of the sandwich elem Tess than 1 per cent. b) Thermal distortion analysis of an an- tenna reflector Figure 2 A three-layered simply supported square plate The second example considered to illustrate the effectiveness of these models is a thermal distortion FINITE ELEMENT NEWS 1995 ISSUE ND.6 (DECEMBER) Page 32Table 1 Geometric and material prope: zis or a simply supported plate: for various idealizations Geometry of the model: Length (a) and Width (b) 10 in, Uniformly distributed pressure (P) = 100 Psi Description Model-1 Mode1-2 Mode1-3 of the property Sandwich Isotropic Orthotropic model shel] mode1 shel] element Eqs.(A2) to (AS) | Equation (A1) t, (in) e 3.669 1.3475 E, (Psi) 1.44 EG 4.156 E45 Ey (Psi) 1.66 E+5 Sy (Psi) 0.779 E+5 Oh 0.3 0.3 6, (Psi) 2.156 E-4 6, (Psi) 0.862 E-4 Rho, (1b sec?/in*) 0.523 E-5 | --1.424 E-5 * Material property for sandwich model: Face sheet =: ty = 0.028 in; & = 10 E+6 Psi; Ey = 4 E+6 Psi; 6, = 1.875 E¥6 Psi; and v, = 0.3 and xy xy Rho, = 1.9 E-4 Ib sec?/in*. Core: t, = 0.75; Gy, =3E+4 Psis 6), = 1.2 E+ Psi and Rho, = 1.14 E-5 Ib sec?/in*. c Table 2 Three-layered simply supported orthotropic sandwich plate: Central deflections and normal modes Model Central Normal frequency (Hz) Deflection| Mode-1 Mode-2 Mode-3— Mode-4 Model-1 0.125 1261.7 3317.7 | 4831.6 | 5877.0 Mode1-2 0.108 1331.0 | 2301.1 | 3889.5 | 4147.7 Model-3 0.122 1276.0 | 3348.0 | 4880.3 | 5871.9 2 at a a Bach Note: The theoretical value is 0.123 in. [5] The geometric material properties and model details are given in Table 1. FINITE ELDENT NEWS 1995 ISSUE NO.6 (DECEMBER) Page 33problem ofa reflector antenna... The reflector studied is a honeycomb sandwich parabolic dish panel stiffened by a ribbed structure. The back-up structure is also made of honeycomb sandwich construction. Both the constructions are of graphite/epoxy face-sheets with aluminium honeycomb core. A typical reflector con- figuration is shown in Figure 3. Shell elements are used to model the reflector surface. Expressions given by Equation (A1) are utilised to obtain the shell properties. The ribs are modelled by beam elements with the appropriate properties derived using the expressions given in Reference [6]. The finite element mesh used tothe analysis is shown in Figure 4. The temperature distribution forthe shell elements include the surface temperature and temperature gradients through the thickness of the shell elements and that of the beam isthe nodel point temperatures and gradients across the depth of the ribs. The results ofthe analysis are nodal point displacements. The maximum displacements of the reflector are given in Table 3-_ These values are compared with the displacements obtained using composite element idealization (7). The results using the equivalent shell idealization agree closely with that of composite element idealization Table 3. Thermal analysis of reflector antenna comparison of maximum displacements [6] S1.No. Model Description Displacements mm uy vy, u, 1 Isotropic model (Eq. A5) -0.339 | -0.409 | -0.088 2 orthotropic model (Eq. A1) | -0.343 | -0.409 | -0.088 3 | Composite model -0.343 | -0.409 | -0.088 c) Free vibration analysis of a spacecraft structure ‘The last example presented to illustrate the present models is a normal modal analysis of a typical spacecraft sructure (Figure 5). ‘The spacecraft consists of four vertical panels and two horizontal decks (including a payload deck) connected through shear frames and a central stiffened cylinder. The mass of various sub- tyatems and packages connected with each of the panels is mniformly distributed in the respective panels. The propellant and tankage mass is distributed in the reaction control system (RCS) deck placed inside the tylinder, An interface ring connecting the spacecraft, with the launch vehicle is placed at the Porton of the cylinder. 7 Figure 6 shows'a typical finite clement idealisation of the spacecraft. All the vertical panels, horizontal and Res decks ave of sandwich construction with aluminium-core sandwiched between aluminium face-sheets, All these panels are modelled as orthotropic shell elements and the corresponding properties are derived using Equation (Al). The interface ring and cylinder are modelled using simple shell elements. The shear frames and cylinder stiffeners are modelled as beam elements. A free vibration analysis of the structure is carried Table 4 Base fixed frequencies of a spacecraft structure | Wode No. | Frequency in Hz | orthotropic Sandwich | | Model (Eq. A?) idealization | 1 31.5 31.3 2 31.8 31.8 3 49.0 47.9 Note: Modes 1,2 (lateral modes) and mode 3 (longitudinal mode) are the global modes of the spacecraft. FINITE ELEMENT NEWS 1995 ISSUE NO.6 (DECEMBER) Page 34Figure 6 Finite element idealization of the spacecraft structure FINITE ELEMENT NEWS 1995 ISSUE NO.6 (DECO-ER) Page 35ut and the three important frequencies ofthe s/c are given in Table 4. The present results are compared with the earlier results obtained by modelling the panels using sandwich elements. There is a good agreement between these results. CONCLUSIONS Conventional shell elements are used to model honeycomb sandwich panels. The elemental properties of the Shell clement are derived by simulating sandwich behaviour for in-plane, bending and shear stiffnesses as isotropie or orthotropic shell model, The isotropic model is used for sandwich panels with isotropic or quasi-isotropic face-sheets. The orthotropic shell model is used for sandwich constructions with face-sheets composed of many layers of isotropic/orthotropic laminate, The models are validated by using them in simple problems of static and normal mode analyses. These formulations are also used for practical applications, pre az the analysis of antenna reflector and a spacecraft structure, Reference (2] gives a number of basic problems solved using these simplified models. ACKNOWLEDGMENT “This work is carted out as a part of structural analysis of subsystems of a spacecraft designed atid developed dn this entre, We thank Professor A.V. Patki, Deputy Director, ISAC, and Dr P'S. Nair, Group Director, Sreuctures Group, for their constant encouragement. We thank our organisation for providing us with the necessary facilities to carry out this work. REFERENCES 1 KS. Ramanath and K. Badari Narayana, “Modelling Honeycomb Sandwich Constructions with Shell Elements in Finite Element Analysis”, Doc.No. ISAC-TDP-01-03-94-08-05-03, 1994. 2, K_ Badari Narayana, K§.Ramanath and D.H. Bonde, “Modelling of Honeycomb Sandwich Panels with Shell Elements in Finite Element Analysis”, Jnl. of Spacecraft Technology, Vol.5, No.3, pp-33-41, 1995. S.W. Tsai, “Composite Deisign”, Think Composite, 4th Edn., 1988. 4, NISA:II Users’ Manual, Version 92-0, EMRC, Troy, USA, 1992. TTP. Khatua and Y.K. Cheung, “Bending and Vibration of Multi-Layer Sandwich Beams and Plates”, INME, Vol.6, pp. 11-24, 1973. 6 T-Paramasivam and John A. Pilla, “Bending Analysis of Composite Built-up Sections”, BRITEC-86, July 14-16, Boston, 1986. 1, KS. Ramanath, K Badari Narayana and D.H. Bonde, “Thermal Distorti Analysis of Antenna Reflector”, Presented at the 3rd MSC/NASTRAN Users’ Conference, Bangalore, India, December 1994 Fre ere er ccee cers or eeieene rele ceeseracel cece access aaa The MSCIARIES User Group will hold its eighth annual meeting on May 5-8, 1996. The meeting'will be held at the Holiday inn in Tewksbury, Massachusetts, USA. The MSC/ARIES User Group has also issued a Call for Papers for the meeting. The User Group is an independent, non-profit organisation of MSC/ARIES Users dirernettiennuseneinerenenenienioenneretecninaiesasmnnsssnnaanns nner ste eee ene S FINITE ELEMENT NEWS 1995 ISSUE ND.6 (DECEMBER) Page 36APPENDIX A ORTHOTROPIC MODEL If the sandwich facings are made of composite laminate or a number of layers of different isotropic materials, the effective engineering properties of a face-sheet (Ey4, Ey 61> and v,,) are obtained 12) from [A], [B] and [D] matrices using laminate theory [3]. The laminate properties and the out-of-plane shear modulii of the core (6,3 and 6,4) together with Equations (2) to (4) are used to derive the expressions for an orthotropic shell model. The resulting expressions are te = Sart(3) * (t, + te) EB, = Ey, (2 te / ty) Eg (2 te / t,) Gy = Gy (2 te / t,) Vey © “12. 6, = G3 (1.2 (t+ t/t td 4g (1-2 (tet te) / te te Gy, = Gog (1.2 (te + te)” / ty te) and Rho, = {2 ty Rhog + t, Rho.} / t, (at) Where Ey, Ey G,y and v,y are the in-plane properties and G,, and Gy, are the transverse shear xy properties of the resulting orthotropic shell model. ISOTROPIC MODEL If the face-sheets are of isotropic material, Equation (A1) can be farther simplified as shell modulus. E, and thickness: t, are the only two goveming parameters of the isotropic shell model. For this case, these two parameters can be derived by simulating different stiffness contributions of the element as discussed below. FINITE ELEMENT NEWS 1995 ISSUE NO.6 (DECEMBER) Page 57} Simulating only the In-plane Stiffness (assuming E, = Ey) at, (a2) Rho, = {2 ty Rhog + t, Rho. } / te ii) Simulating only the Bending Stiffness (assuming E, eT” 6 te (te ¥ ty) WED (a3) iii) Simulating both Bending and In-Plane Stifnesses (assuming v, = V¢) e = Sart(3) * (t+ te) a) EL = 2 Ep te/ te iv) Simulating both Bending and Shear Stiffnesses {assuming v, = vp and Gy ~£_/2( 14 vel} t, = Sqrt { (2-5 Ep ty te) 16 (1+ ve)? (a5) oer E, 6 Ee te (tt, + te) / te For all the above cases, the expression for Rho, given in Equation (A2) is equally valid. If one wants Fo nsider isotropic model for a sandwich with composite fecines, the values of Er and G, maybe approximated 8s = SqrtlEyy * Egg} or (Ey * Eg) 12 (86) = Sati yg * Spa} or (G43 * B23) / 2 ce cssamuvesstaueceaneesuanengesanawersennesnanennscsnancnns cans ee e027 Following an intensive development programme, WS ‘Atkins has launched ASAS-OPEN, which allows easic: integration of its well-known ASAS finite clement ‘analysis software with spreadsheets and databases ‘AS.AS-OPEN provides on-line tools to extract, reformat, input, Epon and display all information held by the user. ‘The toolkit provides engineers who have their own in-house software, with 2 flexible, easy-to" interface system. Currently, the toolkit is available for PCs, workstations, DEC VAX mult computers and supercomputers, Page 38 Wn & (TECIPER)