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Honeycomb Sandwich Design Technology
Honeycomb Sandwich Design Technology
(4TH YEAR)
MANUFACTURE
APPLICATIONS
INTRODUCTION
Honeycomb structures are natural or man-made structures .
The cells are often columnar and hexagonal in shape. The strength of laminated or sandwich panels depends on the
size of the panel. The material takes its name from its visual resemblance to a bee's honeycomb - a hexagonal sheet structure.
The core resists the shear loads, increases the stiffness of the structure.
MATERIAL
The following criteria should be considered in the routine
selection of core, facing, and adhesive. In Structural Considerations such as strength, stiffness, adhesive performance, economical consideration. In Environmental Considerations such as temperature, Heat Transfer, Flammability, Moisture/Humidity. In Mechanical Performance we consider cell size, cell shape, skin materials, adhesive materials. Generally we use material for honeycomb core is graphite polyimide, aluminium, glass polyimide, polyurethane foam.
DESIGN
LOADS: The applied load creates a bending moment which is a maximum at the fixed end, and a shear force along the length of the beam.
DEFLECTIONS: The bending deflection is dependent on the relative tensile and compressive module of the skin materials. The shear deflection is dependent on the shear modulus of the core. Total Deflection = Bending Deflection + Shear Deflection
FAILURE MODES
Designers of sandwich panels must ensure that all
Stiffness
Panel buckling
Shear crimping
Skin wrinkling
MANUFACTURE
Basic Honeycomb Sandwich Production Methods
Heated Press, generally used for the production of flat board
or simple preformed panels. Vacuum Bag Processing, used for curved and complex form panels. Matched Mould Processing, used generally for batch production of finished panels
Heated Press
APPLICATIONS
Aerospace
Aeronautical Naval Automobile Etc.
Aerospace
1. Fairings: Carbon prepregs. Aluminium honeycomb and adhesives. 2.External Payload Carrier Assembly(SPELTRA): Carbon prepregs, aluminium honeycombs and adhesives. 3.EPS Ring: Epoxy/carbon prepreg or RTM.
Aeronautical
1.Radar Transparent Radome: Epoxy or BMI Prepreg or RTM resins And woven preforms (socks). 3.Fuselage Panel Sections: Epoxy carbon Prepregs. Non-metallic Honeycomb core and Redux adhesives. 10.Flying Control Surfaces: Epoxy carbon and glass Prepregs. Honeycomb Core material and Redux adhesives.
Naval
2.Hull Skin Structure: Prepregs, engineered fabrics, honeycombs. 4.Suspended Ceilings: Lightweight sandwich panels/honeycombs. 7.Accommodation Cabin Units: Lightweight sandwich panels, Prepregs and honeycombs. 9.Weather Shield: Prepregs and honeycombs. 10.Communications Equipment: Prepregs and honeycombs.
Automobile
Chassis of Ferrari F50:
Nomex honeycomb core, sandwich construction. Chassis of DOME F150: Carbon fibre/ aluminium honeycomb sandwich monocoque. Bluebird-Proteus CN7: Advanced aluminum honeycomb sandwich of immense strength.
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