Energy absorption of foam-filled corrugated core sandwich panels under quasi-static loading
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The present paper tries to introduce the effect of foam-filled on a type of trapezoidal corrugated core and their structures derived from the related previous studies. The main purpose of this work is to present a novel geometry of trapezoidal cores, and their configurations are inspired by the earlier works. These absorbers have been proposed to raise the specific energy absorption (SEA) while declining the initial peak crushing force. Therefore, five corrugated core sandwich panels have been tested under quasi-static axial compressive load experimentally and then simulated by ABAQUS software. The accuracy of the numerical simulations is validated by comparing the numerical results with the corresponding experimental data. Besides, some other simulations have been carried out to investigate the effect of foam density, core type, and thickness in more detail. The comparison results show that the SEA rate of bi-core sandwich panels which has not been filled by foam is better than the single trapezoidal core sandwich panels, and this rate is roughly around 70%. The best performance is relevant to the pure foam core without any trapezoidal core structure and the next item is the single foam-filled corrugated core and the lowest performance among them is related to the bi-core corrugated core foam-filled.Keywords:
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Aluminium foam sandwich
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The design of lightweight sandwich structures with high specific strength and energy absorption capability is valuable for weight sensitive applications. A novel all-metallic foam-filled Y-shape cored sandwich panel was designed and fabricated by using aluminum foam as filling material to prevent core member buckling. Experimental and numerical investigation of out-of-plane compressive loading was carried out on aluminum foam-filled Y-shape sandwich panels to study their compressive properties as well as on empty panels for comparison. The results show that due to aluminum foam filling, the specific structural stiffness, strength, and energy absorption of the Y-shape cored sandwich panel increased noticeably. For the foam-filled panel, aluminum foam can supply sufficient lateral support to the corrugated core and vertical leg of the Y-shaped core and causes a much more complicated deformation mode, which cannot occur in the empty panel. The complicated deformation mode leads to an obvious coupling effect, with the stress–strain curve of the foam-filled panel much higher than those of the empty panel and aluminum foam, which were tested separately. Metallic foam filling is an effective method to increase the specific strength and energy absorption of sandwich structures with lattice cores, making it competitive in load carrying and energy absorption applications.
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The dynamic response of honeycomb sandwich panels under aluminum foam projectile impact was investigated. The different configurations of panels were tested, and deformation/failure modes were obtained. Corresponding numerical simulations were also presented to investigate the energy absorption and deformation mechanism of sandwich panels. Results showed that the deformation/failure modes of sandwich panels were sensitive to the impact velocity and density of aluminum foam. When the panel was impacted by the aluminum foam projectile with the back mass of nylon, the “accelerating impact” stage can be produced and may lead to further compression and damage of the sandwich structures.
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A new type of composite structure with a metal foam is reinforced by the metal corrugated core, called metal-foam-filled sandwich panel with a corrugated or V-frame core, is modelled, simulated, and studied in this article. All types of samples with different relative densities of the foam are tested and analyzed under the drop hammer load. The sandwich panel included two aluminium face-sheet, aluminium foams, and aluminium corrugated or V-frame cores. Mathematical and finite element models were also been developed to predict the effects of the relative density of the foam and other geometric parameters on the energy absorption. In addition, the mathematical equations based on a mass-spring-damper problem with two degree-of-freedom (DOF) were derived to evaluate the kinetic and kinematic parameters of the sandwich panel, such as velocity, acceleration, contact force, and energy absorption. It was found that the models could represent the dynamic response of the sandwich panel. Finally, in order to improve the performance of the sandwich panel, an optimization method was utilized for finding the optimum parameters which play an important role.
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The dynamic response, blast resistance and energy absorption capability of clamped square sandwich panels comparing two aluminum alloy face-sheets and a layered gradient metallic foam core, subjected to air-blast loading, were studied numerically in this paper. Graded sandwich specimens with six different core-layer arrangements and three different face-sheet thickness arrangements were examined, respectively, compared to those ungraded sandwich panels with an equivalent nominally mass. Simulation results show that the blast resistance and energy absorption capability of sandwich panels with layered gradient metallic foam cores could be improved by optimizing the arrangements of different density metallic foam core-layers, and the graded sandwich panel with low-middle-high density core configuration has the best blast resistance capability. The blast resistance of graded sandwich panels with different thickness arrangements for top and bottom face-sheets has no obvious change tendency, since the normal stress distributions of their sandwich cross sections are controlled simultaneously by face-sheets and gradient foam core.
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In this study, a closed-cell aluminum foam was filled into the interspaces of a sandwich panel with corrugated cores to form a composite structure. The novel structure is expected to have enhanced foam-filled cores with high specific strength and energy absorption capacity. An out-of-plane compressive load under low-velocity impact was experimentally and numerically carried out on both the empty and foam-filled sandwich panels as well as on the aluminum foam. It is found that the empty corrugated sandwich panel has poor energy absorption capacity due to the core member buckling compared to that of the aluminum foam. However, by the filling of the aluminum foam, the impact load resistance of the corrugated panel was increased dramatically. The loading-time response of the foam-filled panel performs a plateau region like the aluminum foam, which has been proved to be an excellent energy absorption material. Numerical results demonstrated that the aluminum foam filling can decrease the corrugated core member defects sensitivity and increase its stability dramatically. The plastic energy dissipation of the core member for the foam-filled panel is much higher than that of the empty one due to the reduced buckling wavelength caused by the aluminum foam filling.
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The sandwich structures with aluminum foam core and metal surfaces have widespread use in the absorption of energy, because they are light weighted with high performance in dissipating energy. The cell structure of the foam core is subjected to plastic deformation in the constant compression level that absorbs a lot of kinetic energy before destruction of the structure. In this research, experimental tests of low-velocity impact on the sandwich structure by a drop machine are simulated by LS-DYNA software. Numerical results are obtained for different velocities and weights of projectile on samples of aluminum foam core sandwich panels with relative density (the ratio of the density of aluminum foam to the density of solid aluminum) of 18, 23, and 27. The results are compared with experimental results which reveal a good conformity. As well, from the numerical simulations, the effect of weight, velocity and energy of the projectile and the density of the foam core on the global deformation and energy loss rate of projectile have been studied.
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Hammer
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In this study, two different foam core aluminum face sheets sandwich panels were developed.The core materials were selected as expanded polypropylene (EPP) and extruded polystyrene (XPS) foams.Two aluminum face sheets and foam cores were combined with flexible epoxy-based adhesives, under 20 N static compression load.The average density of the produced sandwich panels was 0.39 g/cm 3 for EPP foam core sandwich and 0.33 g/cm 3 for XPS foam core sandwich panel.Produced specimens were subjected 3-point bending experiments under impact loading.Damage behavior of the sandwiches was observed using post-mortem pictures.The results show that the produced sandwiches damaged perfectly plastic deformations with face sheets and core.There was not any adhesive and cohesive failure in the core and face sheets interfaces.
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