Non-destructive evaluation of a composite honeycomb sandwich panel with in-plane waviness damage using ultrasonic guided waves
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Composite honeycomb sandwich structures (CHSS) are often manufactured using an autoclave co-cure process, which can introduce in-plane waviness (IW) damage due to fibre misalignment. Such fibre waviness, whether in-plane or out-of-plane, significantly weakens the strength of these structures. Therefore, developing reliable non-destructive evaluation (NDE) techniques is essential for detecting IW. This study presents an NDE technique utilising ultrasonic guided waves (GW) to identify IW damage in CHSS panels. A numerical model was created using COMSOL Multiphysics, where IW damage is simulated through curvilinear coordinate physics, followed by a time-dependent study of GW propagation. This model simulates local fibre orientation changes due to IW damage, enhancing our understanding of GW interaction with IW. Experimental investigations are performed using contact-type transducers to corroborate the numerical observations. The presence of in-plane waviness causes a reduction in the group velocity of the A0 mode, a characteristic that can be exploited for detecting in-plane fibre waviness in CHSS. Also, parametric studies were performed to examine the effects of IW severity (aspect ratio) and increased IW area on GW characteristics. Finally, a technique for IW damage localisation is demonstrated using a convex hull algorithm based on changes in correlation coefficient values of the A0 mode.Keywords:
Waviness
Honeycomb
Honeycomb structure
Sandwich panel
Many industries use honeycomb composites extensively, including the aerospace, automotive, furniture, packaging, and logistic sectors. A specific type of composite material known as a honeycomb sandwich is created by joining two stiff but thin skins to a lightweight but dense core. The sandwich composite strong bending stiffness and overall low density are made possible by the core material's larger thickness despite its typical low strength. The Sandwich panel's strength is influenced by the panel's size, the material chosen for the faceplates, and the density of the honeycomb cells inside. This study investigates the critical buckling stresses numerically for different core densities and materials of honeycomb composite panels. In this investigation, the faceplate material is constant while the core material varies. It can be observed that when core density increases, so do the specimens buckling strength. Analytical investigations on honeycomb sandwich panels are used to examine the behavior of sinusoidal and hexagonal honeycomb sandwich panels under impact loads. LS-DYNA was used for analysis, and HYPER-MESH was used for modeling.
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