Simulation of the forming process for curved composite sandwich panels

Chen, S.; McGregor, O.P.L.; Endruweit, A.; Harper, L.T.; Warrior, N.A.

doi:10.1007/s12289-019-01520-4

Cited by 10 publications

(5 citation statements)

References 24 publications

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“…First following 1306 (2024) 012002 IOP Publishing doi:10.1088/1757-899X/1306/1/012002 9 the theory presented in [13], known as the geometric and physical properties of the HC panel, the mechanical properties in the three directions of an equivalent orthotropic material were computed. Therefore, it was possible to move from a complex geometry in the micro-scale to a macro-scale material with equivalent properties [14].…”

Section: Honeycomb Roofsmentioning

confidence: 99%

Structural behaviour of single-deck floating roof tanks subject to seismic loading

Chiappelloni,

Belardi,

Serraino

et al. 2024

IOP Conf. Ser.: Mater. Sci. Eng.

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During a seismic event, fluid storage tanks are subject to sloshing phenomena; their effect on the structural components of the tanks is one of the main aspects to be considered during the design. The movement in successive modal forms of the roof-fluid system determined by the earthquake can cause severe damage to both the containment shell and the floating roof. The fluid-structure interaction imposes extremely complex out-of-plane deformation fields, mainly in the presence of floating roofs with lower flexible resistance. Such deformations can cause severe structural damage and subsequent catastrophic events such as those experienced in the past in Japan and Turkey. In fact, recently recorded earthquakes in Japan and Turkey, characterized by oscillation periods between 3 and 8 sec (long-period ground motion), compatible with the natural first and second slosh frequencies of the fluid-structure system, led to conspicuous problems of instability failure with the consequent sinking of the floating roof. These events dictated a new starting point for the research into the seismic behaviour of roof-fluid-tank systems.

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Section: Honeycomb Roofsmentioning

confidence: 99%

Structural behaviour of single-deck floating roof tanks subject to seismic loading

Chiappelloni,

Belardi,

Serraino

et al. 2024

IOP Conf. Ser.: Mater. Sci. Eng.

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“…Recently, in high-volume production application, such as lightweight automotive interiors, a reduction in production time is required to manufacture sandwich structures compatible with market demands. For this purpose, first studies on core crushing are present in scientific literature [11,12]. Forming behavior of curved sandwich plates differ from that observed in monolithic sheet material and in composite panels due to the presence of the core material, which affects the overall deformation of the sandwich plate and the occurrence of surface defects [12].…”

Section: Introductionmentioning

confidence: 99%

“…Typical issues observed during the forming process are surface waviness, local buckling, fracture of the skins as well as crushing of the core structure, and they were ascribed as the main factors limiting the formability of thin sandwich panels [11][12][13][14][15]. Optimization of the core design, so that it can provide sufficient resistance against skin buckling and core cell collapsing, demonstrated to be able to mitigate these defects and, therefore, plastic forming method could be used to produce complex shaped panels from flat sandwich plates [12].…”

Section: Introductionmentioning

confidence: 99%

“…In this context, development of numerical simulation techniques for the sandwich forming process able to predict the forming behaviors of core and skins and the forming-induced defects would be helpful. In very recent works, Cai et al [12] and Chen et al [11] proposed finite element models and analytical models to determine the main failure factors in plastic forming of curved sandwich panels. The first authors investigated the multi-point forming of sandwich structures having polyurethane eggbox-like core and aluminum face sheets.…”

Section: Introductionmentioning

confidence: 99%

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Crush core forming: An innovative technology to manufacture structural sandwich parts with variable thickness

Sorrentino

2023

Materials Research Proceedings

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Abstract. Sandwich structures, constituted in honeycomb core and skin in composite material, are usually employed to produce parts having a constant thickness or simple shape. Indeed, sandwich components with complex shapes, curvature or varying thickness are costly to manufacture due to the preliminary machining operations required on the core prior the molding process. A novel approach to manufacture complex sandwich structures, knows as Crush Core Forming (CCF) process, consisting in press-forming simultaneously the core material and the skins into the shape is under study. Such a method is potentially able to increase the production rate and lowering the overall costs. The present work aims to develop an experimental route to produce sandwich panels by means of CCF process and build a FE model of the forming process and validate it against the experimental studies. Experimental study was conducted to derive the fundamental parameters and properties for core and skins to be added in the FEM model of the CCF process. After, the numerical model was implemented to simulate the forming of the core and skins. Finally, a laboratory scale sandwich part was produced to validate the model outputs and assessing the reliability of the proposed approach.

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“…When a full sandwich structure (including the skins and the core) is thermoformed in one single step, cycle time can be significantly reduced [18–20]. Thermoforming with honeycombs could cause severe cell collapse [25,26] and thus reduction in strength. Additionally, honeycombs generally have limitations relating to proper bonding and moisture accumulation.…”

Section: Introductionmentioning

confidence: 99%

A review on manufacture of polymeric foam cores for sandwich structures of complex shape in automotive applications

Chen

Das

2021

Jnl of Sandwich Structures & Materials

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In this work, polymeric foam thermoforming, foam injection moulding, bead foaming and film foaming were reviewed in an effort to explore feasible processes to manufacture sandwich structures of complex geometry for automotive applications. Injection moulded foams generally suffer from high density, poor cell morphologies and unnecessary skin layers. Foamable films currently available are pressure-induced. In order for foamable films to produce foam, high uniformly-distributed pressure needs to be applied, which makes it difficult to manufacture foam parts of three-dimensional complex geometry with foamable films. The majority of commercial high-performance foam cores can be thermoformed. Ideally, thermoformed foam cores would have good mechanical properties if high-performance foam sheets are used. However, the mechanical properties of foams might be reduced during the process of thermoforming, especially around corners. Bead foaming offers a high level of freedom in foam geometry to be moulded, and inserts can be integrated into foam cores during the process of moulding. Moreover, foam cores with high density in high stressed areas and low density in low stressed areas can be manufactured with foam beads of different densities. However, due to nonhomogeneous degree of fusion and weak bonds and voids between beads, bead foams generally show mechanical properties lower than their block counterpart. Relatively speaking, thermoforming with high-performance foam sheets and moulding with high-performance foam beads hold great potentials for mass production of sandwich cores of complex geometry for automotive applications. However, further investigation on the mechanical properties of thermoformed foams and high-performance bead foams is still in need to confirm their suitability.

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Simulation of the forming process for curved composite sandwich panels

Cited by 10 publications

References 24 publications

Structural behaviour of single-deck floating roof tanks subject to seismic loading

Structural behaviour of single-deck floating roof tanks subject to seismic loading

Crush core forming: An innovative technology to manufacture structural sandwich parts with variable thickness

A review on manufacture of polymeric foam cores for sandwich structures of complex shape in automotive applications

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