HONEYCOMB SANDWICH DESIGN TECHNOLOGY
MECHANICAL ENGG. (4TH YEAR)
HONEYCOMB SANDWICH DESIGN TECHNOLOGY
INTRODUCTION MATERIAL DESIGN 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 s depends on the
size of the . 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 s must ensure that all
potential failure modes are considered in their analysis. Strength
• Stiffness
buckling
• Shear crimping
Skin wrinkling
• Intra cell buckling
MANUFACTURE Basic Honeycomb Sandwich Production Methods Heated Press, generally used for the production of flat board
or simple preformed s. Vacuum Bag Processing, used for curved and complex form s. Matched Mould Processing, used generally for batch production of finished s
Heated Press
Vacuum Bag Processing
Matched Mould Processing
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. 5.Booster Capotage: Epoxy glass/non-metallic honeycomb. 6.Yoke: Epoxy carbon filament winding .
Aeronautical
1.Radar Transparent Radome: Epoxy or BMI Prepreg or RTM resins And woven preforms (socks). 3.Fuselage 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 s/honeycombs. 7.Accommodation Cabin Units: Lightweight sandwich s, 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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