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Abstract
The problem of local instability of the compressed facing of a sandwich panel is
discussed in this paper. Proper estimation of wrinkling stress has become a challenging
issue because of a strong tendency to optimize technical parameters and costs. The aim of
the study is numerical and analytical analysis of bending of three-layer panels. Linear
constitutive equations and identical elasticity modules in tension and compression are
assumed. In practice, wrinkling stress depends on many factors, usually neglected in
analytical solutions, though observed in experiments. In this paper we use numerical
methods and hence we can allow for the loss of face adhesion or anisotropy of the core.
Created models are validated and calibrated by experimental results. The analyses are
carried out for various mechanical and geometrical parameters of the sandwich panel. The
influence of these parameters on structural response is studied. The range of applicability
of classical theoretical models is discussed basing on numerical examples. The study
presented in the paper was inspired by sandwich panels producers, with the aim to increase
safety and economy.
Key words: Sandwich panels, wrinkling stress, computational mechanics, local
effects.
1. Introduction
Sandwich panels are used in industry for many years. They are usually composed
of three layers: rigid, external faces and a flexible core. Important role in the analysis of the
structures plays the contact between core and faces, evolution of the core parameters
induced by creep and influence of thermal excitations.
Classical approach to the problem of sandwich panels was presented in [1,2]. The
simplified theoretical models discussed in these papers have been widely used in an
engineering practice. However, increasing industrial requirements enforce more precise and
reliable analysis. Therefore, this issue has focused much attention in the last years and
many papers went up, where modern FEM models were proposed [4, 8].
Apart from analytical and numerical solutions, real experiments still play
important role to find behavior of those structures. They are one of the bases of the
determination of the sandwich plate carrying capacity in EC standard [3]. Application of
the modern experimental methods to the analysis of sandwich panels was presented in [5, 6,
7].
Looking for minimum value of the force P we stipulate dP/da = 0 and thus arrive
at
1/ 3 (4)
2 4 B F 1
a .
f 1
Using (3) and (4), f1 and P can be expressed as:
f 1 21 / 4 B 1 / 4 K 3 / 4 , (5)
P 3 2 1 / 2 B1 / 2 K 1 / 2 . (6)
Introducing a function (or in the simplest case - a scalar) f2, which is scaling a
relation between the Young modulus Ec of the core, depth of the core D and stiffness of the
foundation k:
E (7)
k c f 22 ,
D
the wrinkling stress is finally obtained as
BF 1 E c (8)
P 3 2 f2
cr ,
t 2 t D
where t is the thickness of the compressed facing. Please note that the term of bending
stiffness BF1=EFIF1 contains the Young modulus of the facing material EF and the moment
of inertia of the facing IF1.
The key point is to find the form of f2. Generally, f2 may depends on various
geometrical and mechanical parameters. In the simplest case, this term is assumed as a
scalar, which is calibrated to comply with experimental results.
4. Numerical analysis
Numerical models were prepared in ABAQUS system environment. The span and
width of analyzed sandwich structure are L = 4.40 m and B = 0.50 m. The following depths
of the core were assumed D = 0.079 m, 0.099 m and 0.119 m. The width of supporting
plates was b = 0.10 m. Thickness of facings was equal to t = 0.4 mm, 0.5 mm or 0.6 mm.
tn otherwise
t s 1 G t s ,
t t 1 G t t .
The scalar damage variable G represents the overall damage in the material. The
terms with overbar are the stress components predicted by the elastic traction-separation
behavior for the current strains without damage. To describe the evolution of damage, an
effective displacement is introduced:
2 (12)
m n s2 t2 .
For linear softening, the damage variable G has the following form:
f max m0
G mmax m f
(13)
m 0 ,
m m
5. Comparison of results
The influence of mesh size on the numerical results was the first problem analyzed
in numerical simulations. Three examples of the panel with the parameters D = 0.119 m,
t = 0.5 mm, EC = 8 MPa and the mesh size of compressed facing 0.03 m, 0.02 m, 0.01 m
were analyzed. It occurred that for various sizes of FEM elements, wrinkling stresses were
different. It was presented in the Table 1.
Table 1 : The influence of the mesh size on the wrinkling stress
Above results indicate that the size of the mesh may highly influences numerical
solution. The mesh size should be considered in the context of wave length of wrinkled
facing. If the mesh is coarse and not appropriate, the wrinkling stresses are overestimated.
Evert and al. in [9] recommend the suitable mesh size about 1/8 of the length a, however
this requirement is difficult to fulfill because of huge number of FEM elements.
In the following examples the mesh size 0.02 m was used. The results received for
various geometrical and mechanical parameters are presented in the Table 2.
Table 2 : Wrinkling stress for various structure parameters
1 2 3 4 5 6
Example D [m] t [mm] Ec [kPa] Wrinkling stress σcr σcr / f2 [MPa]
[MPa] (FEM) (analytical
solution)
Ex. 1 0.119 0.50 8000 71.91 51.50
Ex. 2a 0.119 0.50 6000 60.41 44.56
Ex. 2b 0.119 0.50 4000 55.78 36.38
Ex. 3a 0.099 0.50 8000 71.25 56.41
Ex. 3b 0.099 0.40 8000 67.02 50.45
Ex. 3c 0.099 0.60 8000 85.99 61.79
Ex. 4 0.079 0.50 8000 86.09 63.15
In the examples 1, 3a, 3b, 3c and 4, the stresses (14) and (15) are equal to 152.06
MPa and 92.83 MPa, respectively. Furthermore, using (14) and (15) the same results would
be obtained in case of micro-profiled facing. It is because in these equations wrinkling
stress doesn't depend on facing stiffness. [11]
Our recently conducted experimental tests indicate that neither analytical nor
presented numerical model describe properly the phenomenon of the local instability of the
sandwich panel.
Figure 2: Local effects in bending of sandwich panel: normal stresses and wrinkles in
the steel upper facing in direction x
6. Concluding remarks
The numerical and analytical analysis as also laboratory tests proved that bending
of the sandwich panels and occurring local effects are a complex problem. Various
parameters have influence on the results, namely: geometrical values as panel depth and
facing thickness and material features of the core and facings. The presented examples
verify classical approach to the problem of wrinkling stress of the sandwich panel and
demonstrate that hitherto existing in engineering practice simplifications can lead to
considerable errors.
Proposed analytical approach express the wrinkling stress as a function of the most
important parameters of sandwich structure. In terms of quality, the analytical and
numerical solutions are in good agreement. In spite of this, the existing models should be
References
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