COMPARATIVE STATIC ANALYSIS FOR EFFECT OF LINEAR,

TRIANGULAR STRUCTURAL CORE PLY MATERIALS

P.Ganesh kumar1, R.Sivasubramanian2, I.Jenish3
1
PG- student, Infant Jesus College of Engineering and Technology, Kellavallanadu, Thoothukudi
E-mail: ganeshkumar08@hotmail.com
2Assistant Professor, Infant Jesus College of Engineering and Technology, Keelavallanadu, Thoothukudi.
3
Assistant Professor, Infant Jesus College of Engineering and Technology, Keelavallanadu, Thoothukudi

II. PERIODIC CELLULAR MATERIALS TOPOLOGY

Abstract: A Comparative static analysis for various
structural materials is done by using ANSYS for an alloy of Periodic cellular metals (PCM) are highly
Aluminium AA3003, AA5051 combination with varying core porous structures with 20% or less of their interior
structure. Ply materials are majorly used as supporting volume occupied by metal. Some, such as hexagonal
structure for various applications like chairs, tables, honeycomb, are widely used to enable the design of
platform used for inspection in boilers and vertical and light weight sandwich panel structures, for creating
horizontal ply materials lead to fracture (or) failure often.
unidirectional fluid flows, for absorbing the energy
So, the hollow rectangular core is replaced with linear, of impacts, to impede thermal transport across the
triangular and combination of both to increase the strength.
faces of sandwich panels and for acoustic damping.
An experimental static analysis is done for columns with Corrugated (prismatic) metals are also a form of
core structure like triangular, linear, and combined linearperiodic cellular metal structure. They have their
and triangular is done and the results are tabulated. And voids arranged in one direction enabling fluid flow in
virtual analysis is done on the same structures by using one direction but not the others. They are widely
analysis software ANSYS. The virtual results thus obtained used in building and ship construction and for cross
are compared with the experimental results and it flow is heat exchangers. More recently, significant
verified. Through the verified results the structure with interest has emerged in lattice structures which have
higher strength can be suggested for ply material 3-D to interconnected void spaces well suited for
withstand loads. allowing fluid flow through them. The structures of
interest here are composed of repeating unit cells
Keywords: Structure, fracture, failure, core, static with cell diameters that range from tens of
analysis, virtual analysis. micrometers to tens of millimetres. 
INTRODUCTION
I. HONEYCOMB STRUCTURES:
Sandwich composites have high strength to Honeycomb structures are composed of plates or
weight ratio (which results in increase of payload, sheets that form the edges of unit cells. These can be
provides greater range and reduced fuel consumption), arranged to create triangular, square, hexagonal or
extended operational life, lower maintenance cost (due related shapes. Their unit cells are repeated in two
to less corrosion, and resistance to marine boring dimensions to create a cellular solid. One of the
organisms). Macro mechanical analysis with manufacturing methods used to create hexagonal
experimental validation is used to construct parametric honeycomb leads to a doubling in wall thickness of
values and create model. Simulation results have been every other web which results in anisotropic mechanical
completed to prove effect of various structural cores to behaviour. All honeycombs are closed cell structures.
improve stiffness and strength properties of Composite
sandwich panels. The problem considered is consisting III. FAILURES OF PLY MATERIALS
of the following objectives: the mechanical properties Failure mode of sandwich panels are been
of the sandwich structure (tensile strength, elongation at classified regarding to its materials and applying load.
break, maximum stress at break) are subjected to Depends upon that it is classified into two types they
maximization and the cost of the materials subjected to are
minimization. (i) Skin Failure.
 (ii) Core Failure.
A. SKIN FAILURE:
This section gives an expression for the
maximum stress in the skins. This can be used to predict
beam failure due to the skin failure modes of face
yielding, intra-cell dimpling or face wrinkling, as
illustrated in below Fig
is then given by
Respectively, so above equation becomes
B. CORE FAILURE:
Honeycomb sandwich structures loaded in
bending can fail due to core failure. Pertinent failure
modes are shear failure or indentation by local
crushing in the vicinity of the loads, as illustrated in
below Figure
IV. BEAM THEORY FOR PLY MATERIALS
Consider a simply supported sandwich beam
of span (L) and width (b) loaded in 3-point bending
with a central load (W) per unit width as illustrated
in below Figure The skins each have thickness (t)
and are separated by a thick layer of honeycomb core
of thickness (c).
The flexural rigidity (D) of the sandwich beam
where (d) is the distance between the midplanes
of the upper and bottom skins (Efx)and (Ecx)are the in-
plane Young’s moduli of the skin and core
respectively for loading in the x direction (along the
axis of the beam) Subscripts ‘f’ and ‘c’ denote the face
material and the honeycomb core respectively.
Where (I) is second moment of area of the
cross-section of the sandwich beam. With 3-point
bending the maximum bending moment (M) is at the
mid-span and the corresponding maximum stress
(σfx)in the skins is given by
However, the above theoretical model neglects
the effect of shear deflection in the core, which
becomes significant for low density cores. Inclusion of
this effect also allows a prediction of observed
differences in beam strength for different orientations
of the honeycomb ribbon. For the above reasons we
follow the suggestion for the maximum axial stresses
in the faces

(Gcxz ) is the out of plane shear modulus of the
core, (I) is the second moment of area of the sandwich
with respect to its neutral axis.
A. SKIN FAILURE:
Face yielding:
Failure occurs in the top skin due to face
yielding when the axial stress in either of the skins
reaches the in-plane strength (σfY)of the face material
for loading along the beam axis.
Where (υcxz) is the out of plane Poisson’s ratio
and E3 the out of plane Young’s modulus of the
honeycomb core
B. CORE FAILURE:
Core shear:
Assuming simple beam behaviour, the shear
stress varies through the face and core in a parabolic
way under 3-point bending. If the faces are much stiffer
and thinner than the core, the shear stress can be taken
as linear through the face and constant in the core.
Neglecting the contribution from the skins, the mean
shear stress in the core is given by

It is assumed that the skin behaves in a brittle

manner. With a symmetrical beam the stress is the Assuming brittle behavior, failure occurs when
same in the tension and compression faces. For the applied shear stress (τxz) equals the shear strength
composite face materials the compressive face is (τcs)of the honeycomb core in this direction.
generally the critical one.
Intra cell dimpling:
A sandwich with a honeycomb core may fail by
buckling of the face where it is unsupported by the Low density Nomex cores are particular
walls of the honeycomb. Simple elastic plate buckling susceptible to this failure mode. Due to the anisotropy
theory can be used to derive an expression for the in- of the honeycomb structure the shear strength of the
plane stress (σfi) in the skins at which intra-cell bucklingcore depends on the loading direction.
occurs as Local indentation:
Failure of sandwich panels in 3-point bending
can occur at the load point due to local indentation.
Failure is due to core crushing under the indenter. The
bending stiffness of the skin and the core stiffness
Face wrinkling: determine the degree to which the load is spread out at
Face wrinkling is a buckling mode of the skin the point of application. It is important here to mention
with a wavelength greater than the cell width of the the main failure characteristic by which indentation
honeycomb. Buckling may occur either in towards the differs from skin wrinkling. In indentation the top skin
core or outwards, depending on the stiffness of the core defects after failure with a wavelength of the same scale
in compression and the adhesive strength. In practice, as the indenter-top skin contact length, whereas in skin
with 3-point bending, inward wrinkling of the top skin wrinkling the deflection of the top skin after failure
occurs in the vicinity of the central load. By modeling exhibits wavelengths that are larger than the contact
the skin as a plate on an elastic foundation, gives the length between the indenter and the top skin.
critical compressive stress (σfw) that results in wrinkling Indentation failure has not been adequately
of the top skin as modeled for honeycomb sandwich panels. To include
this important failure mechanism, we use a simple
empirical approach used in handbooks on sandwich
panel construction . In more accurate model will be
presented for indentation failure prediction. Here we
assume that we know the length of contact (δ) between
the central roller and the top skin. It is further assumed
that the load is transferred uniformly to the core over (iii) Failure in the core will not be governed
this contact length, so that the out of plane compressive solely by the compressive stress in the
stress (σzz) in the core is given by core but will also be influenced by the
local shear stress.
PROPERTI AA3003 AA5052 V.LOAD CONSIDERATION
ES
Category/Cla Aluminum Aluminum
ss alloy/Wro alloy/Wro Demo table was taken into the consideration.
Composition Al-98.6%, Al- 97.2%,
The demo table was generally having AA6065 solid.
(Weight) Mn- 1.2%, Mg-2.5%,
That will give inconvenience for the inspection and
Cu-0.12% Cr- 0.25%
MECHANICAL required special attachment for fixing engine for
Density demoing and inspecting. It is not able to make
(×1000 2.73 2.68 additional attachments for inspecting the entire engine.
Poisson’s 0.33 0.33 So, by using light weight table will help to rectify above
ratio limitations. For such cases one of the best applicable
Elastic medium is make a light weight and capable of the all
Modulus 70-80 70-80 model engine load. Through that way the demo table
(GPa) will be capable for additional attachments and make the
Tensile table as flexible to make more convenience for
Strength 130 230 inspection and demoing. For this application the entire
(MPa) model of an engine of a company was considered. From
Yield that maximum applicable load was 3000N.
Strength 125 195
(MPa)
Elongation 10 12
(%)
Hardness
(HB500) 35 60
Shear
strength 83 140
(MPa)
Fatigue
strength 55 115 VI.PROJECT MATERIALS FOR CONSIDERATION
(MPa)
TABLE I
MATERIAL PROPERTIES

This length derives from the assumption that the
skins are ‘transparent’ enough to equate the contact
length with the length of initial damage in the top skin
core interface
The above approach is deficient in three respects
(i) The contact area must be estimated in
some way in the experiments.
(ii) Load transfer from the roller to the core
is over simplified; this will depend on
the relative skin and core stiffness’s.
VII. VISUAL ANALYSIS
A. LINEAR CORE PLY MATERIAL:
Basic sandwich panel was had three
terminologies named as top face plate, core and bottom
face plate. In all type core plates are placed in form of
various structures. In here linear and triangular core are
been considered. For the linear the core material was
perpendicular (900) to the axis of face plate. In here the
core height was varied from minimum to maximum
ranges (40,60 and 80mm).
 Fig.1 Displacement result for core height (C = 40mm)
Fig.4 Displacement result for core height (C = 40mm)

Fig.2 Displacement result for core height

(C = 60mm)
Fig.5 Displacement result for core height (C = 60mm)

Fig.3 Displacement result for core height (C = 80mm)

B. TRIANGULAR CORE PLY MATERIALS: Fig.6
For the triangular the core material was Displacement result for core height (C = 80mm)
0
perpendicular (60 ) to the axis of face plate. In here C.COMBINED STRUCTURAL CORE PLY
the core height was varied from minimum to MATERIALS:
maximum ranges (40,60 and 80mm). For the combined structural core ply material
was having combination of both linear and triangular
core structures. In here the core height was varied from
minimum to maximum ranges (40,60 and 80mm).
 Comparing the above three various core heights
with various structures (linear and triangular). The
result was given as per below charts on
displacement values of linear, triangular and
combined structural core ply materials
60

50

LINEAR (40)
40 TRIANGULAR (40)
COMBINED (40)
LINEAR (60)
30
TRIANGULAR (60)
COMBINED (60)
20 LINEAR (80)
Fig.7 Displacement result for core height (C = TRIANGULAR (80)

40mm) 10
COMBINED (80)

0
1 2 3 4 5

IX. CONCLUSIONS
Optimal design of the light-weight sandwich
panel has been performed. Different combinations of
the core structure and layer thicknesses are considered.
The study involves virtual investigation and numerical
simulation for determining mechanical properties of
the layer materials of the sandwich structure. It can be
concluded that:
Fig.8 Displacement result for core height (C = (i) The solution appears more sensitive with
60mm) respect to core material selection than core layer
thickness (it was assumed that the total
dimensions on the sandwich structure remains
unchanged, i. e. core thickness and structure can
varied);
(ii) The use of certain expensive core materials
leads to sudden increase in cost, but does not
provide significant improvement of the
mechanical properties; thus in most of cases use
of such core materials is not reasonable

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