Low Velocity Impact on Foam Core Sandwich Panels

Sandwich structures are a special type of composites that include a middle layer of a low elastic modulus material, called the core. This layer is sandwiched between two sheets of high elastic modulus material, called the face sheets. This configuration of materials provides a high stiffness to weig

Project Title

Low Velocity Impact on Foam Core Sandwich Panels

Project Area of Specialization

Mechanical Engineering

Project Summary

Sandwich structures are a special type of composites that include a middle layer of a low elastic modulus material, called the core. This layer is sandwiched between two sheets of high elastic modulus material, called the face sheets. This configuration of materials provides a high stiffness to weight ratio and strength to weight ratio. Unfortunately, sandwich panels are prone to damage when subjected to low-velocity impact. Hence, it is important to study a sandwich panel with a low-velocity impact to evaluate and optimize its performance. Examples of Low-velocity impact are bird strike, hailstone, tool drops, debris is thrown up from runways, etc. Experimentally, the panel is made from rigid polyurethane foam core and aluminum face sheets. Initially, an analytical model will be developed on the sandwich panel with a low-velocity impact and then verified through experiments and Finite Element (FE) analysis in ABAQUS software.

Project Objectives

• To study the effect of low-velocity impact on foam core sandwich panel analytically, experimentally, and through FE analysis.

• To perform the damage evaluation and find penetration depth caused by the impactor.

• To find the sandwich construction that provides an efficient solution to increased bending stiffness without a significant increase in structural weight.

• To incorporate the new optimized sandwich panel configuration in the solution of impact scenarios faced by aircrafts.

Project Implementation Method

• Literature review thoroughly to understand the basic theory and the way forward

• Analytical modeling of sandwich panel for low-velocity impact.

• Simulating the sandwich panel model in Abaqus and obtain indentation and perforation results for low-velocity impact scenario.

• Preparation of core foams with varying densities (at least three different densities).

• Variation in face-sheets thickness and configuration.

• Based on the variations as discussed above, sandwich panel samples will be prepared. 

• Tensile, compression and, if possible, hydrostatic behavior of foam will be carried out experimentally.

• To study the effect of varying densities on impact response of sandwich panels under high-speed loading using the gas gun facility, (It will be carried out experimentally if and only if the said facility is available))

• 3-point bend test will be used to find out the flexural resistance.

• The experimental data will be used in Abaqus (or any other FE packages) to simulate loading responses (possible using crushable foam material model).

• Writing of report.

Benefits of the Project

Since the sandwich panels provide very high stiffness to weight ratios, the scope of their applications is immense. Following are some of the major industries that are utilizing the potential that sandwich panels hold:

• Aerospace Industries:

Almost all modern aerospace vehicles especially commercial aircrafts have their body parts made from sandwich panels. This is because they significantly remove the weight penalty that conventional materials e.g., metals add to the aerodynamics of the aircraft. The fuselage of commercial aircrafts is being developed that are made from sandwich panels. This reduces the bodyweight of the aircraft and hence improves the fuel consumption without any loss to the structural strength.

• Space Applications:

The outer space vehicles such as rovers have bodies made from sandwich panels due to excellent insulation properties combined with structural strength and stiffness in the harsh conditions in space.

• Construction Industries: 

Heavy construction elements are being replaced by sandwich panels that provide the same load-bearing capacities and strengths. Sandwich panel beams, plates and shells are now used in constructions that provide optimized bending, shear and buckling strengths.

• Cold Storages in Agriculture:

Since the sandwich panels have a foam core, they are now being used as cold storage for agricultural industries. Crop yields are stored in compartments made from sandwich panels that primarily keep the goods protected from heat and also provide strength to the container for safe and efficient transportation.

Technical Details of Final Deliverable

Sandwich panel will be constructed using ductile face sheets and expanded Polyurethane foam as its core. Impact testing of the samples will be performed, along with the tensile, compression and 3-point test. The experimental results will then be compared with simulations to further validate the results.

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Manufacturing

Other Industries

Education , Transportation , Security

Core Technology

Others

Other Technologies

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and Production

Required Resources

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