Deformation control technology for honeycomb during the manufacture of large curvature honeycomb sandwich structures

doi:10.19936/j.cnki.2096-8000.20221128.032

Abstract

Abstract: To prevent severe tensile and extrusion deformation between the honeycomb cores due to bending during the manufacture of large curvature honeycomb sandwich structures and to ensure the excellent mechanical properties of honeycomb sandwich structures, the honeycomb deformation is governed by means of grooving. Bending tests were designed for honeycombs of different thicknesses and widths at different bending radii, and a method was proposed to evaluate the deformation of honeycomb cores by extracting the upper surface contours of the honeycombs after bending. The effects of bending radius and thickness on the deformation of honeycombs were investigated. Based on the proposed honeycomb grooving deformation control method, the grooving parameters of a honeycomb sandwich fairing part are designed and verified. The results show that the deformation of honeycomb increases with the increase of bending radius and decreases with the increase of thickness; the grooving spacing can be linearly fitted with the bending radius and honeycomb thickness; after the grooved honeycomb sandwich fairing part is bent, the maximum spacing of the grooves is less than 1 mm after bending, which meets the manufacturing accuracy requirements of the part.

Key words: large curvature, honeycomb sandwich structures, bending deformation, deformation control, composites

CLC Number:

TB332

LIU Qi, CHENG Yanna, XU Xiaowei, WANG Xiaokai, HAN Qiangru, ZHAO Zhiyong. Deformation control technology for honeycomb during the manufacture of large curvature honeycomb sandwich structures[J]. COMPOSITES SCIENCE AND ENGINEERING, 2023, 0(8): 115-120.

References

[1] 范金娟, 程小全, 王占彬. 夹层复合材料结构与失效机制[M]. 北京: 国防工业出版社, 2019.
[2] GIBSON L H, ASHBY M F. Cellular solid: Structure and properties[M]. 2nd ed. Cambridge: Cambridge University Press, 1997.
[3] CASTANIE B, BOUVET C, GINOT M. Review of composite sandwich structure in aeronautic applications[J]. Composites Part C: Open Access, 2020(1): 100004.
[4] GIGLIO M, GILIOLI A, MANES A. Numerical investigation of a three-point bending test on sandwich panels with aluminum skins and Nomex honeycomb core[J]. Computational Materials Science, 2012, 56: 69-78.
[5] HA N S, LU G. A review of recent research on bio-inspired structures and materials for energy absorption applications[J]. Composites Part B: Engineering, 2019, 181: 107496.
[6] BIRMAN V, KARDOMATEAS G A. Review of current trends in research and applications of sandwich structures[J]. Composites Part B: Engineering, 2018, 142: 221-240.
[7] CAPRIO F D, CRISTILLO D, SAPUTO S, et al. Crashworthiness of wing leading edges under bird impact event[J]. Composite Structures, 2019, 216: 39-52.
[8] 梁春生, 邱启艳, 陈静, 等. 蜂窝夹芯结构复合材料胶接共固化工艺技术研究[J]. 航空制造技术, 2014, 459(15): 86-89.
[9] KERMANI N N, SIMACEK P, ADVANI S G. A bond-line porosity model that integrates fillet shape and prepreg facesheet consolidation during equilibrated co-cure of sandwich composite structures[J]. Composites Part A: Applied Science and Manufacturing, 2020, 139: 106071.
[10] AL-DHAHERI M, KHAN K A, UMER R, et al. Process-induced deformation in U-shaped honeycomb aerospace composite structures[J]. Composite Structures, 2020, 248(15): 112503.
[11] CHEN S, MCGREGOR O, ENDRUWEIT A, et al. Simulation of the forming process for curved composite sandwich panels[J]. International Journal of Material Forming, 2020, 13: 967-980.
[12] ZHAO Z, LIU C, SUN L, et al. Experimental and numerical study on the constrained bending-induced collapse of hexagonal honeycomb[J]. Composite Structures, 2021, 277: 114604.
[13] 成艳娜, 刘训新, 李楠. 深U形蜂窝夹层结构整流罩制造技术研究[J]. 粘接, 2019, 40(5): 158-162.
[14] 乔巧玲. 复合材料“U”型蜂窝夹层件制造技术研究[J]. 化工管理, 2018(14): 76-77.
[15] SUKUMAR N, MALSCH E A. Recent advances in the construction of polygonal finite element interpolants[J]. Archives Computer Methods Engineering, 2006, 13: 129-163.
[16] TABARRAEI A, SUKUMAR N. Application of polygonal finite element in linear elasticity[J]. International Journal of Computer Methods, 2006(3): 503-520.