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A Virtual Testing Approach for Honeycomb Sandwich Panel Joints in Aircraft Interior

:	Ralf Seemann
:	A Virtual Testing Approach for Honeycomb Sandwich Panel Joints in Aircraft Interior
:	Springer Vieweg
:	9783662602768
:	1
:	CHF 85.30
:

:	Maschinenbau, Fertigungstechnik
:	English

:	210
:	Wasserzeichen/DRM
:	PC/MAC/eReader/Tablet
:	PDF

Virtual test methods can contribute to reducing the great effort for physical tests in the development of lightweight products. The present work describes an approach for virtual testing of sandwich panel joints based on the Building Block Approach and the Finite Elements Method. Building on a multitude of physical tests on sandwich materials and joints, adequate sub-models are developed, validated and synthesized to top-level models. The developed approach is eventually applied for the development of a novel sandwich panel joint.

Ralf Seemann studied mechanical Engineering at TU Hamburg (TUHH) and at National University of Singapore. From 2011-2016 he worked as research engineer at the Institut of Product Development and Mechanical Engneering Design at TUHH. Since 2017 he works as stress& weight engineer at Diehl Aviation.

	Vorwort	8
	Zusammenfassung	9
	Table of contents	10
	Abbreviations	13
	Nomenclature	15
	1 Introduction	16
	1.1 Motivation	16
	1.2 Thesis objectives	17
	1.3 Thesis structure	17
	2 State of the art	19
	2.1 Sandwich structures	19
	2.1.1 Face sheets	19
	2.1.2 Core	21
	2.1.3 Bonded sandwich panel	22
	2.1.4 Failure modes	25
	2.2 Sandwich structure joints	26
	2.2.1 Inserts	26
	2.2.2 Panel edges	29
	2.2.3 Novel joint designs	30
	2.3 Computational analysis	31
	2.3.1 Finite Element Method	33
	2.3.2 Literature survey on sandwich panel joint modelling	36
	2.4 Virtual testing	37
	2.5 Assessment of the state of the art and need for further research	44
	3 Overall concept of mechanical characterization	47
	4 Mechanical characterization on constituent level	49
	4.1 Sandwich core	49
	4.1.1 Materials	50
	4.1.2 Experimental analysis	53
	4.1.3 Numerical modelling on meso scale	58
	4.1.4 Numerical modelling with 3D-contiuum elements	73
	4.1.5 Conclusion	76
	4.2 Face sheets	76
	4.2.1 Experimental analysis	78
	4.2.2 Numerical modelling and calibration	79
	4.3 Adhesives	82
	4.3.1 Experimental analysis	82
	4.3.2 Numerical modelling and calibration	86
	5 Mechanical characterization on structural element level	87
	5.1 Panel flexure	87
	5.1.1 Experimental analysis	89
	5.1.2 Numerical analysis	93
	5.2 In-plane shear	101
	5.2.1 Experimental analysis	101
	5.2.2 Numerical analysis	102
	5.3 Additional test methods	105
	6 Mechanical characterization on sub-component level	108
	6.1 Threaded inserts perpendicular to the face sheet	108
	6.1.1 Out-of-plane tension (pull-out)	109
	6.1.2 In-plane tension (shear)	112
	6.2 L-Joints	113
	6.2.1 L-Joint bending test	114
	6.2.2 L-Joint shear test	115
	7 Virtual testing approach for sandwich panel joints	117
	7.1 Overview	117
	7.2 Phase 1 - Problem analysis	118
	7.3 Phase 2 - Definition of model framework	122
	7.4 Phase 3 - Model development	126
	7.4.1 Investigation	127
	7.4.2 Building blocks	137
	7.4.3 Modelling database	148
	7.5 Phase 4 - Application of virtual test	148
	7.6 Summary	152
	7.7 Validation based on different joint configurations	153
	7.7.1 Partially potted inserts	153
	7.7.2 Corner joints	160
	7.7.3 Conclusion	165
	8 Development of novel sandwich panel joints	166
	8.1 Virtual testing of design alternatives	168
	8.2 Validation by experimental investigation	171
	9 Summary and outlook	173
	Literature	175
	Appendix A – Constituent level	189
	A1 Implemented material models of Nomex honeycomb	189
	A2 Implemented material models for face sheets	193
	A3 Implemented material models for adhesives	197
	Appendix B – Structural element level	202
	B1 Sandwich bending test details	202
	B2 Comparison of modelling approaches in case of bending	204
	B3 Frame shear test details	205
	Appendix C – Sub-component level	206
	C1 Damage progression for pull-out test on fully potted insert	206
	C2 Implemented cohesive behavior of potting-face contact	207
	C3 Experimental results in novel design study	208
	Lebenslauf	210