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2020 | Book

Introduction Read chapter Read first chapter

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

Author: Ralf Seemann

Publisher: Springer Berlin Heidelberg

Book Series : Produktentwicklung und Konstruktionstechnik

Part of: Springer Professional "Wirtschaft+Technik" , Springer Professional "Technik"

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About this book

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.

Table of Contents

Frontmatter
Chapter 1. Introduction
Abstract
Due to their good weight specific mechanical properties, composite sandwich structures have become essential in modern commercial passenger aircraft. Typical applications include external secondary structure components and cabin interior parts (Figure 1). In fact, the vast majority of the cabin furnishing including floor to ceiling lining is made of composite sandwich panels. As secondary aircraft structure, the mechanical strength of the cabin monuments is not crucial for the flight safety of the aircraft. However, the passenger safety is closely linked to the integrity of the cabin.
Ralf Seemann
Chapter 2. State of the art
Abstract
Sandwich structures are based on the principle of separating two thin and stiff faces by a thick, mechanically weak lightweight core. Load transfer between these three components is achieved by adhesive bonding (Figure 2). This arrangement functions like an Ibeam, where as much material as possible is placed farthest away from the neutral axis, thus providing excellent weight specific bending stiffness and strength.
Ralf Seemann
Chapter 3. Overall concept of mechanical characterization
Abstract
In the framework of this thesis a multitude of experimental and numerical studies on sandwich structures were performed. With regards to the Building Block Approach and the previously introduced hierarchy levels (Figure 25) the performed studies can be associated with a specific level. The following chapters 4 to 6 are each dedicated to one of the three investigated hierarchy levels, constituents, structural elements and sub-components. Within these chapters the investigated materials are firstly summarized before the experimental setups and results are presented. In case of chapters 4 and 5, the performed experiments are subsequently implemented as virtual tests.
Ralf Seemann
Chapter 4. Mechanical characterization on constituent level
Abstract
In composite sandwich construction, three main constituents are of primary interest on constituent level. These include core, face sheets and adhesives. In case plastics are used for load introduction elements, such as inserts, these materials may be also of interest on constituent level. Additionally, used metallic elements are usually the strongest component in sandwich construction. Therefore, they do not require a detailed analysis. In addition, elastic material properties are readily available for common metals. This chapter describes the mechanical characterization of the relevant constituents in the framework of the present thesis.
Ralf Seemann
Chapter 5. Mechanical characterization on structural element level
Abstract
In sandwich construction, the structural element level coincides with the bonded sandwich panel, which represents the combination of the two main constituents, face sheet and core. It is generally assumed that the material properties and modelling approaches, which are derived on constituent level, enable to predict the material behavior on structural element level. The investigations within this second building block were firstly intended to validate this assumption. In addition, the objective was to consider additional relevant aspects that can only be investigated on structural element level.
Ralf Seemann
Chapter 6. Mechanical characterization on sub-component level
Abstract
The sub-component level is typically concerned with all joints and fasteners within sandwich constructions. In the framework of the present thesis various configurations of common sandwich fastener designs were investigated in experimental studies. These experimental studies serve as reference for the development and validation of a virtual testing approach, which is described in chapter 7. The performed experimental studies are described in the following. They are clustered according to the studied type of fastener or joint.
Ralf Seemann
Chapter 7. Virtual testing approach for sandwich panel joints
Abstract
This chapter describes the developed approach for virtual testing of sandwich panel joints using the sub-component tests of chapter 6 as example and for validation. The investigations in chapter 4 and 5 are integral parts of this approach. Therefore, aspects of these chapters are revisited and put into perspective of the approach. In the following, an overview over the approach and it’s four phases is given in section 7.1. Then each phase is described in section 7.2, 7.3, 7.4 and 7.5 using a demonstration example. Sections 7.6 and 7.7 summarize and conclude with additional case studies as validation.
Ralf Seemann
Chapter 8. Development of novel sandwich panel joints
Abstract
Chapter 8 describes the application of the established virtual test of inserts under out-of-plane tension for the development of a novel sandwich panel joint design. The premise of this study is based on the general mechanic that the effective potting radius of the insert directly affects the core shear buckling as first damage mechanism. Increasing the potting radius increases the number of cell walls adjacent to the potting thus increasing the initial stiffness of the insert and postponing shear failure of the core. These two effects typically result in an increased overall strength of the insert configuration. This is illustrated in Figure 123.
Ralf Seemann
Chapter 9. Summary and outlook
Abstract
The determination of the mechanical properties by means of physical testing is a major cost driver in the development process of lightweight products. The implementation of virtual tests based on FE-simulations can be a significant contributor to reducing the development cost. However, composite sandwich structures are characterized by a complicated failure behavior, making reliable predictions via FE-simulations challenging. The present work addresses this problem by establishing a virtual testing approach for sandwich structures.
Ralf Seemann
Backmatter
Metadata
Title
A Virtual Testing Approach for Honeycomb Sandwich Panel Joints in Aircraft Interior
Author
Ralf Seemann
Copyright Year
2020
Publisher
Springer Berlin Heidelberg
Electronic ISBN
978-3-662-60276-8
Print ISBN
978-3-662-60275-1
DOI
https://doi.org/10.1007/978-3-662-60276-8

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