Mechanics of Composite Sinusoidal Honeycomb Cores

Abstract

Lightweight and heavy-duty fiber-reinforced polymer (FRP) composite honeycomb sandwich structures have been increasingly used in civil infrastructure. Unique cellular core configurations, such as sinusoidal core, have been applied in sandwich construction. Due to specific core geometry, the solutions for core effective stiffness properties are not readily available. This paper presents a mechanics of materials approach to evaluate the effective stiffness properties of sinusoidal cores. In particular, the internal forces of a curved wall in a unit cell are expressed in terms of resultant forces, and based on the energy method and principle of equivalence analysis, the in-plane stiffness properties of sinusoidal cores are derived. Both finite-element modeling and experimental testing are carried out to verify the accuracy of the proposed analytical formulation. To illustrate the present analytical approach as an efficient tool in optimal analysis and size selection of sinusoidal cores, several design plots are provided and discussed. The simplified analysis and formulation presented for sinusoidal cores can be used in design application of FRP honeycomb sandwich and optimization of efficient cellular core structures.