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Impact Response of Honeycomb Structures
Impact Response of Honeycomb Structures
Impact Response of
Sandwich Structures
Project report submitted to Visvesvaraya National Institute of Technology, Nagpur in
partial fulfilment of the requirements for the award of the degree.
By
November 2023
Table of Contents
Introduction.................................................................................2
Impact Loading...............................................................................................................................3
Diplegia Classification....................................................................................................................3
Gait Analysis...................................................................................................................................5
Dataset.............................................................................................................................................5
Joint Coordinate System..................................................................................................................7
Literature Survey........................................................................8
Paper 3 [3].....................................................................................................................................10
Paper 5 [4].....................................................................................................................................12
Impact Loading
Impact loading pertains to the application of a sudden and intense force on a material or structure within a
brief duration. It induces rapid stress propagation, causing deformation or failure. In engineering,
comprehending impact loading is pivotal for designing structures to endure abrupt forces, such as collisions
or dynamic loads. This phenomenon involves analyzing stress wave propagation, energy dissipation, and
material behavior during rapid loading events.
Material properties like elasticity, ductility, and toughness significantly affect how a material responds to
impact loading. The strain rate, which represents the rate of deformation, also plays a crucial role in
determining a material's behavior under sudden loading conditions. Factors such as damping, and stress
concentrations further influence the structural response to impact loading.
In-depth understanding and analysis of impact loading aid in devising resilient structures and materials for
diverse engineering applications. It facilitates the design of safety features in automotive structures,
protective equipment, and building infrastructure, ensuring they can withstand and dissipate energy
efficiently during unforeseen high-force events, safeguarding against potential damage or failure.
Blast Loading
Blast loading is the sudden release of energy resulting from an explosive detonation, generating powerful
shock waves that exert immense pressure on nearby structures. These shock waves produce rapid changes in
pressure and can cause severe damage to buildings, infrastructure, and human life. Understanding blast
loading involves analyzing the propagation of shock waves, their interaction with structures, and the resulting
dynamic responses.
Designing structures to resist blast loading involves utilizing materials with high-strength properties,
implementing blast-resistant designs, and incorporating mitigation strategies like sacrificial layers or blast-
absorbing materials. These measures aim to reduce the impact of blast forces and enhance the resilience of
structures against potential damage caused by explosive events. The study of blast loading is crucial in fields
such as civil engineering, military applications, and infrastructure protection, ensuring the safety and
durability of structures in high-risk environments.
Applications: -
In aerospace, foam-filled sandwich structures are used in aircraft wings, fuselages, and interior panels,
offering reduced weight without compromising structural strength. In automotive engineering, these
structures find application in car body panels, providing enhanced crash resistance and fuel efficiency.
Moreover, they are employed in marine constructions for boat hulls, ensuring buoyancy and durability.
The design versatility of foam-filled sandwich structures allows customization for specific needs, such as
thermal insulation, sound absorption, or vibration dampening. The selection of foam materials and face sheet
compositions influences properties like stiffness, strength, and energy absorption.
Applications: -
In aerospace, honeycomb-filled sandwiches are widely used in aircraft components like floors, walls, and
bulkheads, offering high strength-to-weight ratios crucial for flight performance. The automotive industry
employs these structures in vehicle panels for enhanced crash resistance and weight reduction, improving fuel
efficiency.
Moreover, honeycomb-filled sandwich structures find applications in industries requiring high stiffness and
strength, such as in shipbuilding for hulls and in construction for building facades. Their ability to withstand
high loads and distribute stresses evenly makes them valuable in diverse fields. Customization of core
materials and face sheets allows engineers to tailor properties like stiffness, strength, and thermal insulation
to suit specific requirements.
Paper 1 [1]
Title - Quasi Static Axial Crushing of Foam Filled Thin-Walled Circular Tubes
Authors - Kevin Mathew Koshy and S. Jeyanthi
Name of Journal - Indian Journal of Science and Technology
Year of Publication - 2016
Objective: This research explores the dynamic progressive buckling response of thin-walled circular
tubes, specifically aluminum 6063-T5 tubes integrated with low-density polyurethane foam. The
study aims to validate results using LS-DYNA, focusing on quasi-static loading conditions.
Method/Analysis: Experimental tests involve subjecting both empty and foam-filled tubes to quasi-
static loading to analyze buckling response and deformation shapes. Load-displacement graphs are
utilized to quantify energy absorption. Numerical simulations with LS-DYNA are conducted,
allowing a systematic comparison with experimental data.
Findings: Integration of low-density foam in empty aluminum tubes increases energy absorption by
1.4%. The foam-filled tubes exhibit enhanced stability in deformation. The study demonstrates
satisfactory agreements (error < 15%) between finite element models and experimental data for
deformed shapes, load-displacement, number of folds, and energy absorption.
Applications/Improvements: Polyurethane foams can serve as reinforcement in energy-absorbing
structures. Understanding the system's response in diverse loading conditions is crucial for improving
crashworthiness. The research suggests potential applications for polyurethane foams in enhancing
energy absorption and stability in structures subjected to impact.
Conclusion: Quasi-static crushing behavior of polyurethane foam-filled aluminum tubes is
investigated both experimentally and numerically. LS-DYNA simulations align well with
experimental values for peak force, average force, energy absorption, and folds formed. Although the
addition of low-density foams doesn't significantly increase energy absorption, it contributes to
stabilizing deformation in the structure.
Paper 2 [2]
Title - Auxeticity effect on crushing characteristics of auxetic foam-filled square T tubes under axial
loading
Authors - S. Mohsenizadeh, Z. Ahmad
Name of Journal - Thin-Walled Structures
Year of Publication- 2019
Research Focus: Investigating the energy absorption and crushing characteristics of auxetic foam-
filled square-section tubes under axial loading, with a specific emphasis on the influence of auxeticity
on structural collapse.
Experimental Insights: Through experimental analysis, the study explores the interaction effect
between the negative Poisson's ratios of auxetic foam and square tube walls, ranging from −0.31 to
0.03, under both quasi-static and dynamic loadings.
Computer Simulation Validation: Validated computer simulation techniques were employed,
confirming the experimental findings. A parametric study was conducted to evaluate the impact of
tube parameters on energy absorption responses.
Negative Poisson Ratio Influence: The study establishes that a negative Poisson ratio significantly
impacts the crushing response and energy absorption capability of auxetic foam-filled square tubes.
Enhanced Crashworthiness: Increasing the auxeticity level of the foam filler is found to enhance
crashworthiness performance under both quasi-static and dynamic loading conditions, offering
valuable insights for structural design.
Design Guideline Outcome: The primary outcome of the research is the formulation of a design
guideline. This guideline recommends the use of auxetic foam with different Poisson's ratios as a core
for energy absorber devices subject to impact loading.
Poisson's Ratio Interaction: The study experimentally determines the interaction effect between
auxetic foam and tube walls, revealing a substantial increase (about 121%) in the interaction effect
with a foam Poisson's ratio of −0.31 compared to conventional foam.
Geometric Impact: Introducing an auxetic foam core reduces the total fold wavelength and inward
penetration length of square tube walls. This alteration increases the number of collapse lobes, leading
to a 9.7% reduction in total fold wavelength for auxetic foam-filled tubes.
Strain Rate Sensitivity: The study discovers that the auxeticity level affects the strain rate sensitivity
of auxetic foam materials, particularly when subjected to varying loading velocities ranging from 5 ×
10−2 to 5 × 103 mm/s.
Wall Thickness Impact: Increasing wall thickness is found to enhance specific energy absorption
and absorbed energy for empty, conventional, and auxetic foam-filled square tubes. However, a
drawback is noted in the form of low crush force efficiency, making thicker tubes undesirable in
crashworthiness design when considering CFE as a design interest for energy-absorbing devices.
Paper 3 [3]
Title - Energy absorption and in-plane crushing behavior of aluminum reinforced honeycomb.
Authors - Tiju Thomas and Gaurav Tiwari
Name of Journal - Vacuum
Year of Publication - 2018
Aluminum Honeycomb in Aerospace and Automotive: Aluminum honeycomb, a lightweight load-
carrying structure, finds widespread use in aerospace and automotive industries.
In-Plane Compression Analysis: This research delves into the in-plane compression analysis of AA
8011 reinforced honeycomb, employing both numerical simulations and experimental evaluations.
Geometric Parameters Variation: The study explores the impact of varying geometric parameters
such as cell size, cell wall thickness, and node length on the honeycomb models.
Cell Size and Node Length Variations: Different configurations were examined with cell sizes of 7
mm and 10 mm and node lengths of 25 mm, 30 mm, and 35 mm, revealing their influence on
structural performance.
Cell Wall Thickness Influence: Notably, the research identifies cell wall thickness as a critical factor
affecting energy absorption and peak crushing force in the honeycomb structure.
Finite Element Simulations: Various combinations of reinforced honeycomb configurations were
subjected to finite element simulations using LS DYNA, providing a comprehensive analysis.
Validation with Experimental Results: The numerical model's accuracy was affirmed through
validation with experimental results obtained from the reinforced core.
Impact of Geometric Parameters: The study reveals that variations in cell wall thickness
significantly affect the crushing strength and energy absorption capacity, while cell size alterations
produce a reverse effect.
Node Length's Limited Impact: Interestingly, the research notes that node length has a lesser impact
on the honeycomb core's performance characteristics, emphasizing the dominance of other geometric
factors.
Reinforced Honeycomb Advantages: The conclusion underscores the superiority of reinforced
honeycomb structures, demonstrating higher mean force, peak force, and energy absorption compared
to conventional honeycomb structures.
Paper 4 [6]
Title - Influence of reinforcement in the honeycomb structures under axial compressive load
Authors - Tiju Thomas, R.P. Khandelwal and Gaurav Tiwari
Name of Journal - Thin-Walled Structures
Year of Publication - 2017
Paper 5 [4]
Title - Performance evaluation of reinforced honeycomb structure under blast load
Author - Tiju Thomas* and Gaurav Tiwari
Name of Journal - Journal of Engineering Research
Year of Publication - 2021
Objective: This study investigates the response of a reinforced honeycomb sandwich structure,
exploring variations in cell sizes, node lengths, and cell wall thicknesses.
Materials: Aluminum alloy 8011 honeycomb structures subjected to low-intensity blast loads, with
TNT masses ranging from 10 g to 25 g and standoff distances of 200 mm, 250 mm, and 300 mm.
Simulation Tool: LS-DYNA, a commercial finite element code, was used for numerical simulations,
comparing conventional and reinforced honeycomb structures with identical geometrical and blast
load parameters.
Key Parameter: The deformation of the back facesheet is crucial in establishing blast resistance,
with failure mechanisms categorized into fully folded, partially folded, and clamped regions.
Reinforced vs. Conventional: The reinforced honeycomb sandwich outperforms its conventional
counterpart under similar blast loads, showcasing enhanced blast resistance.
Influence of Geometry: Cell-wall thickness and node length augmentation improve blast resistance,
while an increase in cell size reduces the blast resistance of the reinforced honeycomb structure.
Deformation Regions: Modes of deformation include fully folded, partially folded, and clamped
regions, with visible failures such as debonding of facesheets, core crushing, and densification.
Major Findings: Blast resistance correlates with cell-wall thickness, node length increase, and mass
of TNT. Reinforced honeycomb structures exhibit better blast resistance compared to conventional
honeycombs.
Specific Effects: Increment in cell size decreases blast resistance, while node length increases and
thicker cell walls enhance blast resistance. The study provides valuable insights into optimizing
honeycomb structures for improved blast performance.
Methodology
Impact Response of foam filled square tubes:
The FE model of a foam-filled tube comprises of four parts namely rigid
stationary plate, rigid movable mass, foam core and deformable square
tube, as shown in Figure 1. The stationary plate and movable mass were
modeled as rigid parts. The dimensions of the square tube and the foam
to be filled are specified in the figure. The material that used for the outer
shell material is aluminum and the material properties of aluminum tube
is specified in Table 1. A rigid plate will be fixed at the bottom of the tube
and another rigid plate will be there at the top of the square tube to which
the displacement has to be provided. Here both the rigid plates are made
up of steel. A conventional foam is filled inside the square and the
material properties of conventional foam is provided in Table 2. And to
get the accurate results of the square tube during impact the stress strain
data of the materials is also required. Stress strain curve for conventional
foam is provided in Figure 2.
The modelling and the FE analysis has been done in Lsdyna. During the modelling first Figure
outer square part
and inside foam are modelled according to the specified dimensions and Rigid plates are 1 provided at both
Figure 2 the top and bottom side of the arrangement. Here the
bottom rigid plate is fixed in all the directions and
displacement is given to top rigid plate (i.e., 36mm) along
the compression direction of the square tube. Proper
contacts should be provided between the contact parts for
proper results. Now coming to the meshing part, the mesh
size of square tube and inner foam is 0.8mm. And the
number of meshing divisions on the rigid plate should be
adjusted according to the situation.
During the modelling stationary plate was fully constrained
in all degrees of freedom, and the rigid movable mass was
constrained to only translate vertically along the z axis.
The motion of the rigid movable mass was defined using a prescribed motion in load curve. For this quasi-
static simulation, displacement boundary condition is used for the rigid movable mass to simulate the
displacement-controlled experiment in order to achieve an accurate and efficient quasi-static analysis.
Generally, inertia effect is duly minimized by ramping the velocity in the quasi-static loading. Three different
contact algorithms were defined in this FE model. An automatic node to surface contact was selected for the
contact interfaces of the tube and rigid plates. Also, self-contact algorithm was adopted for the tube in order
to avoid interpenetration of the tube folding during the crushing process using “automatic_single_surface’’.
To account for the contact interface between the foam filler, rigid parts and tube wall, an automatic surface
to surface contact was simulated with dynamic and static frictional coefficients of 0.2 and 0.3, respectively.
MAT_24 (MAT_PIECEWISE_LINEAR_PLASTICITY) material model is adopted to model the aluminum
square tube. The stress strain data Tableand 1 other material properties
required are given in Table 1.
MAT_063 (MAT_CRUSHABLE_FOAM)
material model is defined for the conventional
foam. This material model is suitable for
modeling the crushable foam with high
efficiency and performance terms of
computational time. The Stress strain curve
for conventional foam is given in Figure 2
and other material property required for
conventional foam are given in Table 2. Table 2
For modeling the rigid bodies (stationary
plate and movable mass), MAT_20 (MAT_RIGID) material model is assigned.
First foamless square should be compressed and analyze the response of that aluminum square tube which
is placed in between the Rigid plates with a displacement being provided to the top rigid plate. In section
shell should be assigned to outer aluminum square tube and solid should be assigned to the inner foam
material. Now assign material, section for all the elements modelled in the part. Select options whatever
required at the output of the simulation in the Ascii option. Adjust the initial time step and termination time
according to the compression velocity of the top rigid plate. Since this is a case of static compression of the
foam material assembly so more and more termination time will be suggested for a given displacement of
the rigid block.
Now after analyzing the foamless square tube now, we must fill the foam material inside the square tube
according to above specified properties of the conventional foam. Now due to the solid material inside the
square tube the number of contacts will be increased in this case as compared to the previous foam less
square tube compression case. Here in this foam filled square tube case an additional contact called
CONTACT_INTERIOR was assigned to prevent negative volume error in foams.
The top and bottom plates are rigid Steel S1080. The motion
of bottom plate is constrained. The top plate is moving with a
constant velocity of 5mm/min thus crushing the honeycomb
core.
3. Kevin Mathew Koshy* and S. Jeyanthi, “Quasi Static Axial Crushing of Foam Filled Thin-
Walled Circular Tubes”, Indian Journal of Science and Technology, Vol 9(33), September
2016. DOI: 10.17485/ijst/2016/v9i33/101344