Performance enhancement of sandwich panels with honeycomb–corrugation hybrid core

The concept of combining metallic honeycomb with folded thin metallic sheets(corrugation) to construct a novel core type for lightweight sandwich structures is proposed. The honeycomb–corrugation hybrid core is manufactured by filling the interstices of aluminum corrugations with precision-cut trapezoidal aluminum honeycomb blocks, bonded together using epoxy glue. The performance of such hybrid-cored sandwich panels subjected to out-of-plane compression, transverse shear, and three-point bending is investigated, both experimentally and numerically. The strength and energy absorption of the sandwich are dramatically enhanced, compared to those of a sandwich with either empty corrugation or honeycomb core. The enhancement is induced by the beneficial interaction effects of honeycomb blocks and folded panels on improved buckling resistance as well as altered crushing modes at large plastic deformation.The present approach provides an effective method to further improve the mechanical properties of conventional honeycomb-cored sandwich constructions with low relative densities.     

Cell size effects for vibration analysis and design of sandwich beams

In this work, sandwich beams are studied to reveal the underlying size effects of the periodic core cells for the first time within the framework of free vibration analysis of such an advanced lightweight structure. The energy equivalence method is formulated as a theoretical approach that takes into account the cell size effect. It is compared with the asymptotic homogenization method and direct finite element method systematically to show their consistence and applicability. The accuracy of free vibration responses predicted by the detailed finite element model is used as the standard of comparison. It is shown that the cell size is an important parameter characterizing the cellular core rigidities that influence vibration responses. The homogenization model agrees exactly with the asymptotic solution of the analytical expression of the beam model only whenever the cell size tends to be infinitely small.     

THE SATELLITE STRUCTURE TOPOLOGY OPTIMIZATION BASED ON HOMOGENIZATION METHOD AND ITS SIZE SENSITIVITY ANALYSIS

With the development of satellite structure technology, more and more design parameters will affect its structural performance. It is desirable to obtain an optimal structure design with a minimum weight, including optimal configuration and sizes. The present paper aims to describe an optimization analysis for a satellite structure, including topology optimization and size optimization. Based on the homogenization method, the topology optimization is carried out for the main supporting frame of service module under given constraints and load conditions, and then the sensitivity analysis is made of 15 structural size parameters of the whole satellite and the optimal sizes are obtained. The numerical result shows that the present optimization design method is very effective.     

Aerodynamic optimization of 3D wing based on iSIGHT

A method for combining the CFD software,Fluent,with the iSIGHT design platform is presented to optimize a three-dimensional wing to ameliorate its aerodynamics performance.In the optimization design,two kinds of genetic algorithms,the Neighborhood Cultivation Genetic Algorithm（NCGA）and the Non-dominated Sorting Genetic Algorithm（NSGAII）,are employed and the Navier-Stoke（N-S）equations are adopted to derive the aerodynamics functions of the 3D wing.The aerodynamic performance of the optimized wing has been significantly improved,which shows that the approach can be extended and employed in other cases.     

ON RESIDUAL COMPRESSIVE STRENGTH PREDICTION OF COMPOSITE SANDWICH PANELS AFTER LOW-VELOCITY IMPACT DAMAGE

This paper introduces a nonlinear finite element analysis on damage propagation behavior of composite sandwich panels under in-plane uniaxial quasi-static compression after a low velocity impact. The major damage modes due to the impact, including the residual indentation on the impacted facesheet, the initially crushed core under the impacted area, and the delamination are incorporated into the model. A consequential core crushing mechanism is incorporated into the analysis by using an element deactivation technique. Damage propagation behavior, which corresponds to those observed in sandwich compression after impact (SCAI) tests, has been successfully captured in the numerical simulation. The critical far field stress corresponding to the onset of damage propagation at specified critical locations near the damage zone are captured successfully. They show a good correlation with experimental data. These values can be used to effectively predict the residual compressive strength of low-velocity impact damaged composite sandwich panels.     

Size effect of lattice material and minimum weight design

The size effects of microstructure of lattice materials on structural analysis and minimum weight design are studied with extented multiscale finite element method（EMsFEM） in the paper. With the same volume of base material and configuration, the structural displacement and maximum axial stress of micro-rod of lattice structures with different sizes of microstructure are analyzed and compared.It is pointed out that different from the traditional mathematical homogenization method, EMsFEM is suitable for analyzing the structures which is constituted with lattice materials and composed of quantities of finite-sized micro-rods.The minimum weight design of structures composed of lattice material is studied with downscaling calculation of EMsFEM under stress constraints of micro-rods. The optimal design results show that the weight of the structure increases with the decrease of the size of basic sub-unit cells. The paper presents a new approach for analysis and optimization of lattice materials in complex engineering constructions.     

DECAY RATE OF SAINT-VENANT END EFFECTS FOR PLANE DEFORMATIONS OF PIEZOELECTRIC-PIEZOMAGNETIC SANDWICH STRUCTURES

This paper is concerned with the decay of Saint-Venant end effects for plane deformations of piezoelectric （PE）-piezomagnetic （PM） sandwich structures, where a PM layer is located between two PE layers with the same material properties or reversely. The end of the sandwich structure is subjected to a set of self-equilibrated magneto-electro-elastic loads. The upper and lower surfaces of the sandwich structure axe mechanically free, electrically open or shorted as well as magnetically open or shorted. Firstly the constitutive equations of PE mate- rials and PM materials for plane strain are given and normalized. Secondly, the simplified state space approach is employed to arrange the constitutive equations into differential equations in a matrix form. Finally, by using the transfer matrix method, the characteristic equations for eigen- values or decay rates axe derived. Based on the obtained characteristic equations, the decay rates for the PE-PM-PE and PM-PE-PM sandwich structures are calculated. The influences of the electromagnetic boundary conditions, material properties of PE layers and volume fraction on the decay rates are discussed in detail.     

EXTENDED CORE STRUCTURE OF DISSOCIATED EDGE DISLOCATIONS IN FCC CRYSTALS WITH CONSIDERATION OF DISCRETENESS

The extended core structure of the dissociated edge dislocation in Al, Au, Ag, Cu and Ni is determined within lattice theory of dislocation. The 2D dislocation equation governing the displacements is coupled by the restoring forces that are determined by the parameterization of the generalized stacking fault energies. The Ritz variational method is presented to solve the dislocation equation and the trial solution is constituted by two arctan-type functions with two undetermined parameters. The core widths of partial dislocations are wider than that obtained in generalized Peierls-Nabarro model due to the consideration of discreteness of crystal.     

Critical velocity of sandwich cylindrical shell under moving internal pressure

Critical velocity of an infinite long sandwich shell under moving internal pressure is studied using the sandwich shell theory and elastodynamics theory. Propagation of axisymmetric free harmonic waves in the sandwich shell is studied using the sandwich shell theory by considering compressibility and transverse shear deformation of the core, and transverse shear deformation of face sheets. Based on the elastodynamics theory, displacement components expanded by Legendre polynomials, and position-dependent elastic constants and densities are introduced into the equations of motion. Critical velocity is the minimum phase velocity on the desperation relation curve obtained by using the two methods. Numerical examples and the finite element （FE） simulations are presented. The results show that the two critical velocities agree well with each other, and two desperation relation curves agree well with each other when the wave number k is relatively small. However, two limit phase velocities approach to the shear wave velocities of the face sheet and the core respectively when k limits to infinite. The two methods are efficient in the investigation of wave propagation in a sandwich cylindrical shell when k is relatively small. The critical velocity predicted in the FE simulations agrees with theoretical prediction.     

Geometric and material nonlinearities of sandwich beams under static loads

A new theory developed from extended high-order sandwich panel theory(EHSAPT)is set up to assess the static response of sandwich panels by considering the geometrical and material nonlinearities simultaneously.The geometrical nonlinearity is considered by adopting the Green-Lagrange-type strain for the face sheets and core.The material nonlinearity is included as a piecewise function matched to the experimental stress-strain curve using a polynomial fitting technique.A Ritz technique is applied to solve the governing equations.The results show that the stress stiffening feature is well captured in the geometric nonlinear analysis.The effect of the geometric nonlinearity in the face sheets on the displacement response is more significant when the stiffness ratio of the face sheets to the core is large.The geometric nonlinearity decreases the shear stress and increases the normal stress in the sandwich core.By comparison with open literature and finite element simulations,the present nonlinear EHSAPT is shown to be sufficiently precise for estimating the nonlinear static response of sandwich beams by considering the geometric and material nonlinearities simultaneously.     

Optimum design of laminated composite foam-filled sandwich plates subjected to strength constraint

Optimum design of laminated composite sandwich plates with both continuous (core thickness) and discrete (layer group fiber angles and thicknesses) design variables subjected to strength constraint is studied via a two-level optimization technique. The strength of a sandwich plate is determined in a failure analysis using the Tsai–Wu failure criterion and the finite element method which is formulated on the basis of the layerwise linear displacement theory. In the first level optimization of the design process, the discrete design variables are temporarily treated as continuous variables and the corresponding minimum weight of the sandwich plate is evaluated subject to the strength constraint using a constrained multi-start global optimization method. In the second level optimization, the optimal solution obtained in the first level optimization is used in the branch and bound method for solving a discrete optimization problem to determine the optimal design parameters and the final weight of the plate. Failure test of laminated composite foam-filled sandwich plates with different lamination arrangements are performed to validate the proposed optimal design method. A number of examples of the design of laminated composite foam-filled sandwich plates are given to demonstrate the feasibility and applications of the proposed method.     

面向增材制造的双蒙皮夹层结构加筋拓扑优化方法

双蒙皮夹层结构是航空航天装备中的特殊承力结构,其典型代表为发动机尾喷管中的同步环构件。近年来,增材制造技术为该类薄壁结构的创新型设计提供了有利条件。但增材制造有其特殊的工艺要求,基于传统拓扑优化得到的设计结果往往存在大量的悬空区域,无法直接应用于增材制造工艺。因此,需要在优化设计阶段统筹考虑结构的力学性能和自支撑工艺约束。针对上述问题,本文提出了一种面向增材制造的双蒙皮夹层薄壁结构加筋拓扑优化方法,可在一次优化中同时得到优化的加筋布局和非均匀点阵分布,从而解决悬空结构的支撑问题,确保优化结果的工艺可达性。为了平衡计算成本和分析精度,本文采用渐进均匀化方法来求解不同类型单胞等效弹性性能,以适应不同复杂单胞构型。基于上述方法,本文给出了某发动机同步环结构的拓扑优化算例,结果表明,本文优化设计方法可以实现双蒙皮夹层结构中夹层加筋和点阵的共同优化,为航空航天装备中发动机同步环结构轻量化设计提供了思路。     

冲击载荷下轻质夹芯拱最大刚度拓扑优化及动力响应

基于双向渐进结构优化方法（bi-directional evolutionary structural optimization,BESO）框架,将传统动态载荷优化法中的内外层迭代引入到ABAQUS-MATLAB平台集成优化中,改进动态载荷拓扑优化流程。对初速度为100 m/s的子弹冲击下的夹芯拱结构进行拓扑优化设计和动力学响应分析。优化后夹芯拱芯层的变形模式可分为3个对称的部分,跨中区域的中部和上部主要发生压缩变形,呈现类三角点阵桁架结构,边界区域上部发生拉伸变形,下部发生压缩变形,呈现C形型结构,跨中和边界之间的过渡区域以拉弯联合变形为主,呈现Y形结构。通过与两种等质量的拱结构对比,分析了3种结构在不同初速度的子弹冲击下结构的挠度以及芯层的能量吸收情况。结果表明:在相同的冲击速度下,优化后的结构挠度最小,芯层比吸能最高;当冲击速度较低时,优化后的结构的抗冲击性能优势并不明显;在所研究的冲击速度范围内,冲击速度越高,优化后结构的抗冲击性能越好。对比对称载荷与非对称载荷（冲击点偏移量为100%）下2种优化结构在不同载荷工况下的动态响应,结果表明:载荷工况不同,得到的最终优化结果也略有所不同,但在相同载荷下结构的响应相差较小,每种工况下得到的优化结果在相应工况下所展现的力学性能略优,但均明显优于传统结构。因此,在对称冲击载荷下优化所得的结构具有一定的普遍性。     

Selection of the optimum parameters for sandwich construction with honeycomb core

The minimum weight of sandwich construction which is regarded as objective function has been discussed. Under given constraint condition of the strength or the stiffness, the four optimum parameters of sandwich construction with honeycomb core (thickness of the face t_f, thickness of the honeycomb core h_c, thickness of the honeycomb wall t_s, side length of the honeycomb cell c) are evaluated. By using constraint condition of the strength, a equation of high degree is finally solved. In the constraint condition of the stiffness, the constraint optimization problem is treated as inconstraint optimization problem with the method of obtaining extreme value solution by undetermined parameter multiplication. Also, the results are discussed.     

Bi-functional optimization of actively cooled, pressurized hollow sandwich cylinders with prismatic cores

All metallic, hollow sandwich cylinders having ultralight two-dimensional (2D) prismatic cores are optimally designed for maximum thermo-mechanical performance at minimum mass. The heated cylinder is subjected to uniform internal pressure and actively cooled by forced air convection. The use of two different core topologies is exploited: square- and triangular-celled cores. The minimum mass design model is so defined that three failure modes are prevented: facesheet yielding, core member yielding, and core member buckling. The intersection-of-asymptotes method, in conjunction with the fin analogy model, is employed to build the optimization model for maximum heat transfer rate. A non-dimensional parameter is introduced to couple the two objectives—structural and thermal—in a single cost function. It is found that the geometry corresponding to maximum heat transfer rate is not unique, and square-celled core sandwich cylinders outperform those having triangular cells. The eight-layered sandwich cylinders with square cells have the best overall performance in comparison with other core topologies. Whilst a sandwich cylinder with shorter length is preferred for enhanced thermo-mechanical performance, the influence of the outer radius of the cylinder is rather weak.     

负高斯曲率曲面薄壁管吸能特性研究

为设计出具备优良吸能特性的薄壁结构,提出一种新型负高斯曲率曲面圆形横截面薄壁管(negative Gaussian curvature surface circular tube, NGC-C)。利用经验证的有限元分析方法对其进行轴向动态冲击模拟,提取各项性能指标,借助复杂比例评估法(complex proportion assessment, COPRAS)将其与传统薄壁吸能结构进行了综合性能对比。采用拉丁超立方抽样法从设计空间中提取样本点并获取各样本点对应性能响应值,建立代理模型。基于该代理模型,借助改进非支配排序遗传算法(non-dominated sorting genetic algorithm, NSGA-Ⅱ)对其进行了多目标优化设计。结果表明:NGC-C综合性能优于传统薄壁吸能结构,经优化后比吸能提高了16.47%,有效压溃长度降低了12.40%,质量减少了20.18%。将负高斯曲率曲面形态引入薄壁管构型,能够提高薄壁管的耐撞性和轴向抗变形能力。     

撞击载荷下Nomex蜂窝夹芯梁的变形模式研究

本文研究了Nomex蜂窝夹芯结构在不同冲量下的变形模式和失效模式.实验采用子弹撞击的加载方式,对Nomex蜂窝夹芯梁施加大小不同的冲量,使用激光位移传感器测量每个试件后蒙皮的变形位移.分析了同芯层厚度,不同蒙皮厚度的Nomex蜂窝夹芯梁在不同冲量作用下抵抗变形的能力,以及冲量大小与蒙皮厚度对夹芯梁抵抗撞击能力的影响,计算分析了蒙皮与芯层的吸能性.实验结果表明:增加蒙皮的厚度能够改善夹芯梁在撞击荷载下抵抗变形的能力,在撞击过程中芯层吸收了50％左右的能量,且冲量越大,芯层吸收的能量越多.     

基于77GHz毫米波雷达接收天线的周期性条形阵列解耦结构优化方法

阵列天线是77 GHz毫米波雷达的核心硬件之一，其天线性能决定着雷达的探测能力。由于工作频率的升高以及毫米波雷达小型化、集成化的发展趋势，使得雷达阵列天线阵元间距过密，从而相互干扰出现强互耦效应，严重恶化雷达阵列天线的性能。为了解决上述问题，本文提出了一种基于77 GHz毫米波雷达接收天线的周期性条形阵列解耦结构优化方法。该方法通过优化周期性条形阵列解耦结构单元的条形厚度和间距，在保证阵列天线辐射性能的基础上，来抑制毫米波雷达接收天线阵元间的互耦并提高其阵元间的隔离度。仿真结果表明，相比于无解耦结构的阵列天线，提出的解耦结构能够有效地降低毫米波雷达接收天线间的耦合，尤其在中心频率77.75 GHz处互耦减少了13.29 dB。在施加周期性条形阵列解耦结构前后，阵列天线均在77.5 GHz～78.5 GHz指定频段内正常工作，且合成辐射方向图的最大增益几乎保持不变，从而保证了毫米波雷达阵列天线的辐射性能。典型的数值算例能够很好地验证所提方法的有效性。     

Multi-objective optimization of the sandwich panels with prismatic cores using genetic algorithms

In the present study, a new type of sandwich panels with prismatic cores, which are capable of load bearing as well as cooling, is optimized to have minimum weight and maximum heat transfer performance. In order to simultaneously minimize the total weight and maximize the heat transfer performance, a multi-objective optimization approach has been developed using genetic algorithms. A set of compromised solutions, known as the tradeoff surface, is obtained. The tradeoff information between the two objectives is exploited in terms of multi-functionality of the sandwich panels, and the relation between the two objectives is quantified in the present study. The detailed configurations and dimensions of the sandwich panels at the optima are provided. Some basic characteristics of the sandwich panels with prismatic cores have been observed in terms of their multi-functionality.     

复合材料层合夹层壳的非线性稳定性有限元分析

本文用有限元法分析了复合材料层板为面板的夹层壳的非线性稳定性问题,求得屈曲时的临界载荷因子及初始后屈曲参数.通过对飞机雷达罩的稳定性计算,表明本文分析与试验结果是吻合的.