Loading points for industrial scale sandwich structures – A numerical and experimental design study

Abstract

Objective of the present study is a design study on optimum geometries for load application points for thermoplastic sandwich structures suitable for industrial scale mass production. The design of the loading points is performed using a combined numerical and experimental multi-step approch. In a preliminary numerical study, promising design options are identified using a four-step procedure: starting from an initial concept phase, a trade-off analysis of a variety of design options is performed. Based on the results, the three most promising options are optimized further until a detailed optimization of the leading design option is performed. All design options are chosen such that they can be manufactured in an economic manner using a compression molding process for functionalization of sandwich structures with thermoplastic tape laminates as their face sheets. In a subsequent experimental study, the three most promising options identified in the preliminary numerical design study are re-designed considering manufacturing aspects, manufactured, tested and assessed under quasi-static, creep and fatigue conditions.