Honeycomb Panels Research Articles

Phase Diagrams for Anticlastic and Synclastic Bending Curvatures of Hexagonal and Re-entrant Honeycombs

Abstract Transformation between saddle- and dome-like bending shapes of regular and re-entrant hexagonal honeycomb panels are explored. An analytical model is proposed to uncover the underlying mechanisms and identify the controlling parameter when the cell walls are slender beams. Then, 3D finite element simulations are performed to examine the architecture dependence of bending shape and construct the phase diagrams of anticlastic and synclastic curvatures when the cell walls have a general geometry. The results are believed helpful to the design and application of related honeycomb structures.

Paper‐based sensors for real‐time cure monitoring in the production of glass fiber‐reinforced phenol‐formaldehyde composites for aerospace interiors

AbstractThe aerospace industries demand for advanced materials necessitates stringent quality control measures, particularly for composite structures to ensure optimal curing and structural integrity. Traditional methods like differential scanning calorimetry (DSC) and dynamic mechanical analysis, while useful, are limited to laboratory settings. This study explores the use of a printed paper‐based sensor for real‐time cure monitoring of glass fiber‐reinforced phenol‐formaldehyde (PF/GF) prepregs. The sensor, composed of a cellulose paper substrate with screen‐printed electrodes, offers flexibility, ease of integration, and cost‐effectiveness compared to commercial polymer‐based dielectric sensors. Real‐time monitoring with the printed paper‐based sensor was conducted at temperatures ranging from 130 to 180°C, both with and without pressure, and validated against DSC and Fourier‐transform infrared (FTIR) spectroscopy. The results showed a strong correlation between real‐time monitoring and the DSC prediction model, as well as FTIR spectroscopy. Notably, the real‐time monitoring revealed a shorter curing cycle on the production line than the predicted cure kinetic model, which is crucial for large‐scale production, such as fabricating honeycomb panels for aircraft interiors. This research underscores the importance of innovative sensor technologies in improving quality control and manufacturing efficiency in aerospace composites.Highlights Cure Monitoring of PF‐based prepregs was carried out using paper‐based sensor. Sensor offered reproducibility and seamless integration in composites. Sensor data showed a strong correlation with DSC and FTIR spectroscopy results. Paper sensors enable online monitoring of composite in aerospace manufacturing.

Reverse design and application of phononic crystals based on deep learning

Abstract This paper reverse-design phononic crystals with band gaps within a targeted frequency band using the trained Conditional Variational Autoencoder (CVAE) and further studies the vibro-acoustic characteristics of a composite sandwich plate with a phononic crystal panel as the core layer. Firstly, a matrix composed of 0s and 1s, representing scatterers and substrates, is randomly generated by MATLAB to represent two-dimensional phononic crystals. The three-dimensional phononic crystals are obtained by stretching the two-dimensional phononic crystals along the average direction, and COMSOL Multiphysics is used to calculate the band gap. In order to maximize the production of phononic crystals with a band gap distribution, the Convolutional Neural Network (CNN) is trained to predict whether the generated phononic crystals have band gaps. Finally, using data on the structures of phononic crystals and their band gap distributions, the CVAE is trained to achieve the reverse design of artificial periodic structures based on the target band gap. To verify the effectiveness of the structures obtained through the reverse design method on vibration and noise reduction, the submerged vibro-acoustic characteristics of a composite sandwich plate consisting of a phononic crystal panel and carbon fiber panels are studied. The model of the composite sandwich plate is fabricated, and its submerged vibro-acoustic characteristics are tested and compared with numerical results. Finally, the submerged vibro-acoustic response levels of composite sandwich plates with phononic crystal panels and honeycomb panels as core layers are compared using numerical methods to assess the phononic crystal panel's vibration and noise reduction effects.

Effects of honeycomb panel's finite dimensions on acoustic performance for lightweight sound insulation

A honeycomb panel is considered as a lightweight sound insulation solution both numerically and experimentally. First, a unit cell with fixed and infinite periodic conditions is modeled, exhibiting high insulation levels up to the membrane's eigenfrequency. Closer to industrial applications, a numerical model is developed, where the fixed conditions are applied only on the sides of the finite honeycomb panel. Taking into account structural modes of longer wavelength with this configuration, the panel's first eigenfrequency occurs at lower frequency than the previous case, yielding to a reduced insulation power. Nevertheless, the low frequency performance obtained numerically on the honeycomb panel is validated with measurements under normal incidence plane waves and diffuse field excitations.

Acoustic Black Holes ceiling for noise control on board cruise ships

Entertainment is one of the principal noise sources on board cruise ships. To ensure high comfort standards in cabins located above public areas, ceilings made by rockwool and honeycomb panels are used as acoustic insulation. Engineers are searching for new solutions to substitute the traditional system, as the rockwool presents health concerns. Acoustic metamaterials are among the candidates for new products in this field. This paper aims to verify the feasibility of an innovative ceiling design with enhanced Acoustic Black Holes (ABH). The proposed solution is compared with the traditional ones, using the Sound Reduction (R) as Key Performance Index (KPI). Traditional solutions are experimentally tested, and the data are used to assess an acoustic Finite Element Method (FEM) model, which is then used to simulate the acoustic properties of the proposed ceiling.

Manufacturing Technology, Experimental and Numerical Analysis of Static Bending of Three-Layer Composite Plate with Honeycomb Structure

The use of thin-walled constructions with honeycomb structure manufactured using additive technologies has several advantages compared to the constructions manufactured using traditional technologies. First of all, this is explained by the fact that additive technologies greatly simplify the production of honeycomb structures. A technology for manufacturing a three-layer composite plate with a honeycomb structure obtained using additive technologies is proposed in the paper. PLA plastic was chosen as the material for the honeycomb structure production. Printing was carried out using a "Delta" printer with parallel kinematic chains using FDM technologies. The printing temperature was 215 °C, table temperature – 60 °C. A fundamentally new scheme of an experimental plant for studying the bending of a three-layer plate is proposed. The aim of the research is to conduct tests of samples of a three-layer honeycomb panel for static bending when one edge of the sample is rigidly pinched. For the tests, a certified TiraTest 2300 universal testing machine (UTM), which allows to perform tensile and compression tests at a given traverse speed and measure the load with a relative error of 1%, was used. The UTM allows to load the sample and measure the load and displacement of the traverse. A sixteen-channel strain gauge station is used to measure the surface deformations of the housings. Transverse displacements of a three-layer plate were obtained as experimental data. The bending of the three-layer plate is modeled in the commercial package ANSYS. The results of experimental and numerical analysis coincide well.

Sound absorption performance of honeycomb metamaterials Inspired by Mortise-and-Tenon structures

To address the limitations of traditional honeycomb sandwich structures in attenuating mid to low-frequency sounds, particularly in configurations with minimal thickness and weight, this study introduces an innovative honeycomb acoustic metamaterial incorporating the traditional Chinese mortise-and-tenon joint. We systematically investigate the acoustic absorption characteristics of the modified honeycomb structure through theoretical analysis, empirical validation, and numerical simulations. Our experimental setup maintained consistent geometric parameters across all trials and demonstrated that the resonance frequency of the modified honeycomb structure decreased by 10 % relative to its conventional counterpart. We conducted detailed analyses on the influence of micropore positioning, tenon geometric dimensions, and micropore diameters on the acoustic performance. Notably, elongating the tenon from 2 mm to 6 mm resulted in a 15 % reduction in resonance frequency, whereas increasing the micropore-to-tenon distance from 0 mm to 4 mm led to a 30 % increase. The integration of the mortise-and-tenon joint significantly enhances the mid to low-frequency sound absorption performance of the honeycomb panels. This improvement is achieved while preserving the structural benefits of low panel thickness and shallow cavity depth, alongside simplified processing of micropores. Our findings elucidate a promising approach to augmenting the acoustic properties of lightweight structural materials, thereby extending their application potential in noise control engineering. This study not only contributes a novel perspective to the design and optimization of acoustic metamaterials but also highlights the potential for integrating traditional architectural techniques with modern material science to enhance noise control solutions.

Effect of Honeycomb Geometrical Parameters on Equivalent Radiated Power and Frequency Response of Motor Casing and Gearbox Surface of a Powertrain

ABSTRACTThe powertrain, as a central source of noise and vibration, is crucial in determining the overall NVH (noise, vibration and harshness) performance of vehicles, necessitating the optimisation of its structural components for improved durability and passenger comfort. This paper investigates the influence of key geometrical parameters—cell thickness, skin thickness and cell length—on the complex frequency modes of honeycomb and square sandwich structures using the Altair OptiStruct solver 2022 and fast Fourier transform analyser. The driven and non‐driven ends of a motor casing and a gearbox, represented by honeycomb structures and ribs, were subjected to an evaluation of equivalent radiated power (ERP). The results show that the square structure performs better at higher skin thickness when resisting severe lateral stresses than the honeycomb while being less stiff at higher cell thickness. Notably, smaller cell length had a substantial impact on the modes of the honeycomb structure, whereas larger cell length had an impact on the square structure. Response surface methodology was used to optimise the modal frequencies of both square and honeycomb panels simultaneously. An ideal cell length of 5.88 mm, skin thickness of 1.303 mm and cell thickness of 0.381 mm were found for the honeycomb construction, yielding a composite desirability of 0.981. On the other hand, with a cell length of 5.045 mm, skin thickness of 1.484 mm and cell thickness of 0.331 mm, the square structure achieved a composite desirability of 0.989. It is interesting to note that the driven end casing of the motor casing made more noise with the addition of ribs than the non‐driven end and gearbox. But compared to the original powertrain model, adding a honeycomb structure resulted in a noise reduction of about 10%.

Global buckling response of sandwich panels with additively manufactured lattice cores

This paper deals with the analytical and numerical global buckling analysis of rectangular sandwich plates utilized AlSi10 Mg in both facesheets and lattice cores. In this study, six different strut-based lattice core models are designed. Additionally, the buckling resistance of lattice panels is compared with a typical honeycomb panel. Analytical studies were carried out using Kirchoff plate theory (CLPT), first-order shear deformation theory (FSDT) coded on MATLAB and finite element (FE) analyses in Abaqus. In the theoretical approaches, the Navier solution is derived for sandwich plates with simply supported boundary conditions at all edges. In the FE analyses, validated homogenized lattice structures models were used to avoid excessive numbers of elements and to save computational time. The parametric effects of side-to-thickness ratio, and different designed core cells on global buckling responses are investigated. As a result of comparing the analytical results with the FE model, a good agreement is obtained, and it is found that analytical buckling analyses FSDT can be used within certain size limits for the global buckling analysis of lattice core sandwich structures.

Static and Dynamic Characteristics of 3D-Printed Orthogonal Hybrid Honeycomb Panels with Tunable Poisson’s Ratio

By adjusting the two wall angles of the orthogonal hybrid honeycomb (OHH), the tunable Poisson’s ratio change from negative to positive values and the variation in stiffness can be achieved. To effectively analyze its static and dynamic characteristics, a two-dimensional equivalent Kirchhoff–Love model (2D-EKM) is established based on the variational asymptotic method (VAM).This model aids in effectively addressing the complexity arising from anisotropy. The obtained equivalent orthotropic properties are validated through unit-cell uniaxial compression tests and three-point bending experiments on 3D-printed specimens. The numerical simulation results suggest that the VAM-based 2D-EKM can predict the in-plane and out-of-plane static behaviors of OHH panels, with a maximum error below 10%. Particularly in the dynamic analysis of a four-sided fixed OHH panel, the analysis time required by 2D-EKM is only 0.37% of that needed for the 3D FE model. The OHH-ZPR panel exhibits exceptional resistance to deformation, with a maximum deformation under in-plane tension reaching only 27% of that in the OHH-PPR panel. Moreover, each 1% increase in the height–length ratio results in a respective increase of 275.62% and 281.93% in equivalent bending stiffness along both directions. This highlights that enhancing this ratio effectively boosts the fundamental frequency compared to the elastic modulus ratio, effectively prevents low-frequency resonance occurrences, and offers vital insights for the design and optimization of OHH panels.

Evaluating water ingress in glass fiber plastic/Nomex honeycomb panels under varying panel orientation

The paper presents the results of experimental and numerical investigations on water ingress trapped in aircraft honeycomb panels. The ingress of atmospheric water during aircraft service may cause minor or major damages of airplane crucial components. The percentage of water/ice filling honeycomb cells is an important factor related to possible cell damage. This study is focused on the analysis of the following inspection parameters: 1) influence of panel orientation (horizontal, vertical and Inclined at 30, 45 and 60°) on the efficiency of water detection, 2) efficiency and optimization of a heating technique in evaluating water ingress, 3) influence of water/ice phase transformation on detectability of water ingress. The numerical analysis was conducted by using the ThermoCalc-3D software in order to evaluate the detectability of water ingress in the cases where a test panel is placed in different spatial orientations. The samples with water and ice were tested and analysed by using several data processing algorithms available in the ThermoFit software to enhance water detection performance. The signal-to-noise ratio concept was used to compare efficiency of image processing algorithms in the inspection of water ingress in honeycomb panels with varying water content, spatial orientation and water/ice phase transformation.

Damage mechanism and bending properties degradation of aviation composite honeycomb sandwich structures under laser irradiation

Damage mechanism and bending properties degradation of aviation composite honeycomb sandwich structures are studied under different laser conditions in this paper. Firstly, the damage test of composite honeycomb sandwich structures is conducted. Temperature field and ablation process during laser irradiation are analyzed. Damage morphology and mechanism are verified. Secondly, the influence of laser damage on the bending properties of composite honeycomb panels is studied. Progressive damage process and failure mechanism of honeycomb structures during loading are explored by digital image correlation (DIC) and strain trend. The results show that the temperature at the center point of front surface reaches more than 2000 °C within 1 s under the laser irradiation, while the temperature of back surface exhibits hysteresis. The ablation hole is funnel-shaped and has severe delamination. In the heat affected zone (HAZ), resin matrix has been basically sublimated and oxidized, leaving only carbon fiber bundles and some residual carbon. The honeycomb core in this area has been completely carbonized and deformed. During bending process, the honeycomb core breaks firstly, and strain appears peak at both crack ends, leading the crack extend along both sides. The ultimate load of damaged specimen is 2.35kN, which has a 42.26 % drop compared to that of healthy specimen 4.07kN. Bending properties of specimen are significantly degraded by laser damage.

A finite element model for analyzing curved surface sandwich panel forming

The article establishes a finite element (FE) model of sandwich panel (referred to as CSC FE model) using shell structure core and solid structure face sheet and provides a detailed derivation of the data transfer process between the shell structure and the solid structure in the FE model. In order to explore the application of CSC FE model in the curved surface sandwich panel forming, this paper studies the single curvature and double curvature sandwich panel forming in detail. Based on the maturity of the three-point bending theory, in order to facilitate theoretical verification, the article chooses the three-point bending process to study the single curvature sandwich panels forming. It is proved that the CSC FE model can be effectively applied to single curvature sandwich panel forming through three-point bending theory, numerical simulations and experiments of brazed aluminum honeycomb panel (BAHP). Low cost and efficient multi-point forming (MPF) process is used to analyze the double curvature sandwich panel forming. By MPF experiments and numerical simulations of saddle-shaped and spherical BAHPs, and with the help of 3D laser scanning technology, it is proved that the CSC FE model can accurately predict the curved surface shape of double curvature sandwich panel forming.

Application of Cellulose and Paper-Based Products in Building Acoustics

This article presents a comprehensive acoustic study of paper-based building products: cellulose wool, paperboard, corrugated cardboard, and honeycomb panels. The material configurations included the intact form as well as the various modifications, i.e., density variation, multiple-layered staking, perforation or acoustic metamaterial setup. Tests covered acoustic absorption and insulation properties, with the last examined under excitation of both a plane wave and a diffused field. Additionally, the cellulose wool is provided with the characteristic impedance and propagation wavenumber results; and the paperboard was tested for its dynamic elastic and damping properties. The paper-based products, giving their weight, prove to be a convincing replacement for conventional materials by both absorptive and insulation performance. The maximum acquired sound reduction index, for exceptionally lightweight (2.2 kg/m2) paper double-wall metamaterial structure, reached 26 dB.

Sound Absorption Performance of Ultralight Honeycomb Sandwich Panels Filled with "Network" Fibers-Juncus effusus.

This study investigates lightweight and efficient candidates for sound absorption to address the growing demand for sustainable and eco-friendly materials in noise attenuation. Juncus effusus (JE) is a natural fiber known for its unique three-dimensional network, providing a viable and sustainable filler for enhanced sound absorption in honeycomb panels. Microperforated-panel (MPP) honeycomb absorbers incorporating JE fillers were fabricated and designed, focusing on optimizing the absorber designs by varying JE filler densities, geometrical arrangements, and MPP parameters. At optimal filling densities, the MPP-type honeycomb structures filled with JE fibers achieved high noise reduction coefficients (NRC) of 0.5 and 0.7 at 20 mm and 50 mm thicknesses, respectively. Using an analytical model and an artificial neural network (ANN) model, the sound absorption characteristics of these absorbers were successfully predicted. This study demonstrates the potential of JE fibers in improving noise mitigation strategies across different industries, offering more sustainable and efficient solutions for construction and transportation.

Evaluating Water Ingress in Glass Fiber Plastic/Nomex Honeycomb Panels under Varying Panel Orientation

Evaluating Water Ingress in Glass Fiber Plastic/Nomex Honeycomb Panels under Varying Panel Orientation

Damage identification of honeycomb sandwich structures based on Lamb waves and 1D-CNN

A specific method combining Lamb waves and 1D-CNN is proposed in this paper for damage assessment of honeycomb sandwich structures, which can identify the location and degree of damage simultaneously. The applicability of the Lamb waves method is verified by simulating the interaction between the Lamb waves and different degrees of damage on the honeycomb panel. In the experiment, four identical piezoelectric wafers were placed on a honeycomb plate in a square shape, and a mass block was placed inside to simulate damage. One of the sensors was used as an actuator to generate the Lamb waves signal, and the remaining three sensors received the response signals after interacting with the damage. The collected signals were denoised by Kalman filter, and the time domain signals were transformed into the frequency domain signals by Fourier transform, so as to extract the feature more effectively. The amplitude frequency characteristics of Lamb wave signals were used as inputs to the 1D-CNN model, and the damage categories were used as outputs. 365 samples were used for model testing, 364 were correctly identified with a correct recognition rate of 99.7 %. The result shows that the proposed method is feasible for damage identification of honeycomb sandwich structures.

Thermomechanical Collaborative Design and Experimental Verification of a Sandwich Structure with a Polyimide Foam Core

This paper introduces the technology and performance of a new sandwich structure consisting of carbon fiber composite face sheets, a polyimide foam core, and an aluminum honeycomb panel with both heat insulation and load-bearing functions. The heat-resistant performance of the sandwich structure was evaluated. The vacuum thermal conductivity of the sandwich structure in the vertical direction ranges from 0.54 to 0.92 (W/[m⋅K]) with increasing temperature from −170 to 135°C. A multilayer finite element model of carbon fiber cloth, polyimide foam, and aluminum honeycomb was established. Finally, a comprehensive evaluation of the mechanical and thermal insulation performance of the sandwich structure was conducted through random vibration testing and thermal vacuum testing. The results showed that the sandwich structure had good stiffness and thermal insulation performance, successfully verifying the effectiveness of the collaborative design.

Quantitative assessment of impact damage in stitched foam‐filled Aluminium honeycomb Sandwich panels by experimental and machine learning methods

AbstractNovel Stitched Foam‐filled Honeycomb Sandwich (SFHS) panels have been fabricated using vacuum‐assisted resin transfer molding to address the weak interfaces between the face sheets and the core in the Foam‐filled Honeycomb Sandwich (FHS) panel. The SFHS panels have shown better load‐bearing capacity and performance characteristics compared to FHS panel after Low‐Velocity Impact (LVI) tests. After the LVI test, MATLAB image processing was used to analyze the impact damage areas and failure mechanisms. In addition, Machine Learning regression algorithms were employed to predict the optimal amount of energy absorbed during low‐velocity impact testing of fabricated panels with a maximum impactor drop height of 700 mm. The results indicated that nylon yarn stitching significantly improved energy absorption and interfacial behavior compared to unstitched honeycomb panels. This research also revealed that SFHS1 panels with adjacent honeycomb cell stitching are more impact resistant, provide increased load carrying capacity, and are cost‐effective. These panels can be utilized by modern engineers to increase economy, durability, and functionality in industrial, automotive, and construction applications.Highlights Stitched Foam Filled Honeycomb Sandwich (SFHS) panels, manufactured via resin transfer molding, and eliminates weak interfaces between the face sheets and core. SFHS panels outperformed unstitched panels in load‐bearing and energy absorption during low‐velocity impact, as confirmed by MATLAB image analysis showing reduced damage and failure. Machine learning algorithms particularly polynomial regression model predicted maximum absorption energy precisely with 99.9% accuracy, close to experimental results. SFHS panels can be used in automotive and industrial applications due to their through‐thickness stitching.

Investigation of Static Flexural Strength of Aluminium Honeycomb Panels with Varying Cell Sizes

Investigation of Static Flexural Strength of Aluminium Honeycomb Panels with Varying Cell Sizes