This study presents a comprehensive investigation into the mechanical behavior of sandwich composite structures featuring six distinct core geometries under three-point bending conditions. Through detailed finite element analysis (FEA), the research examines the performance characteristics of I-shaped, traditional honeycomb (NIDA), O-shaped, X-shaped, semi-circular, and modified core geometries. The analysis focused on stress distribution patterns, displacement responses, and overall structural integrity. Results demonstrate that the semi-circular core geometry exhibits superior mechanical properties, achieving an 84.66% improvement in positive stress resistance and 74.79% enhancement in negative stress resistance compared to the traditional honeycomb reference model. The study revealed consistent linear elastic behavior across all models within the tested displacement range, with the semi-circular configuration showing optimal stress distribution and minimal core deformation. Using aluminum for facings and core materials, the research evaluated mechanical responses through displacement-controlled loading conditions, measuring stress concentrations at critical points and analyzing deformation patterns. This research provides valuable insights into the relationship between core geometry and mechanical performance, offering practical implications for engineering applications requiring high strength-to-weight ratios and enhanced flexural resistance in modern structural design.
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