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Christos Kassapoglou,^ Steven C. Fantle,^ and Jack C. Chou^
R E F E R E N C E : Kassapoglou, C, Fantle, S. C, and Chou, J. C, More specifically, H o f f and Mautner [7] used an energy method
"Wrinkling of Composite Sandwicli Structures Under Compres- and a sinusoidal wave to model the out-of-plane deflections of the
sion," Journal of Composites Teciinology & Research, JCTRER, Vol. sandwich facesheets. Comparison with test results was not very
17, No. 4, October 1995, pp. 308-316.
favorable because some of the material properties were not accu-
rately known. In his treatment, Yussuff [2] modeled the facesheet
A B S T R A C T : The phenomenon of wrinkling as a failure mode of
sandwich composite structures under compression is examined using as a beam with initial waviness on an elastic foundation. Due to
analysis verified by testing. Two cases are considered. In the first case, similar lack of accurate data on material properties, he fitted the
the facesheets are assumed flat and the wrinkling compression load is experimental data with his analytical predictions. Gutierrez and
determined as a buckling load along with the associated short wave- Webber [3] were among the first to attempt to realistically model
length. This solution is then compared to finite element predictions
and is shown to be in very good agreement. In the second case, the the facesheet/core interface. In an earlier work, Webber et al. [5]
facesheets are assumed to have a wavy shape of known amplitude included the membrane-bending coupling effects of the facesheets.
and wavelength. The various failure modes possible (core tension, Finally, the treatment in Ref 4 is based on a series of publications.
compression or shear, adhesive tension or shear, and facesheet bending) It is perhaps one of the most detailed treatments of the problem.
are modeled in an effort to predict failure. Test specimens were fabri-
In an experimental investigation conducted by Llorente [6], a
cated and the waviness of the facesheets was measured. The specimens
were then tested in compression. Reasonable agreement was found compression specimen was used to produce face wrinkling in
with theoretical predictions. sandwiches of toughened thermoset faces and Nomex core. Bonded
loading tabs and locally dense aluminum core were used to prevent
K E Y W O R D S : sandwich structure, wrinkling, waviness, compression the sandwich from crushing when installed in the hydraulic grips
failure, local buckling, short wavelength buckling for testing. This is by no means an exhaustive account o f previous
work. It only aims to highlight some of the main thrusts of the
Composite sandwich structures have been used widely in aircraft work in the subject.
industry because of their increased stiffness and reduced weight. The present investigation builds upon previous work, in particu-
Early on in their application, it was realized that one o f the most lar that o f H o f f and Mautner [1] and Yussuff [2], but attempts to
common failure modes under compression involved a short wave- go beyond a simple model of the waviness effect and examines
length stability type of failure. This local buckling was termed various failure modes that may arise in a wavy, facesheet under
wrinkling and many investigators developed approaches for the compression. These failure modes are particular to the constituents
quantification of this effect. of the structure: (1) core (compression, tension, or shear failure);
In the first analyses, facesheets were assumed perfectly flat and (2) adhesive (tension or shear); and (3) facesheet (local bending).
wrinkling was treated as a bifurcation problem where no out-of- The analytical expressions derived are verified against finite
plane deflections were allowed until some compressive load was element predictions (for facesheets without waviness) and test
reached where the facesheets would locally buckle in a symmetric results (for facesheets with waviness). A simple test specimen was
or antisymmetric mode. Such solutions can be found in Refs 1 designed to isolate the wrinkling failure mode and was shown to
through 5. I t was realized, however, that due to imperfections perform very well.
inherent in the fabrication process, such as core machining, or
cocuring the facesheets, or both, the fabricated structures exhibited
a small amplitude waviness [l-4\ that led to failures at loads Analytical Model
significantly lower than those predicted f r o m an analysis assuming
The analysis focuses on modeling the symmetric wrinlding
perfectly flat facesheets.
shown in Fig. 1. It is assumed that, before loading, each facesheet
While no accurate measurements of the waviness were provided, has a sinusoidal shape with amplitude A,, and half-wave length /.
certain investigators (notably Ref 4) recommended certain wavi- This shape is given by
ness ratios (ratio of waviness amplitude to facesheet thickness)
that, combined with a waviness analysis, seemed to give reasonable
'nx
agreement with the test results. = Ao sin (1)
T
'Stress analysts, Pratt and Whitney, West Palm Beach, FL.
^Stress analyst, Boeing Commercial Airplane Company, Seattle, WA. During loading, some portion o f the core w i l l deform. For thici<
© 1995 by the American Society for Testing and Materials
308
KASSAPOGLOU ET AL. ON COMPOSITE SANDWICH STRUCTURES 309
•ll v . = 77 sm — (7)
M I
G,vv , E, /2
M=\ - PmlP Pm = + (8)
12'2
w = 0.91 t (9a)
Core Failure
Pfnil ~ (14)
Differentiating Eq 11 with respect to y and multiplying by the
core compression or tension modulus, the maximum compression 1 -I-
and tension stresses in the core are determined (Locations A and
B in Fig. 2)
These expressions assume a constitutive law for the core in the
form of
Man
tens
This is a valid assumption since the in-plane stiffnesses for most
types of core are negligible.
Adhesive Failure
Core compression A
Core tension B P rail — (15)
Core shear C
Adhesive shear C
Adhesive tension B
Facesheet bending B or A
where 7„ is the ultimate shear strain for the adhesive. In a similar
KASSAPOGLOU ET AL. ON COMPOSITE SANDWICH STRUCTURES 311
anner, the applied load that results in adhesive normal stresses Because of the dependence on all these parameters, no single
[ual to the adhesive peel failure stresses is given by values of waviness amplitude and wavelength can be used. They
will vary with manufacturer and tooling used. Some average values
that tend to fit the data well can be used, as is recommended in
Pm = , (16) Ref 4. In addition, measurement of these parameters is complicated,
as will be shown.
here is the adhesive tension modulus and F,a is the adhesive Verification
nsion failure stress. Equations 15 and 16 should be regarded Analytical Model
approximate, since the adhesive is modeled with infinitesimal
ickness and as linearly elastic. The assumption of linear stress- To verify the model in the case of no waviness, a detailed
rain adhesive behavior is probably valid for the normal stress finite element model was constructed using MSC/NASTRAN. The
nee adhesives constrained between adherends exhibit plasticity model consisted of a 5.08- by 5.08-cm squared facesheet on 1.905-
cm core. The facesheet thickness was 0.0762 cm and was made
shear at loads significantly lower than the tension yield stress.
of four plain weave fabric plies with lay-up [ 0 / ± 4 5 / + 4 5 / 0 ] and
more elaborate analysis would be necessary to account for
material properties given in Table 2. The facesheet was modeled
Ihesive thickness effects, the local adhesive cusps at the core
with four-noded quadrilateral elements. The facesheet thickness
11 locations, and adhesive plasticity. The simplifications in the
consisted of one element with equivalent bending stiffness given
irrent model are not serious drawbacks since for most types of
by classical laminated-plate theory. The core was modeled with
ndwich structures, the adhesive does not fail, or, when it does,
eight noded solid elements with negligible in-plane stiffnesses
)es so in tension.
compared to the out-of-plane moduli. The model was loaded in
compression.
icesheet Failure To accurately pick up the modal shape in the loading direction,
a fine mesh was used with 50 equal sized elements (element
By assuming that the facesheet undergoes cylindrical bending
dimension 0.1016 cm). Perpendicular to the load, a coarse mesh
the applied Toad increases, the minimum curvature (and thus
with only four elements was used (element dimension 1.27 cm).
aximum bending stress) in the facesheet can be calculated by
The finite element mesh is shown in Fig. 3. Three different cases
king the second derivative of Eq 11 with respect to x This
were run in which the core axial (out-of-plane) stiffness and
bscript would correspond to Location A or B in Fig. 2. Then,
shear stiffness were varied. The wrinkling loads and half wave-
inoting by kf the value of curvature at which the facesheet fails
lengths were recorded. They are compared in Table 3 to those
cylindrical bending, the following expression is derived for the
predicted by E q 9.
)rresponding applied load.
Good agreement is observed between the analytical predictions
and the finite element solution both for the wrinkling stress and
the halfwave of the resulting mode. In all cases, the predictions
Pfail — (17)
are somewhat lower than the finite element results.
1 + ^ f ^
Test Results
The curvature at failure kj can be determined for the specific
The predictive capability of Eqs 12 through 17 was evaluated
cesheet by using a standard laminate failure criterion. The Tsai-
by comparing to the test results.
ill first-ply failure criterion was used in the results reported
The two options considered for test specimen configuration were
;low. No post first-ply failure analysis was done since for thin
a compression-type specimen similar to that used in Refs 6 and
cesheets with fabric material; first-ply failure is usually very
7 or a four-point bending specimen. The former configuration
ose to (or coincides with) final failure. The strength values used
requires a relatively complex and costly manufacturing process. The
the failure criterion are showninJTable 2.
latter, when applied to non-metallic cores, would result in large
Equations 12 through 17 form the basis for predicting wrinkling
deformations due to the relatively low shear stiffness of the core.
dure of sandwich panels under compression with initial waviness.
In order to produce low-cost and reliable specimens, a new 152-
3 is seen from these equations, the waviness amplitude and wave-
by 152- by 25-mm compression coupon was designed for the
ngth appear in all equations and become important parameters
face wrinkling tests. Test panels consisted of polyamide (Hexcel
at affect the failure mode and load. Accurate knowledge of these
irameters is necessary for accurate prediction of wrinkling loads.
In general, these parameters will depend on: the materials used TABLE 2—Plain weave fabric material properties.
ores with smaller cell size and thicker walls result in less wavi- Property Value
;ss); the fabrication process (accuracy in machining core flat
rfaces, precured versus cocured facesheets); tooling (use of stiff 65.8 GPa
ul plate and stiff and stretchable bag material reduce waviness); £22 65.8 GPa
G12 5.4 GPa
e thickness of the facesheet (facesheets with more than 7 to 10 Poisson's ratio 0.05
ies exhibit negligible waviness); and cure cycle specifics (cure Fill tension strength 951 MPa
essure, vacuum). Finally, the waviness will be affected by the Fill compression strength 847 MPa
ivironmental conditions. Most adhesives soften significantiy at Warp tension strength 1068 MPa
Warp compression strength 1068 MPa
ïvated temperatures in the presence of moisture. This will tend
Shear strength 125 MPa
alter the waviness from the room temperature ambient condition.
312 JOURNAL OF COMPOSITES TECHNOLOGY & RESEARCH
Face £rt.
Plies Specimen ID Orientation E„ MPa MPa tf, mm
(Note: not t o s c a l e I n Nomex, HRH-10 1/8-3.0 133.1 42.1 2.3 2.4, 1.24
the y d i r e c t i o n ) HFT, HFT-3/16-3.0 221.3 119.9 3.0 3.0" 1.60
P Korex, Korex-1/8-3.0 196.8 102.7 2.6 2.6° 1.46
133 42.0 646 658 -1.8 1.13 1.14 -0.9 Test Procedure
266 42.0 842 1033 -18.5 0.95 0.89 6.7
133 84.0 808 821 -1.6 1.06 1.32 -19.7 The test fixture shown in Fig. 5 was used to introduce loads
into the specimen from the United Datametric 4A test machine.
KASSAPOGLOU ET AL. ON COMPOSITE SANDWICH STRUCTURES 313
25 m m
^ \ a \ strain gages between the faces of the specimen. The procedure was repeated
until equal loading in the facesheets was observed. Then, the
specimen was continuously loaded to failure. With proper care,
^ 225 m m
tests using the fixture shown in Fig. 5 showed little bending effects,
51 m m
as evidenced by the back-to-back axial strain gages (Fig. 6).
1
TABLE 6—Compression face wriniding test faiiure stresses and
52 m m strains.
Core ribbon Number
# 3 0 0 ; ; direction Specimen of Stress, Strain,
Epocast ID Plies Core MPa *(0-6
potting
(typ) 3NB 2 Nomex 313.1 5890
INB 3 Nomex 297.2 6790
-152 m m - 2NB 4 Nomex 337.0 6340
H3NB 2 HFT 350.3 6590
HINB 3 HFT 348.9 7970
F I G . 4—Sandwich compression test specimen geometry.
H2NB 4 HFT 381.6 7180
KINB 3 Korex 365.5 8350
ï r ^ T e s t machine
top head
C-channel
Specimen
C-channel
Test machine
bottom head
C-clamps
TABLE i i—Comparison of predictions to test results. In order to apply Eqs 12 through 17, the waviness information
Experiment, Theory, Difference, particular to the fabrication process and materials used in this
Specimen MPa MPa % study is needed. Two additional untested specimens ( I N B and
2NB) were examined. The specimens were sectioned along the
3NB 313 295 -5.8 loading axis and approximately 3-cm long by 1-cm wide portions
INB 297 264 -11.2
2NB 337 426 +26.4 were mounted for examination under a microscope. Under 200
H3NB 350 344 -1.8 magnification, photographs were taken along a line parallel to the
HINB 349 255 -26.9 facesheet covering the whole length of the mount (Fig. 8). The
H2NB 382 309 -19.0 microscope traversed the mount so that the bottom of the field of
KINB 365 246 -32.7
view for every exposure was exacüy aligned with that of the
previous exposure. This guaranteed that the bottom of the frames
for all photographs formed a straight horizontal line at a fixed
Test Results and Comparison to Theoretical Predictions
distance f r o m the mount.
Post-test visual inspection suggests that all specimens failed by Using the bottom of the frame of each photograph as a reference,
wrinkling-initiated bond tension between one face sheet and the the distances o f the top and bottom of the facesheet were measured
core. Photographs of typical failures are shown in Fig. 7. The from that reference at 0.05-cm intervals. The location of the face-
failures extended the f u l l width of the specimens, with a failure sheet midplane was then calculated relative to the reference line
zone length of approximately 6.4 mm. None of the specimens as half the sum o f these two distances. A typical plot o f the
exhibited the core compression failure, which has been reported facesheet midplane distance from the reference line is shown in
in honeycomb panels with Kevlar® face sheets [6]. Fig. 9. Even though some noise is present, a distinct waviness is
The failure stress and strain values are given in Table 6. Stresses evident. The dashed lines show the points used to measure the
were calculated using the following relation amplitude and wavelength of the waviness. These measurements
are summarized in Table 7. The largest peak is used as it is expected
to drive failure. The measured facesheet thickness (averaged over
O'fail
2tfW 15 measurements at 0.05-cm intervals) for these specimens is also
shown i n Table 7.
where While the amplitudes are very close for the two specimens, the
half wavelengths vary significantly. It is interesting to note that
Pm — average compression failure load,
for the 2NB specimen, the half wavelength is close to the core
tf = nominal face sheet thickness from Table 2, and
cell size of 3.2 m m . This suggests that other core-related failure
W = specimen width.
modes such as intracellular buckling may interact with the failure
Strains were calculated using the following relation modes discussed above to precipitate specimen failure. This is not
the case for the I N B specimen. A third specimen was made with
o-rai the same configuration as I N B , but using 0.31 MPa autoclave
^raii —
pressure during cure (compared to 0.48 MPa for the other speci-
mens). The waviness o f this specimen showed significantly higher
where calculated elastic modulus parallel to the loading amplitude (by 30%), indicating a strong dependence of the wavi-
direction. ness on processing. Here, only the two specimens with the same
Conclusions
lacesneecj-
CORE
L O.Olcm
.0483. 0.019
.0157 I
.0432
S .0406
.0381
.0356-1
components affect the failure load of the sandwich. Thus, it w i l l [2] Yussuff, S., "Face Wrinkling and Core Strength in Sandwich Construc-
tion," Journal of the Royal Aeronautical Society, Vol. 64, 1960, pp.
facilitate material selection, give guidelines for improved materials, 164-167.
and make possible more efficient designs. [3] Gutierrez, A. J. and Webber, J. P H., "Flexural Wrinkling of Honey-
comb Sandwich Beams with Laminated Faces," International Journal
of Solids and Structures, Vol. 16, 1980, pp 645-651.
[4] Structural Sandwich Composites, Military Handbook 23A, Chpt. 3,
Acknowledgment
U.S. Department of Defense, Washington, DC, Dec. 1968.
[5] Webber, J. P H, Kyriakides, S., and Lee, C. T , "On the Wrinkling of
Honeycomb Sandwich Columns with Laminated Cross-Ply Faces,"
The test program in this investigation was funded by the US Aeronautics Journal, June 1976, pp. 264-272.
Army RAH-66 Program. The authors wish to express their grati- [Ó] Weems, D. and Llorente, S., "Evaluation of a Simplified Approach to
tude to the U.S. Army RAH-66 Comanche office for their support. In-Plane Shear Testing for Damage Tolerance Evaluation," American
Helicopter Society, 46th Annual Forum Proceedings, Washington, DC,
May 1990, pp. 713-720.
References [7] Kassapoglou, C , Jonas, R J., and Abbott, R., "Compressive Strengtli
of Composite Sandwich Panels After Impact Damage: An Experimen-
[/] Hoff, N. J. and Mautner, S. E„ "The Buckling of Sandwich Type tal and Analytical Study," Journal of Composites Technology and
Panels," Journal of Aeronautical Sciences, July 1945, pp. 285-297. Research, JCTRER, Vol. 10, Summer 1988, pp. 65-73.