Experimental and numerical study of effecting core configurations on the static and dynamic behavior of honeycomb plate with aluminum material

The sandwich panel incorporated a honeycomb core, a widely utilized composite structure recognized as a fundamental classification of composite materials. Comprised a core resembling a honeycomb, possessing thickness and softness, and is flank by rigid face sheets that sandwich various shapes and materials. In this paper, an investigation of static and dynamic analysis of aluminum honeycomb sandwich composite lightweight plates has been presented. Honeycomb sandwich plate samples are 300 mm long, and 300 mm wide, with various heights (10, 15, 20, and 25) mm. Aluminum honeycomb core is manufactured using resistance spot welding (RSW) as a novel technique instead of adhesive material, which is often used when an industrial flaw is detected. Numerical optimization based on response surface methodology (RSM) and design of experiment software (DOE) was used to verify the current work. A theoretical examination of the crashworthiness behavior (maximum bending load, maximum deflection) and vibration attributes (natural frequency, damping ratio, transient temporal response) of honeycomb sandwich panels with different design parameters was also carried out. In addition, the finite element method-based ANSYS software was used to confirm the theoretical conclusions. The findings of the present work showed that the relationship between the natural frequency, core height, and cell size is direct. In contrast, the relationship between the natural frequency and the thickness of the cell wall is inverse. Conversely, the damping ratio is inversely proportional to the core height and cell size but directly proportional to the thickness of the cell wall. The study indicates that altering the core height within 10–25 mm leads to a significant increase of 82 % in the natural frequency and a notable decrease of 49 % in the damping ratio. These findings are based on a specific cell size value of 0.01 m and a cell wall thickness of 0.001 m. Also, the results indicate that for a given set of cell wall thickness and size values, an increase in core height from 0.01 m to 0.025 m leads to a reduction of the maximum transient response percentage of approximately 76 %. Conversely, the increasing thickness of the cell wall, spanning from 0.3 to 0.7 mm at a constant core height equal to 0.015 m, resulted in a decrease of the maximum transient response by 7.8 %.