Influence of Aspect Ratio on the Flexural and Buckling Behavior of an Aluminium Sandwich Composite: A Numerical and Experimental Approach

In the field of engineering materials, lightweight and ultra-lightweight composites are used in real time to a greater extent, with high-performance targeting for tailor-made systems in aerospace, automotive, and biomedical applications. Sandwich composites are among the most popular lightweight materials used in structural and vehicle-building applications. In the present investigation, one such sandwich composite laminate composed of aluminum face sheets and a high-density polyethylene core was considered to analyze sandwich composites’ flexural and buckling behavior experimentally and numerically. The influence of aspect ratios, such as length to thickness and width to thickness, on the flexural and buckling performance of sandwich composite laminates was explored in the study. Laminates with different widths, namely, 10, 12, and 15 mm, and a uniform thickness and length of 3 mm and 150 mm, respectively, were used for flexural analysis, whereas laminates with widths of 10, 12, and 15 mm and a uniform thickness and length of 3 mm and 350 mm, respectively, were used for buckling analysis. The geometrical influence of the laminates on mechanical performance was studied through performance measures such as critical bending load, flexural stiffness, inter-laminar shear stress, and critical buckling load. A significant influence of aspect ratio on the mechanical behavior of the laminates was observed using both experimental and numerical approaches. Flexural behavior was observed to be better at greater widths, namely, 15 mm, and with a minimum support span of 90 mm due to reduced spring back effects and increased bending resistance. A maximum width of 15 mm allowed for a higher buckling load capacity similar to that of bending resistance. A critical buckling load of 655.8 N seemed to be the maximum and was obtained for the highest aspect ratio, b/t = 5. The soft core and ductile metal face sheets offered combined resistance to both bending and buckling. A lower aspect ratio (span to thickness) rendered these sandwich laminates better in terms of both bending and buckling.