Sandwich Construction

Eng. Marco Leite

Prof. Manuel de Freitas
Prof. Arlindo Silva

Sandwich Construction
Introduo
Leis

Constitutivas
Exemplo
Design procedures
Aplicaes
Bibliografia

NOV 2004

Introduo
Origem
Princpio

Sandwich
Vantagens e Desvantagens

NOV 2004

Origem

II Gerra Mundial de Havilland Mosquito TT35 TA639

Fuselagem Plywood/Balsa/Plywood

Mosquito. The timber terror. Light, fast, deadly.

The excellent performance demonstrated by this airplane

had convinced numerous aircraft designers of the
superiority of sandwich structure as a means of
constructing more efficient airplanes

Falta de materiais na G.B. no auge na II Guerra Mundial

NOV 2004

Origem

II Guerra Mundial Vultee BT15 (USA)

Fuselagem Fibra de vidro em matriz de poliester com ncleo

em honeycomb de fibra de vidro ou ncleo de balsa.

NOV 2004

Princpio Sandwich
(c) web core

(d) corrugated core

NOV 2004

Vantagens e desvantagens

Vantagens

Desvantagens

Alta Resistncia Especfica

Perigoso para a sade durante a

construo (Resinas)

Alta Rigidez Especfica

Fracas possibilidades de reciclagem

(compsitos)

Baixo Peso

Falta de informao nos engenheiros

e designers

Isolamento Trmico e Acstico

Problemas de temperatura

Capacidade de resistncia corroso

Mudana de mentalidades

Facilidade de formas completas

Controlo de Qualidade

Capacidade de absoro de Energia

Variedade de critrios de rotura

Poucas peas estruturais necessrias

Incompatibilidade de materiais

Mltiplas possibilidades de escolha de

materiais
NOV 2004

Leis Constitutivas

Leis Constitutivas
Teoria

clssica vs Teoria 1 ordem

Campo de deslocamentos
Campo de deformaes
Relao Tenso-Extenso TCL
Leis Constitutivas TCL
Relao Tenso-Extenso 1 ordem
Leis Constitutivas 1 ordem
9

NOV 2004

Teoria clssica vs Teoria 1 ordem

Teoria Clssica Laminados

10

NOV 2004

Teoria 1 ordem

Campo de Deslocamentos
Teoria Clssica
Laminados

u x, y , z u0 x , y , z z x x , y

w 0
x
w
y 0
y
x

v x, y, z v0 x, y, z z y x, y
w x, y, z w0 x, y

Teoria 1 ordem
u
rotation about y - axis
z
v
y x, y
rotation about x - axis
z
x x, y

11

NOV 2004

Campo de Deformaes
Teoria Clssica Laminados
2

u 0 1 w 0
2w 0
x

z
x 2 x
x 2
2

v 0 1 w 0
2w 0
z
y

y 2 y
y 2
z 0
1 u 0 v 0 w 0 w 0
2w 0
2z
xy

2 y
x
x y
xy
1 w 0 w 0
xz

0
2
x
x
yz

12

1 w 0 w 0

0

2
y
y

NOV 2004

Teoria 1 ordem
2

u
1 w 0

x 0
z x
x 2 x
x
v
1 w 0

y 0
y 2 y
z 0

y
z
y

x y
u 0 v 0 w 0 w 0

z
xy

x
x y
x
y
y
w 0

xz x
0

w 0
0
yz y

Relao Tenso-Extenso TCL

Teoria Clssica Laminados 0 u 1 w0
x

x 2 x
0

13

0y

Extenses superfcie
mdia

u 0 v 0 w0 w0

y
x
y x

Curvaturas

2 w0
x 2
x

Relao
Tenso/Extenso

NOV 2004

v 1 w0

y 2 y
0

0
xy

x

y

xy

2 w0
y 2
y

2 w0
xy 2
xy

0x z x

i
0
Q
y z y
0

z
xy
xy

Leis Constitutivas TCL

Force per unit length:
N x
t2

N
t2
xy

xy

x0
N

i
dz
Q y0
k 1
xy 0

kx
zk
N
i
dz

Q ky
z
k 1
k 1
k xy

zk

zdz

zk 1

14

xy

NOV 2004

Moment per unit length:

x

A
B

B D

M x
t2

M y

M
t2
xy

Foras de membrana
actuantes no laminado

x0

i
zdz
Q y0
k 1
xy 0
N

kx
i
zdz

Q ky

z
k 1
k 1
k xy
zk

zk

z dz
2

zk 1

Momentos actuantes
no laminado

Relao Tenso-Extenso 1 ordem

Extenses superfcie mdia

0yz

w
y
y
0

v 0 1 w0

y 2 y
w0
0
xz
x
x

u 0 1 w0

x 2 x
0
x

0
y

u 0 v 0 w0 w0

y
x
x y
0
xy

Curvaturas
y
x
x
y
x
x

xy x y
yz xz 0
y
x
NOV 2004

15

Relao Tenso/Extenso

x

y
xy

yz
xz

Q i

0x z x
0

y
y

0
xy z xy
0yz

0
xz

Leis constitutivas 1 Ordem

Transverse shear
force resultants:
h

Qx

xz

Qy

dz

yz

dz

h 2

Qx

Q y

16

A 44

NOV 2004

A 45

N y A

N

xy

h 2
h

A 45

A 55

w 0
x
x
w 0

y
y

u 0 1 w 0

x 2 x
2
v 0 1 w 0

y 2 y
u 0 v 0 w 0 w 0

y
x
x y

M y B

M

xy

u 0 1 w 0

x 2 x
2
v 0 1 w 0

y 2 y
u 0 v 0 w 0 w 0

y
x
x y

x
x
y

x y
y x

Mx

Nx

x
x
y

x y
y x

Exemplo Ensaios 3PB

Viga

de contraplacado

Comparao entre a TCL e 1 Ordem

Vigas

17

sandwich faces em GRP ncleo PU

Comparao entre a TCL e 1 Ordem

NOV 2004

Exemplo Ensaios 3PB

Deslocamento a meio vo:

PL3 PL
w

48D 4U
Corte
TCL (bending)
1 Ordem

18

NOV 2004

Viga de contraplacado 18.2 mm

Contraplacado

de
madeira de vidoeiro

19

13 camadas
[0,90,0...,0,90,0]
Material Ortotrpico
Vo 1000 mm
Resultados Fora vs
Deslocamento

NOV 2004

Viga de contraplacado 18.2 mm

1.2
TCL
1

FEM

Fora [kN]

CNTPL 18
0.8
0.6
0.4
0.2
0
0

20

NOV 2004

10

Deslocamento [mm]

15

20

Viga sandwich em GRP + PU

Viga sandwich

Faces em fibra de vidro

em matriz de polister
Espessura de 2.5 mm
Gramagem de 900 g/m2

Materiais Isotrpicos

Ncleo em espuma de
poliuretano
Espessura de 50 mm
Densidade de 40 kg/m3

21

NOV 2004

Faces
E = 6100 MPa
= 0.33
Ncleo
E = 7.5 Mpa
= 0.33

Vigas sandwich em GRP + PU

22

NOV 2004

Design procedures

Design procedures

24

Vrios envelopes de
rotura concorrentes
Altamente dependente
da geometria e do
carregamento

NOV 2004

Design procedures

25

NOV 2004

Design procedures

26

NOV 2004

Design procedures

27

NOV 2004

Aplicaes

Aplicaes
Aeroespacial
Aeronutico
Construo
Desporto
Naval
Automvel
Veculos
etc

29

NOV 2004

Ferrovirios

Satlites

1 Solar Panels : Epoxy carbon prepregs, aluminum honeycomb,

film adhesive
2 Reflectors Antennae : Epoxy/aramid prepreg, cyanate carbon
prepreg, aramid/aluminum honeycomb
3 Satellite Structures : Carbon prepreg, aluminum honeycomb, film
adhesive

30

NOV 2004

Aeroespacial
1 Fairings: Carbon prepregs. Aluminium
honeycomb and adhesives.
2 External Payload Carrier Assembly (SPELTRA):
Carbon prepregs, aluminium honeycombs and
adhesives.
3 EPS Ring: Epoxy/carbon prepreg or RTM.
4 Front Skirt: Carbon prepreg.
5 Booster Capotage: Epoxy glass/non-metallic
honeycomb.
6 Yoke: Epoxy carbon filament winding.
7 Heat Shield: Carbon prepreg/high temperature
resistant glass fabric.

31

NOV 2004

Aeronautico

32

1 Radar Transparent Radome: Epoxy

or BMI Prepreg or RTM resins and
woven preforms (socks)

6 Wing Skins and Ribs: Epoxy carbon

and glass Prepregs

2 Foreplane Canard Wings: Epoxy

carbon Prepregs

7 Fin Tip: Epoxy/quartz Prepregs

3 Fuselage Panel Sections: Epoxy

carbon Prepregs. Non-metallic
honeycomb core and Redux
adhesives

8 Rudder: Epoxy carbon Prepreg

4 Leading Edge Devices: Epoxy

carbon and glass Prepregs

9 Fin: Epoxy carbon/glass Prepreg

5 Fin Fairings: Epoxy glass and

carbon Prepregs

10 Flying Control Surfaces: Epoxy

carbon and glass Prepregs.
Honeycomb core material and Redux
adhesives

NOV 2004

Ps do rotor de um helicptero Sea

King, mostrando a estrutura interna em
compsito. Com a aplicao de
compsitos consegue-se maior
velocidade das ps e menor
transmisso de vibraes estrutura.

33

NOV 2004

Naval

34

1 Decking: Heavy duty structural sandwich panels

9 Weather Shield: Prepregs and honeycombs.

2 Hull Skin Structure: Prepregs, engineered fabrics,

honeycombs.

10 Communications Equipment : Prepregs and

honeycombs.

3 Lightweight Floor Structure: Sandwich panels.

11 Companionway Stairs : Structural sandwich

panels

4 Suspended Ceilings : Lightweight sandwich

panels/honeycombs.

12 Partitions: Lightweight sandwich panels.

5 Interior Furnishings : Lightweight stiff sandwich panels

suitable for fabrication. Prepregs and fabrics.

13 Lightweight Superstructure: Sandwich panels

and Prepregs.

6 Hull Skin Structure: Prepregs, engineered fabrics,

honeycombs.

14 Engine Room : Sandwich panels and special

products for FST and sound attenuation..

7 Accommodation Cabin Units: Lightweight sandwich

panels, Prepregs and honeycombs.

15 Drive Shafts & Couplings: Epoxy Prepregs and

fabrics

8NOV
Bridge
Deck Consoles: Lightweight sandwich panels.
2004

Naval

35

NOV 2004

Desporto

36

NOV 2004

O quadro (que j nem sequer tem a forma tradicional de

um quadro...) da bicicleta da figura feito em carbono/
epoxy, bem como as jantes das rodas. Consegue-se
maior rigidez e menor peso em relao s estruturas de
alumnio. Alm disso, o design pode e deve ser alterado
para maximizar os benefcios do novo material.

37

NOV 2004

Aplicaes diversas de compsitos em artigos de desporto e

lazer. A sua utilizao destina-se, em geral, a poupar peso,
ganhando rigidez e resistncia e, por vezes, permitindo um
design mais atractivo que as ligas metlicas, devido facilidade
de moldagem.

38

NOV 2004

Construo civil

39

NOV 2004

Comboios
Sandwich technology:
The sandwich principle has been successfully
used in the marine and aerospace industries.
Now, Bombardier's new Fully Integrated
Carbody Assembly System (FICAS)
revolutionizes manufacturing in the rail
industry.

40

FICAS consists of a thin sandwich construction

comprising a steel skin bonded to a rigid core.
The advantage of this approach to the overall
space saving equation is that the sidewalls
become significantly thinner than a
conventional wall, with possible savings of up
to 120 millimeters in wall thickness. (May 2003)
NOV 2004

Automvel

With the long version, the A-class sets a new record for compact cars, for no
other automobile in this market segment offers so much cubic capacity, as
much as 68.2 cubic feet which is 11 percent more than the unchanged
current standard version.

The spatial economy of the new body variant is equally

commendable: since the drive units, thanks to the sandwich
concept, are positioned partly in front of and partly beneath the
passenger cell, 53 percent of the 12 foot 5 inch body is available to
the passengers
With the new variant we can now also satisfy prospective customers
who were already convinced by the A-Class design and concept but
wanted to have more room, emphasized D. Joachim Schmidt,
member of divisional management

41

NOV 2004

Automvel

Therefore, American's steel manufacturers hired Porsche Engineering

Services to develop a new kind of steel monocoque technology calls Ultra
Light Steel Auto Body (ULSAB). As shown in the picture, basically it has the
same structure as a conventional monocoque. What it differs from its donor
is in minor details - the use of "Hydroform" parts, sandwich steel and laser
beam welding.

42

Sandwich steel is made from a thermoplastic (polypropylene) core in

between two very thin steel skins. This combination is up to 50
percent lighter compared with a piece of homogenous steel without a
penalty in performance. Because it shows excellent rigidity, it is
applied in areas that call for high bending stiffness. However, it
cannot be used in everywhere because it needs adhesive bonding or
riveting instead of welding.

NOV 2004

Transporte Isotrmico

43

Vantagem da construo sandwich:

Alto isolamento trmico aliado ao desempenho estrutural

NOV 2004

Bibliografia

Bibiografia

45

Plantema, F.J., Sandwich construction; the bending and buckling of sandwich beams, plates,
and shells. 1966, New York,: Wiley. xx, 246.
Allen, H.G., Analysis and design of structural sandwich panels. 1st ed. 1969, Oxford New
York: Pergamon. xvi, 283.
Forest Products, L., Wood handbook : wood as an engineering material. General technical
report (Forest Products Laboratory) ; FPL-GTR-113. 1999, Madison: The Laboratory.
Gay, D., Matriaux composites. 4e d. rev. et augm. ed. Collection Matriaux. 1997, Paris:
Herms,. 672.
Gibson Lorna, J. and F. Ashby Michael, Cellular solids : structure & properties. International
series on materials science & technology. 1988, Oxford: Pergamon 1988.
Metzger, D.J., The selection of sandwich panels. 1970: Ithaca, N.Y. p. x, 142 l.
Middleton, D.H., Composite materials in aircraft structures. 1990, Harlow: Longman Scientific
& Technical.
Vinson, J.R., The behavior of sandwich structures of isotropic and composite materials. 1999,
Lancaster, Pa.: Technomic Publishing Co.
Zenkert, D., An introduction to sandwich construction. 1997, Warley: Emas.
Zenkert, D. and F. Nordic Industrial, The handbook of sandwich construction. North European
engineering and science conference series. 1997, Cradley Heath: EMAS Publishing.
NOV 2004

FIM