Free Vibration Analysis of
Free Vibration Analysis of
Master of Technology
in
Mechanical Engineering
By
AMIT KUMAR JHA
Master of Technology
in
Mechanical Engineering
By
AMIT KUMAR JHA
Under the guidance of
Prof. N.KAVI
CERTIFICATE
This is to certify that the thesis entitled FREE VIBRATION ANALYSIS OF
SANDWICH PANEL submitted by Sri Amit Kumar Jha in partial fulfillment of the
requirements for the award of Master of Technology Degree in Mechanical Engineering at
the National Institute of Technology, Rourkela (Deemed University) is an authentic work
carried out by him under my supervision and guidance.
To the best of my knowledge, the matter embodied in the thesis has not been
submitted to any other University / Institute for the award of any Degree or Diploma.
Mr. A. Ramamoorthy
Hindustan Aeronautics Limited
Bangalore-560017
Prof. N. Kavi
National Institute of Technology
Rourkela-769008
ACKNOWLEDGEMENT
I would like to express my deep sense of profound gratitude to my guide, Prof. N.
Kavi for his guidance and constant support.
I extend my thank to our HOD, Dr. B. K. Nanda for his valuable advices and
encouragement.
I would like to thank Mr. A. Ramamoorthy (CM Production, Aircraft Division and
Bangalore) for his guidance and constant support.
I would like to thank all HAL officers/employees who are supported me in carrying
out the project work in the organization.
I would like to thank to all those who are directly or indirectly supported me in
carrying out this thesis work successfully.
CONTENTS
Acknowledgment..i
Contents..ii
Abstract. iv
List of figures.v
List of tables..vii
1.
Introduction
1.1 Types of sandwich panel .2
1.2 Sandwich construction .2
1.3 Selection of sandwich composite structure ..6
1.4 Current application .......6
2.
Literature survey
2.1 Truss core sandwich 10
2.2Optimization of sandwich material 10
2.3 Global higher theory .11
3.
4.
5.
6.
Sandwich structure
6.1 Sandwich principle ..43
6.2 Stiffness to weight ratio of sandwich plate 44
7.
8.
iii
ABSTRACT
Use of Sandwich construction for an aircraft structural component is very common to
the present day. One of the primary requirements of aerospace structural materials is that they
should have low density, very stiff and strong.
Sandwich panels are thin-walled structures fabricated from two flat sheets separated
by a low density core. The core investigated here is of aluminium honeycomb structure
because of excellent crush strength and fatigue resistance. Sandwich panels have a very high
stiffness to weight ratio with respect equivalent solid plate because of low density core.
Modeling is developed in FEA (ANSYS) by consideration of rotary inertia.
The free
vibration analysis of isotropic plate and sandwich panels are studied. The results of FEA
(ANSYS) are compared with results of experimental and analytical work. Eight nodded
isoparametric shell element is used for FEA (ANSYS). Convergence study is also included
for high accuracy of the results. Analytical results are based on classical bending theory.
Mode shapes and corresponding natural frequencies are studied for simply supported
sandwich panel. Parameter studies of isotropic plate and sandwich panel are also covered in
this analysis. A detailed parameter study has been carried out of a simply supported sandwich
panel by increasing the core depth as a percentage of its total thickness, while maintaining a
constant mass.
iv
LIST OF FIGURES
Sl.
No.
Topic
Page
Sandwich panel with (a) continuous corrugated-core (b) to-hat core (c)
16
18
18
Unidirectional laminae
28
General laminates
31
10
32
11
36
12
36
13
43
Sl.
No.
14
Topic
Page
43
15
44
sections
16
49
17
50
18
51
52
20
53
21
56
22
57
23
58
24
60
61
panel
Effect of increase of face thickness on frequencies of sandwich
26
62
panel
27
63
28
64
vi
LIST OF TABLES
Sl.
No.
Topic
Page
Properties of aluminium
46
Specification of instruments
48
49
51
52
53
Specification of instruments
56
58
59
10
59
11
60
12
61
13
62
14
64
vii
Chapter 1
INTRODUCTION
INTRODUCTION
Sandwich panels have been successfully used for many years in the aviation and
aerospace industries, as well as in marine, and mechanical and civil engineering applications.
This is due to the attendant high stiffness and high strength to weight ratios of sandwich
systems [1]. The use of the sandwich constructions in the aerospace structures can be traced
back to Second World War when British De Havilland Mosquito bomber had utilized the
sandwich constructions [5]. In the early use, the sandwich structure was very simple in
construction, with simple cloth, fabric or thin metal facings were used and soft wood were
used as the core.
The conventional sandwich construction comprises a relatively thick core of lowdensity material which separates top and bottom faceplates (or faces or facings) which are
relatively thin but stiff. The materials that have been used in sandwich construction have been
many and varied but in quite recent times interest in sandwich construction has increased
with the introduction of new materials for use in the facings (e.g. fiber- reinforced composite
laminated material) and in the core (e.g. solid foams) [2].
Because of the separation of the core, face sheets can develop very high bending stresses.
The core stabilizes the face sheets and develops the required shear strength. Like the web of a
beam, the core carries shear stresses. Unlike the web, however, the core maintains continuous
support for the face sheets. The core must be rigid enough perpendicularly to the face sheets
to prevent crushing and its shear rigidity must be sufficient to prevent appreciable shearing
deformations. Although a sandwich composite never has a shearing rigidity as great as that of
a solid piece of face-sheet material, very stiff and light structures can be made from properly
designed sandwich composites.
\
Fig 1.4(b) Application of sandwich structure in helicopter [17].
(1. Rotor Blades, 2. Main and Cargo Doors, 3. Fuselage Panels, 4. Fuselage, 5. Boom and
Tail section)
fig (1.4). Honeycomb sandwich structures have been widely used for load-bearing purposes
in the aerospace due to their lightweight, high specific bending stiffness and strength under
distributed loads in addition to their good energy-absorbing capacity [8]. In a new spaceformed system called "Sunflower," the reflector is of honeycomb construction, having a thin
coating of pure aluminum protected by a thin coating of silicon oxide to give the very high
reflectivity needed for solar-energy collection. Thirty panels fold together into a nose-cone
package in the launch vehicle.
Building Construction
Architects use sandwich construction made of a variety of materials for walls,
ceilings, floor panels, and roofing. Cores for building materials include urethane foam (slab
or foam-in-place), polystyrene foam (board or mold), phenolic foam, phenolic-impregnated
paper honeycomb, woven fabrics (glass, nylon, silk, metal, etc.), balsa wood, plywood, metal
honeycomb, aluminum and ethylene copolymer foam. Facing sheets can be made from rigid
vinyl sheeting (fiat or corrugated) ; glass-reinforced, acrylic-modified polyester; acrylic
sheeting; plywood; hardwood; sheet metal (aluminum or steel); glass reinforced epoxy;
decorative laminate; gypsum; asbestos; and poured concrete [5].
Damped Structures
An increasing number of vibration problems must be controlled by damping resonant
response. By using a symmetric sandwich panel with a viscoelastic core, various degrees of
damping can be achieved, depending on the core material properties, core thickness, and
wavelength of the vibration mode [5].
Chapter 2
LITERATURE SURVEY
LITERATURE SURVEY
2.1 TRUSS CORE SANDWICH
Sandwich panels are thin-walled structures fabricated from two flat sheets, separated by
and attached to a core. An analytical solution for the dynamic response of such structures is
not available but equivalency in the form of a homogenous orthotropic thick plate can be
formulated. This paper considers a truss-core sandwich panel that is similar to conventional
sandwich systems, but eliminates many of the attendant problems associated with fabrication
of conventional forms. The dynamic response of the truss-core sandwich panel is then
formulated as a homogeneous orthotropic thick plate. Closed-form solution for a clamped
plate is derived. Closed-form solutions are compared with both 2-D and 3-D finite element
results. According to T.S. LOK and Q.H. CHENG, corrugated form has many advantages
over other form of sandwich structure. Some advantages are
The elimination of discrete connections and all its attendant problems. This is crucial
for structures or vessels designed to maintain pressure and water-tightness between
the outer and inner environments.
Better material utilization and ease of manufacturing since only one extrusion process
is needed. Transportation, handling and construction cost would be reduced since no
large flexible thin sheets are involved.
Promotion of designer flair to create curved shapes that linear flat conventional
sandwich panels are unable to provide [1].
2.2 OPTIMIZATION OF SANDWICH MATERIAL
This article presents an approach to facilitate comparison and optimization of
sandwich material combinations. Equivalent homogenized sandwich material properties
(bending stiffness, density, and cost) are presented graphically in material selection charts to
enable an efficient performance per cost evaluation. The effects of core shear deformations
and panel production costs can be included in those sandwich material selection charts. In
addition to weight advantages, economical advantages are vital for the potential use of
sandwich construction in many applications.
According to JOCHEN PFLUG AND IGNAAS VERPOEST, Sandwich
construction with a low cost core material can not only be lightweight but also cost effective,
especially since the advancement and automation of production processes enable a reduction
10
in production cost for lightweight sandwich panels. However, for low cost applications,
sandwich construction is frequently not considered because of limited knowledge about their
cost-saving potential. It is thus important to provide tools to evaluate and present the costsaving potential of sandwich material combinations already in the stage of materials
selection. For a given sandwich material combination, an optimization, including shear
deformations of the core as well as optimizations toward a maximum bending strength,
involving different failure modes, can be performed [6].
2.3 GLOBAL HIGHER THEORY
Laminated composite and sandwich plates are being increasingly used in advanced
aerospace structures because they can exhibit many favorable characteristics such as high
specific modulus and strength and low specific density. To use them efficiently, it is
necessary to develop appropriate models capable of accurately predicting their structural and
dynamical behavior.
Due to ignoring the transverse shear deformation and overestimating the natural
frequency, the classical laminate plate theory becomes inadequate for the analysis of thick
laminated and sandwich plates. Therefore it is necessary to consider the effect of transverse
shear deformation in the study of thick laminated structures. To take into account the effects
of shear deformation, the first-order shear deformation theories are firstly developed whereas
the accuracy of solutions of this theory will be strongly dependent on the shear correction
factors. In order to overcome the limitations of first-order shear deformation theory, the
global higher-order theories that include higher-order terms in Taylors expansions of the
displacement in the thickness direction. However, by further research, it is found that the
global higher-order theories also overestimate natural frequency for laminated composite
plates with different thickness and materials at each ply and soft-core sandwich plates
because these higher-order theories violate continuity conditions of the transverse stress
components.
To overcome the limitations of the global higher-order theories and layerwise
theories, this paper is to use the globallocal theory to predict dynamical response of
laminated composite plates with arbitrary layout and soft-core sandwich plates. The global
local higher-order theory is firstly developed by Li and Liu and further study on the global
local theory has been presented by Wu and Chen. This theory possesses the accuracy of
layer wise theory and efficiency of global higher-order theory, moreover, which satisfies
displacements and transverse shear stresses continuity conditions at the interfaces.
11
Natural frequencies of laminated composite and sandwich plates have been calculated
by using the globallocal higher-order theory, and these results are compared with those
previously published. These comparisons revealed that the present theory can accurately
predict natural frequencies of general laminated plates. Moreover, this theory is still suitable
for dynamical problems of laminated composite plates with variational thickness and
materials at each layer and soft-core sandwich plates. However, numerical results show that
for these special structures, the global higher- and first-order theories that violate continuity
of interlaminar stresses will encounter some difficulties and overestimate the natural
frequencies [7].
12
Chapter 3
FINITE ELEMENT
FORMULATION
13
where dw/dx is the rotation of the element along the center line due to bending only.
Similarly for the section x = constant (fig 2.1(b))
Hence the average shear strain x and y are given by following relations:-
15
16
where { k } are the plate curvatures,{ } are the planar relations,{ } are the shear strain and
w are the lateral deflections of the plate.
The bending and shear behavior of an anisotropic plate are given by [11]: -
where CS shear correction factor. It is a function of cross sectional shape and Poissons ratio
().
The bending and shear strain energies are expressed as follows:-
where
17
18
where
The stress-strain relations of the lamina with respect to the x, y and z axes are as
follows:-
19
The internal force and moment resultants of the laminate are obtained by integrating
elemental forces and moments over the thickness of the laminate.
20
and
and
deformation. Figure 3.3 shows an eight nodded isoparametric shell element. The geometry of
the element is described by the following relation:-
21
where Ni are the shape functions, xi and yi are the nodal coordinates, (ui, vi and wi) are the
nodal displacements along x, y, z directions,
and
directions.
where [N] is shape function and {d} is the element nodal displacements with respect to the
local axis. The strains {} in an element are defined in terms of the displacements as
The total potential of an element is first computed to apply the Rayleigh-Ritz variational
approach. The total potential of the element is given by
where [Ke ] is element stiffness matrix and {Pe } are the element nodal forces. These
are expressed as
Transformation of eq. (3.31) from the local axes to the global axes and proper assembly of
terms over all elements will lead to a set of equilibrium equations for the complete structure,
as
as
where
After eliminating the non-essential boundary conditions, eq. (3.35) can be written in
the form as given by eq. (3.33).
where [B] is the strain displacement matrix given in eq. (3.36) and [D] is the constitutive
matrix given in eq. (3.18). The total element stiffness matrix [Ke] is the sum of bending
stiffness matrix [Kb] and transverse shear stiffness matrix [Ks].
24
with
and
numerical integration employing the 2x2 Gauss Quadrature .The element matrices are
assembled after performing appropriate transformations. Thus one obtains for the static case
where
25
Chapter 4
MACROMECHANICAL
BEHAVIOUR OF
LAMINATES
26
where
27
For the case of an on-axis lamina with two-dimensional orthotropy (fig 4.1), the stress-strain
relations are
where
28
) are referred
) [11].
and
refer to the (
) and (
) coordinates
respectively, then transformation laws for reduced elastic constants are obtained as follows
[11]:
where
and
are defined as
29
30
Let u10, u20 and w are the mid-plane displacements, and w is constant through the
thickness of the lamina. Then the mid-plane strains are given by
and the curvatures, which are constant through the thickness of the laminate, are
expressed as
31
The stress and moment resultants (fig. 4.3) are evaluated per unit length of the laminate as
follows:
Thus,
32
Equation 4.23 represents the constitutive relations for a general laminate, and Aij, Bij,
and Dij are the inplane, extension bending coupling and bending stiffnesses, respectively. All
these stiffnesses are derived for a unit length of the laminate. The elastic properties of each
lamina are generally assumed to be constant through its thickness, as these laminae are
considered to be thin. Then Aij, Bij, and Dij are approximated as
33
Chapter 5
0
0
u1,1
and u2,2
The normals to the undeformed middle plane are assumed to remain straight, normal
and inextensional during the deformation so that transverse normal and shear strains
are neglected in deriving the plate kinematic relations.
per unit
0
0
length. Let us consider u1 ,u 2 and w are mid-plane displacement components. It is assumed
that Kirchhoff's assumptions for the small deflection bending theory of a thin plate are valid
in the present case. One of these assumptions is related to transverse strains
which are neglected in derivation of plate kinematic
relations i.e., stress-strain relations [13].
35
36
Considering the dynamic equilibrium of an infinitesimally small element dx1 dx2 (fig. 5.2),
the following equations of motion are obtained
where commas are used to denote partial differentiation. Combining equations (5.3) through
(5.5), we obtain
Substituting equation (4.23) in equations (5.1), (5.2) and (5.6) and noting equations
(4.16) and (4.17), we obtain the following governing differential equations in terms of mid0
0
plane displacements u1 ,u 2 and w.
37
Consider effect of transverse load q only on the laminates. Equations (5.7) to (5.9) reduce to
Symmetric laminates:
For symmetric laminated plates, the extension-bending coupling matrix [B] = 0 and
the above equations simplify to
38
Substituting (5.23) into above equations (5.19), (5.20) and (5.21) yield the following
where
39
Expanding the determinant in the above equation (5.25), the circular frequency is obtained.
where
40
and
41
Chapter 6
SANDWICH STRUCTURE
42
SANDWICH STRUCTURE
6.1 SANDWICH PRINCIPLE
The basic prerequisite for high-performance structural component parts as used in
aerospace applications is light-weight design wherever possible. An essential component of
these light-weight structures is load-bearing and buckling optimized shell elements. The
classical method to obtain improved buckling properties is using sandwich structures have
also proven their worth in a number of fields. The performance of a sandwich structure
depends primarily upon the efficiency of surface skins and the distance between them. A
great distance between the surface skins produces a correspondingly great geometrical
moment of inertia, thus leading to high bending stiffness. Since this arrangement subjects the
core of the sandwich to a relatively small amount of stress, it can be reduced in weight
significantly. Extremely thin-walled sandwich structures present the problem of how force is
introduced and the sandwich structure's sensitivity towards impact loads. This means that a
minimum wall thickness is required for the surface skins to be able to ensure that it is
adequate to the purpose.
43
.From Case III discussion, for a face/core thickness ratio =1/10, which gives a relative
bending stiffness 75.8 times the stiffness of the equivalent single skin. Hence, sandwich is a
structurally efficient structure with regard to stiffness/ weight ratio.
44
Chapter 7
Property
Value
Youngs Modulus
70GPa
Poissons Ratio
0.33
Density
2700 kg/m3
oscillation was measured in terms of the shaker current indicated by an output ammeter on
47
As the frequency was increased, the response of the plate also increased and the
frequency was kept constant when the plate was vibrating with the largest amplitude. This
was the first significant resonance behavior and it corresponded to the first fundamental
frequency was kept constant when the plate was vibrating with the largest amplitude.
This was the first significant resonance behavior and it corresponded to the first fundamental
frequency, i.e. the first mode of vibration. The frequency of the plate was then equal to the
excitation frequency. This is a characteristic resonance. As the frequency was further
increase, again large amplitude plate vibrations were observed. This corresponded to the
second mode of resonance. The corresponding excitation frequency was recorded. The
procedure was repeated for further values of resonant frequencies corresponding to higher
modes.
48
240
154
373
229
414
287
449
302
Meshed model
First Mode
49
Second Mode
Third Mode
Fourth Mode
Fifth Mode
First Mode
50
Fourth Mode
Fifth Mode
52
Three cases are studied and results depend upon increment and decrement of width
and thickness. 625 elements are used for the effect of dimension change on natural frequency.
For the following cases the results are given in the table 7.3.
53
Chapter 8
54
56
57
Fig 8.4 Deflection vs. frequency graph at nodes 1877 and 1333
8.2.2 CONVERGENCE STUDY
The results for different discretization of the simply supported sandwich plate are
presented in Table 8.2. ANSYS uses 1x1, 2x2, 3x3 and 4x4 mesh sizes and corresponding
elements 1218, 759, 532 and 294 for convergence study. The uniformly converging results
assure the accuracy and correctness of the present analysis.
58
Table 8.3 Comparison of experimental results with FEA (ANSYS) results, analytical results
and FEA (MSC/NASTRAN)
Frequency
Mode
Number
Experimental
Results(Hz)
1
2
3
4
5
44
67
78
89
FEA
(ANSYS)
Results(Hz)
Analytical
Results(Hz)
FEA
(MSC/NASTRAN)
Results(Hz)
21.670
43.315
64.991
79.370
86.616
24.280
48.248
69.781
82.454
93.312
25.079
51.396
72.435
81.974
91.001
Error**
(%)
+1.56
+3.08
-1.72
+2.75
** Error is calculated on the basis of comparison between FEA (ANSYS) and Experimental
Results
Note: - Frequency means natural frequency of transverse vibration
8.4 STUDY OF COMPARISON BETWEEN SANDWICH PLATE AND
EQUIVALENT PLATE
Comparison of modal analysis between simply supported sandwich plate and same
dimensions aluminium face plate is shown in the table 8.4. Mesh sizes for present study are
1x1 and 2x2. Figure 8.3 shows that sandwich plate having 1.4 times higher fundamental
frequency than equivalent plate. Increase in frequency is due increase in flexural stiffness of
the plate.
59
Fig 8.5 Variation of frequency between sandwich panel and equivalent panel
60
61
Fig 8.7 Effect of increase of face sheets thickness on frequencies of sandwich panel
8.5.3 THE EFFECT OF INCREASE OF DENSITY OF THE CORE ON THE
NATURAL FREQUENCY OF SANDWICH PLATE
Study of variation of natural frequencies due to increase of density of core of simply
supported sandwich plate are analyzed by FEA (ANSYS).Table 8.7 shows the different
modes of natural frequencies for different densities of the core [16]. Figure 8.6 shows the
graph between natural frequencies and densities of the core. Considering other parameters
constant, increase in density of the core decreases natural frequency of the sandwich plate.
Increase in density is more effective for higher modes of vibration of simply supported
sandwich panel.
62
Keeping the mass per unit area constant of equivalent solid plate (made of face sheet), total
mass of sandwich plate is represented by
By varying Alpha between 0.40 and 0.80, it is possible to see what effect the introduction of a
particular depth of honeycomb core will have on the natural frequencies of sandwich
plate. Table 8.8 gives natural frequencies for different values of alpha. Figure 8.7 shows the
first five frequencies plotted against alpha. The rise in frequency in all five modes is due to
63
increase in the percentage depth of the core. This is due to the relative increase in the flexural
stiffness of the plate caused by the increasing depth of sandwich core.
To raise the fundamental frequency of the equivalent solid plate (15.426 Hz) without
increasing the structural mass, it would be related to replace the equivalent solid plate by a
sandwich plate - the fundamental frequency could be doubled by making the thickness of
both face plates 3.4793 mm and the core depth 4.639 mm (corresponding to alpha = 0.4), or
increased 6-fold by making the thickness of both face plates 3.04 mm and the core depth
24.36 mm (corresponding to alpha = 0.80).
64
face plate shows that sandwich plate having 1.4 times higher
fundamental frequency than equivalent face plate. Difference in frequency is more at higher
modes. Increase in frequency is due to increase in flexural stiffness of the plate.
Parameter studies have been carried out using the finite element model to investigate
the effects of changing thickness of the core and face sheets and variation of density of the
core of the sandwich structure on the natural frequencies of free vibration.
Increase in thickness of core increases natural frequency and increase is more at
higher modes. Increase in density of the core decreases the natural frequency of the sandwich
plate. Theoretically natural frequency is inversely proportional to density of the sandwich
plate hence density increase natural frequency decreases. A detailed parameter study is
carried out that examined the effect on the natural frequencies of a simply supported
sandwich panel by increasing the core depth as a percentage of its total thickness, while
maintaining a constant mass. To raise the fundamental frequency of the equivalent solid plate
(15.426 Hz) without increasing the structural mass, it would be related to replace the
equivalent solid plate by a sandwich plate - the fundamental frequency could be doubled by
making the thickness of both face plates 3.4793 mm and the core depth 4.639 mm
(corresponding to alpha = 0.4).
Present analysis is used in ALH and LCA for reducing the weight of the parts (tail
boom, main doors, fuselage panel, rotor blades, wings etc) and increase the frequency of the
parts above the frequency of the ALH and LCA (15 Hz).
65
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