CHAPTER VIII SANDWICH PANELS ‘Table of Contents 2,100 Motalite 8.110 Stability of Metalte 8,111 Conversion to Equivalent aotrople Plate 6,112 Calculation of Delections and stresses 8.119 Buckling of Panels In Compression or Shear 8,114 Allowable Stress in Facings 8.115 Esfoets of Cutouts 8,120 Properties of Core Materia! 8.190 enign of Connections in Metalite 8.191 Core Shear Stress 8,192 Adhesive Stear Stress 8.198 Mechanical Fasteners Sinuctural Design Manual 1 October 1052SANDWICH PANELS CHAPTER VIII SANDWICH PANELS 109_METALITE Metaliteconsiate basicaly oftwothin shects of metal epa~ sale by and bonded to atnleker core of ow-denaity mater! tithe principal functions of the core are to stabilize the facings. against Tocal buckling and to transmit the major portion of the transverse shear loads. ales wood, with {he grain normal to the facings, is the best core material fvalbible for pritary structure.” The priseipal function of the faelnga are to provide strength and alliness in bending, {naxtal loading and in ineplane shear. Facings ofthe Mgh= Strength aluminum alloys, such 28 735-T6,produce the best Strongth-welght and stlinesaawelght ration, A two-com- Ponent adhesive requiring relaively high curing pressu End temperatures 1a weed for bonding. Details of the fab- ‘leation processes may be found in the CVA Design Marsal, Most ofthe strvetural proportie of Metalitecan be deter= mined by converting the Metallte panel to an equlvalent Iso- trope plate by the method given tn section &. 111. The pro Codurefor strcsoanalysia fora Metalitepancl consists of four fases: (0) uring the equlvalent isotropic plate method to heck the plate or abell for general instability, since the bekling load 1s the ultimate load of the Metalite panel; (2) Checking the panel (under loads normal to the faces) for List of Symbols ab anel dimensions g Elastic modulus of equivalent ‘sotropie plate Ee Elastic modulus of core materiat 5 Blaotie modulus of face material G ‘Shear modilus of core material o ‘Shear modulus of face matertal G, Shear modulus of bonding 8 Distance betwaon centroids of facings K, Ky, Ky Correction factors 1 Lap Length ‘ ‘Thickness of equivatent isotropie plate t ‘Thickness of core te tye ty Theres of facings te ‘Thickness of achestve Poisson's rato for equivalent a ‘sotrople plate Poisson's rato for facing Sinuctural Design Manual transverse shear strength and additional lenbiity due to shear deformation, aa described n section 8.112; (0) chock ing the face slresecs againat the allowables given In para fragh 8.114; and (4) checking Joint dooign and attachment Strength ab described In section 8.120, For additional In~ formation, refer CVA Report No, 1412 oF consult Struc {ures Development. 8,110. STABILITY OF METALITE 8.111 Converoion to Equtvalest Lotrople Plate ‘The propertice of the equivalont Isotrople plate are obtained by equating Mts axlal and flenuzal stifinesses to those of the Metalite panel. moon ach UCLA | EeHe ey ee et? — «Efe ty3- met). Se. Axial atin By = BEY eter Ee anal On the asumption hat anetLare small, these equations agreement : tan For unequal facing thicknesses ty and tg: nae tevin 2, hee 1 Oetaber 1982ae 8.112 Caleulation of Dettetions and Stresses Dy using the thickaess and modulus of the equivalent Iotropie plate In standard deflection equations, nearly cor. eet defieetions can be oblalned for the Metaite plate oF Shell. When a balsa core is used, a maximum error ot 1-8 percent oceura for 0.28 >1y /h>. 01 1m some eases, it may be necessary 10 take into ac~ count the shoar deformation ia the core wileh produces ad- Gitional tlexiity ta the Metaite panel, Normally, this shear deformation is negligible In Isotropic plates i the Plate thickness 19 small compared to its length. The cor= Feelion required for Metallto plates may be obiained from figures .112-1 and 8112-2. Even if this correction te ‘Small, in some cases ii cannot be overlooked. ‘Total percentage Ineroase in deflection = KyKyy 3035 Figure 6.412-1, 1 October 1952 Sige tructura: esign Mlanua Siucturall Design Manual SANDWICIE PANELS ‘The corresponding redetlon ln stably stoss = erent ino Ri Tho equlvalontIstrope plate theiness nd modulus azo algo ‘usd in standard sjustios for pate to determine Planar, flexural, and torsional stressea, Howover, calcu: fated stresses must be soultiplied by the following factors: For planar stresses 5 e =~ hy For floxural or torstonal stresses Bom ok : aasteaeeetaaaas ET 1900 500 800 700 600 500 400 300 200 PERCENT INCREASE OF DEFLECTION(FOR SQUARE PLATE) Percant increase of loteral Gettection auc 10 amcor |g Metalite plote with simply suppories edges oer es ae ‘Shear Deformation Factorto saz. 2ae is 20 ASPECT RATIO ® ALLOWABLE MAXIMUM COMPRESSIVE BUCKLING STRESS FOR METALITE PANELS, KSI 28 . Correction Factor (kg) for Aspect Ratio 8,119 Buckling of Panels in Compression or Shear ‘Theallowable maximum compressive and shear buck ling stresses, computed by the equivalent Isotrople plate rmethodof analysis, are given fn figures 8. 113-1 and 6.119-2 for flat Motalite panels with balsa cores. ‘The correction factor for unequal facing thcknesses ts given in figure 8.11349, ‘The conditions for buckling under combined load= ings, expressed by stress ratios, may be applied to Meta Ite panets in the sanne manner a to seotropte panels (refer to chapter VI of ths mamwal). For detalied analysos of curved panels or large flat panels, consult Structures Development 2° T racines are OF ~] | EQUAL THICKNESS < LOADING IN DIRECTION ~~ OF DIMENSION 9 20 or | 40 oy ' a et 7 Sz 30) ~ SV 20] | v | 7 ‘0 S | |_.—cLawPeo Des a c--smeLy suPPorTED _€00es| ° 0008 08.015 ozo ° Figure 8,113-1, Critical Compressive Duckling Stress in Flat Metalite Panels (Galaa Core, 153-T0 Facings) Siractural Design Manual 1 October 10828.4 2 SANDWICH PANELS 1 October 1952 sad = ioueny, FACINGS ARE OF EQUAL THICKNESS: 50 40} 30] 20) + CLAMPED EDGES ALLOWABLE ULTIMATE SHEAR BUCKLING STRESS FOR ETALITE PANEL, KS! SIMPLY SUPPORTED EDGES ° 0.008 (0.010 0.015 0.020 Figure 8,113-2, Critical Shear Buckling Stress ia Flat Metatite Panels. (Dalaa Core, 258-76 Facings) ALLOWABLE BUCKLING STRESS#%x (STRESS FOR PANCL HAVING EQUAL FACING THICKNESS AND SAME TOTAL THICKNESS) | | : s || | 2 6 [ : $ | Figure 8.119-3. Correction Factor for Facings of Unequal Thicknesse# (Use this factor only upto cutoff stress of the material.) Sinuctural Design WawaSANDWICH PANELS 6.114 Allowable Stresses in Facings ‘Yield and ultimate streases of Metallte facings oder combined principal foadings are ven by the elliptical feurves in figures 8, 114-1 and 8.114-2, The generat eqs= vert by ton for these curved fs F= Fy? = FyR, + Fy ‘waxtmm Loading Material Allowable Stress. Compression 5,000 pat Shear $5,000 Pal POLIT eet T 115 Effects of Cutouts In the absence of adequate theory for the Uehavior of plates having lange culoutn, empleteal curves have been established on the busta of teats made on Metalite panels ‘with elreular cttovla of various dameters, The curves shown in figure 8,115-1 are based on teat results for panels lnder shear loading, Little information is avallable con ‘cerning the effects of extosts in panels under compression, For test resulta of compre ye buckling loads on Metalite panels with rectangular cutouts, refer to CVA Report No. as, Adequate theoretical methodsarenct yetavailable for the design of edge reintorcements for cutout In eritcally Toaded panels. Until data are available, teats should be conducted 10 substantiate the strength of articular panels. ie 20990 oozoin 155-76 clad Fain TI O.35sin Dolne Core = 3 savooh {| easocin 725-6 ied Reatrcemet, Ges ich wie srcnce : my B 30R00) ct UETIMATE 1 t 5 i % zoo +s Combined Principal Sirens Curve for ‘So-T8 clas Facnge : (Based on probability sllowables) 3 se0e}— im ee SSNIOTH OF PANEL Figure 118-1. Ultinatesheae Strength of ncn x neh Figure S102, Combined Principal Stress Curve Tor ‘sseTo Clad Facings (Based on nilninunsyearanteed allowables) Siructural Design Manual ‘Metaiite Shear Panels with Cireslar Cutouts8,120 PROPERTIES OF CORE MATERIAL. and 8.12042 and table 8,120 Whon balsa is used for core material, a permissible When transfer of large shear loads occurs between range of densities wpecified. Indesign, alowablostressesMetaite facings. a hardwood inset\ ts used aa the core fr ‘ther mechanical properites should ve the minimom niaterial. At present, white pino la ueee Tor all ingore ie ‘ales specified in the density range. The slrengih and Metalite panel. "The design allowable properties of this sliliness properties of balsa are given in figures 8.120-1 material are givon in table 6120-2. 120,000 = ; | 14 Ibveu #4 BALSA 0900 lL | 49000 ~ Face sarsa | Kb 9 tereu tants i | | + {—7 tbveu tt BALSA 20,000 o 0.04 0.06 0.08 o10 SNGLE_FACE THeKNESS ‘CORE THIXNESS Pure 8.120-1, shear Modulus of Balsa Core Metalite Under Transverse Loading {For design, use modslus for lowest values of density range speclied) TT — 2 Li ge Sect = 300 EL a Ree ausa ® sof At — 4 = hts neice : A 5 [— Lt toyen tt oats oer ao ore SINGLE FACE THICKNESS CORE THICKNESS Figure 8.120-2, Design Allowable TranaverseShear Strensth of Balsa Core Metaite (For design, use stress for lowest values of density rance specified) ‘Table. 8, 120-9, Desig AHlowahle Streuths and Hlastic Constants for Halas and White Pine Mostanient Property wel)” | Usiun Tb eu) | ne Pn Teo emma pra To za ae 0 Fenson, perpen t grain Fe comprar crushing, pees 3 «$00 Compression propo ea in arte % So Icompreetn’peopar teat nt fergeletae ° 0 Seda ean 200,088 10,008 Sar ota acter pane trace fey ‘setae Seat ean pare (riers otc 33 } Gractural Design Manual 1 October 19528.7 8.190. DESIGN OF CONNECTIONS IN METALITE the design of Metalite panel, detailed consideration rust ‘be given to the problem of transferring load © and From the gunel, ‘The transter 48 usually accomplished by the use of mechanical faaterers, such as rivets or bolts, ‘vith known shear strengina, it bond strength and core Uren are adequate, conventional dosign assumgtlons can ibe naed to evaluate shear and bearing stresses atthe fas teners and Interrivet shear and tension stresses in the panel faces, Towever, the analyais of Jomts for prediction Efmastor bond and core stresses Involves the use of Complex formulas which are not wultable for use In routine Salen work, Use the information presented in paragraphs 1,191 trough 0.153 as a fulde for determining the atrensth ofa Metaite joint Core sean sTRESS* Lz 6 lnche Design Approximate Core shear Stress Ssuggeations for Design a fae” eae f z Comparisons of calculated maximum core Seman. [Sa (2.2) ust be made tothe allowable 1 ee Gee intable 8. 120-8. ‘oae re D Wo Ro. 8 plfieation of detailed analy bis is made. Refer to CVA Report ‘Used in appiteatons requling countersunk aotenersandlarge crushing strength. Note thatmarkedchange fn bending tlfnces oc~ ‘cursat edge of core at inert, Both insert Sndcoreshear stress should be claculated, For eouatersinking doubler use lengths and {lcknesses suggested in Design Mamal. LLengthot other doubler measured from {2 fener centerline shouldbetwicethe counter Sinking doubler. Determine thickness for Dearing failure Extend Insert 0.5 Inch Deyond the larger doubler. us ve Design ADHESIVE SHEAR STRESS # P L x applied average shear stress, and —- with figure 7.910-1 to obtain allowable average shear stress, L Effective Shoot Thickness t Applied Load P on Bonded Jotnt rire | eqety Popp (rasrener ota tse 6 [eee STD, FASTENER Figure 6.130-1, Detailed D 1 October 1952 Structural Design Manual % For additonal Information, refer to Structures Development, of Jolnts in Metaite8.191 Core Shear Stress For panels with largo loads applied to one facing, the core shear stress Ia olen the eritcal ‘actor in determining folot ‘strength. Dotalled analyses and sugzested design ‘methods havebeendoveloped in CVA Report No 7608, These ‘design methods are summarized in figure 8, 150-1 8.192 Adhesive Sher Stress “The design values of a simple unsupported tap folnty atscussed tn Section 7.100, may be used in the design of Joints in Metalite. Join’ strength can bo estimated trom ig luce 7.310-1 by using the equations for effective thckacss And loading given in figure 0150-1. Analyses for eapstrip to Metalitestacing jlnts are given ia CVA Report No. TEI, 4.192 Mechanteat Fasteners At the present time, mast connections to Metalite aro made by meenanteal fasteners, elther alone or in comb tation with bonding, In maay applications It is desirable to lselarge diameter fasteners So order to introduce loads l= flclently to the thin faces. Design of fasteners In Metalite fs the same 28 conventiondl fastener desiga. A minimum Spacing of aD lo used and values of fastener strength are glvenintable7, 100-x. Tho following information on bearing Sinucturall Design Manual SANDWICH PANELS allowables and static fastener shear and pullow strength should be used with the Inrmation prevented in the Design Manual concerning requlred edge datances, use of various types of fastonors, and method of dimensioning, Dearing Allowables, For Metaite with 759-T5 facings and pine care, the allovable ultimate stress 1s 133,000 pol. ‘For Maio with facings of 798-76 snd balsa core, the allowable ultimate stress. 120,000 pel. For bearing strengths of ether facing materials, Teter to Struc tures Development, in design, a 15-percent. margin of safely must be shown for ultimate bearing strensth, Statle Fastener Shear and Pullout Strengths, The single shear strengths of fasteners commonly” used with Metalite are lsted intable7.100-w. tn design, a 15-percent rmarginof safety must be shown for sear strengihof fasteners. {In moot applications of Metalite, the design allowable shear sirenyth of the core limits the applied normal 1osds {ovalues whicharebelow the pullout strength of the fastener, Tn designs requiring bolts, « hardwood insert must be weed to gourd against crushing of the core during iatallation, Huck oF Cherry blind riveta are not tobe used when tensile loads are applied 10 the fastonor.. For tea data of pullout fallures, refer to CVA Report No, 412 1 Oetaber 1052