Structural Analysis And Optimization Of Foam-filled Corrugated Sandwich Panels

The adoption of new lightweight composite materials,structural optimization of components,and enhancement of manufacturing process levels can reduce the overall vehicle quality effectively.Combined with the current research status,lightweight composite materials have great potential in the automotive lightweight field.At the same time,the endless new technologies also provide unlimited possibilities for the development of lightweight composite materials.However,as the cost of lightweight,the safety and cost of the vehicle can not be ignored.Therefore,the pursuit of low-cost,high-strength lightweight composite materials is the key to the development of lightweight vehicles.The corrugated structural plate has high strength both in the transverse direction and in the longitudinal direction,and is often used for the research of impact resistant materials.it is easy to realize mass production for its structure has good flexibility and low manufacturing cost.The sandwich panel composite material with the corrugated board as the core layer has a higher specific rigidity and specific strength than the single-layer board,and the pore structure in the core layer will have a crush deformation during the stress process to consume the impact energy.Therefore,the corrugated sandwich panel is a more ideal car body material.Now with the continuous innovation of polymer materials,more and more plastics and foams have been applied to the car body in present.As a kind of low-density light foam,polyurethane foam has high energy absorption efficiency,good vibration damping and sound insulation properties,and it has a good application prospect in automobiles because of its lower cost.In this paper,the advantages of corrugated sandwich panels and polyurethane foam are combined,and polyurethane foam is filled into the corrugated pores of the corrugated sandwich panels to produce foam-filled corrugated sandwich panels with different thicknesses,and their mechanical properties are studied and optimized.This will provide research foundation for the application of the plate in the car.The specific research contents are as follows:(1)Detailed description of the sample preparation process and mechanical experiment process.The raw materials for the preparation of the sample and the basis for material selection are introduced.The panel and the corrugated board are bonded together by means of glue,and the prepared liquid polyurethane foam is filled into the corrugated pores,and the foam is fully foamed and cured under certain conditions.Samples of four different thicknesses are used as the object of this study.Samples containing one,two,three,or four layers of corrugated foam filled with foam and samples without foam were subjected to compression,bending,and impact tests to compare the filled foam with the same number of layers.The impact of mechanical properties such as the flat compressive strength,flexural strength,and impact resistance,and the comparative study of the reinforcing effect of polyurethane foam in different thickness samples.(2)Taking a four-layer corrugated plate sample as an example to investigate the impact of structural parameters on the impact resistance of the sample.A finite element model of foam-filled corrugated sandwich panels was established and subjected to simulation analysis of impact processes.The results were compared with experimental results to verify the validity of the model.To further study the impact resistance of the finite element model,firstly,based on the principle of orthogonal test,the effect of the thickness of the upper panel,the thickness of the corrugated board,and the thickness of the lower panel on the impact resistance of the specimen is studied.Then energy absorption performance of the foam in different sheet thickness combinations is studied with the method of parameter combination.(3)Optimized design of shock-resistance performance of foam-filled corrugatedsandwich panels.Based on the topology optimization theory,the foam filling distribution is optimized for the clamped-clamped,simple supported and rigid base conditions.In the clamped-clamped and simply supported conditions,the displacement at the center point“a”of the following panel is the design response.In the rigid base condition,the reaction force at point a is the design response,and the design response is minimized.Optimize calculations to enhance the impact energy absorption characteristics in the optimized area of the sheet.