Insert Design and Manufacturing for Foam-Core Composite Sandwich Structures

Sandwich structures have been used in the aerospace industry for many years. The high strength to weight ratios that are possible with sandwich constructions makes them desirable for airframe applications. While sandwich structures are effective at handling distributed loads such as aerodynamic forces, they are prone to damage from concentrated loads at joints or due to impact. This is due to the relatively thin face-sheets and soft core materials typically found in sandwich structures.;In this thesis work a methodology for designing and manufacturing inserts for foam-core sandwich structures was developed. The results of this research work enables a designer wishing to design a foam-core sandwich airframe structure, a means of quickly manufacturing optimized inserts for the safe introduction of discrete loads into the airframe.;The previous GeoSury II Prototype insert designs (v.1 & v.2) were performance tested to establish a benchmark with which to compare future insert designs. Several designs and materials were considered for the new v.3 inserts. A plug and sleeve design was selected, due to its ability to effectively transfer the required loads to the sandwich structure. The insert material was chosen to be epoxy, reinforced with chopped carbon fibre. This material was chosen for its combination of strength, low mass and also compatibility with the face-sheet material. The v.3 insert assembly is 60% lighter than the previous insert designs.;A casting process for manufacturing the v.3 inserts was developed. The developed casting process, when producing more than 13 inserts, becomes more economical than machining.;Carleton University's Uninhabited Aerial Vehicle (UAV) Project Team has designed and manufactured a UAV (GeoSury II Prototype) which features an all composite sandwich structure fuselage structure. The purpose of the aircraft is to conduct geomagnetic surveys. The GeoSury II Prototype serves as the test bed for many areas of research in advancing UAV technologies. Those areas of research include: low cost composite materials manufacturing, geomagnetic data acquisition, obstacle detection, autonomous operations and magnetic signature control.;An exploratory study was conducted looking at the effects of dynamic loading on the v.3 insert performance. The results of this study highlighted areas for improving dynamic testing of foam-core sandwich structure inserts.;Correlations were developed relating design variables such as face-sheet thickness and insert diameter to a failure load for different load cases. This was done through simulations using Computer Aided Engineering (CAE) software, and experimental testing. The resulting correlations were integrated into a computer program which outputs the required insert dimensions given a set of design parameters, and load values.