Flexural Behaviour of Foam Cored Sandwich Structures with Through-Thickness Reinforcements

Abstract

Composite sandwich structures are well-suited for applications requiring high bending strength, flexural rigidity, crashworthiness, and light weight. However, skin–core debonding and core failure remain a barrier to optimal structural performance when polymeric foams are used as core materials. Suppressing or compartmentalising these failure modes can enhance the structural integrity of sandwich structures. In this paper, the flexural response of a sandwich structure was improved by adding carbon fibre-reinforced plastic in the form of through-thickness ribs during the manufacturing process. The effect of the position of the ribs was investigated using a quasi-static three-point bend test. A camera was used to capture failure events, while the digital image correlation technique provided the full-strain field at different stages of loading. Improved flexural performance was obtained when a reinforcement was placed on either side of the loading roller. With this configuration, skin–core debonding was restricted to a confined portion of the panel, resulting in a more localised and stable fracture process, which involved enhanced foam crushing and hardening. A simple FEA approach has been adopted in this paper and has proven to be an effective approach for capturing the details of the failure process, including the debonding in the composite foam structures, without the need for complex and computationally expensive interface modelling.