Load-optimised honeycomb cores for sandwich structures

Project description

Lightweight construction is one of the most important keys to energy-efficient and climate-friendly aviation. Modern aircraft often use sandwich structures consisting of solid outer layers and a lightweight honeycomb core. However, the current state of the art has its limitations: conventional honeycomb cores have consistent mechanical properties across the entire component. However, since real components are subjected to very different loads in different areas, this often leads to compromises. Until now, core pieces of different qualities had to be laboriously cut and glued together manually (‘potting’/‘splicing’), which led to weight gain and weak points in the material.

This is where the LastOWabPLUS research project (‘Design methods and manufacturing processes for load-optimised multi-material honeycomb cores’) comes in. The aim of the project is to develop so-called Tailored Honeycomb Cores (THC). These are honeycomb cores whose properties (e.g. cell size, wall thickness or material mix) can be specifically varied within a single component in order to precisely meet local load requirements.

The project is taking a holistic approach to realise this new generation of honeycomb cores. This ranges from the development of automated design methods using evolutionary algorithms to the simulation of the manufacturing process and physical production on new laboratory equipment. There is also a particular focus on durability: for the first time, the behaviour of these innovative multi-material cores under cyclic loads (fatigue) is being examined and simulated in detail in order to ensure safe use throughout the entire service life of an aircraft.

By avoiding material waste and reducing the weight of components, LastOWabPLUS makes a direct contribution to conserving resources and reducing energy consumption in aviation.

Project focus

The project focuses on four key areas of innovation:

• Intelligent design & simulation: Development of an automated design methodology based on evolutionary algorithms and numerical models that predict both the manufacturability and structural behaviour of variable cores.

  Innovative manufacturing technologies: Research into new processes for manufacturing honeycomb cores with variable cell sizes and material transitions (multi-material design) within a single expansion process, including adaptive adhesive application techniques.

  Material characterisation & fatigue: Comprehensive experimental investigation of the aramid papers and resin systems used, particularly with regard to their behaviour under cyclic loading (fatigue strength), in order to close knowledge gaps regarding damage behaviour.

  Validation & demonstration: Manufacture and testing of real demonstrator components (flat and curved sandwich structures) to prove the performance of tailored honeycombs in comparison to conventional solutions.

Partners & Funding

The LastOWabPLUS project is a joint venture that brings together experts from research and industry.

Project partners:

• IMA Materialforschung und Anwendungstechnik GmbH

  (Verbundkoordinator; Zuständig für Testverfahrensentwicklung, Simulation und Validierung)

• Technische Universität Dresden

  • Institut für Luft- und Raumfahrttechnik, Professur für Luftfahrzeugtechnik

    (Zuständig für Auslegungsmethoden, Simulation und zyklische Charakterisierung)

  • Institut für Werkzeugmaschinen und Steuerungstechnik, Professur für Werkzeugmaschinenentwicklung und adaptive Steuerungen

    (Zuständig für die Entwicklung der Fertigungsanlagen und Prozessautomation)

Project data

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