Sandwich Construction Eng. Marco Leite Prof. Manuel de Freitas Prof. Arlindo Silva.
Transcript of Sandwich Construction Eng. Marco Leite Prof. Manuel de Freitas Prof. Arlindo Silva.
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Sandwich Construction
Eng. Marco Leite
Prof. Manuel de Freitas
Prof. Arlindo Silva
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NOV 2004 2
Sandwich Construction
Introdução Leis Constitutivas Exemplo Design procedures Aplicações Bibliografia
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NOV 2004 3
Introdução
Origem Princípio Sandwich Vantagens e Desvantagens
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NOV 2004 4
Origem
II Gerra Mundial – de Havilland Mosquito TT35 TA639
– Fuselagem Plywood/Balsa/Plywood “Mosquito. The timber terror. Light, fast, deadly.”
“The excellent performance demonstrated by this airplane had convinced numerous aircraft designers of the superiority of sandwich structure as a means of constructing more efficient airplanes”
Falta de materiais na G.B. no auge na II Guerra Mundial
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NOV 2004 5
Origem
II Guerra Mundial – Vultee BT15 (USA)– Fuselagem Fibra de vidro em matriz de poliester com núcleo
em honeycomb de fibra de vidro ou núcleo de balsa.
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NOV 2004 6
Princípio Sandwich
(c) web core
(d) corrugated core
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NOV 2004 7
Vantagens e desvantagens
Vantagens Desvantagens
Alta Resistência EspecíficaPerigoso para a saúde durante a
construção (Resinas)
Alta Rigidez EspecíficaFracas possibilidades de reciclagem
(compósitos)
Baixo PesoFalta de informação nos engenheiros
e designers
Isolamento Térmico e Acústico Problemas de temperatura
Capacidade de resistência à corrosão Mudança de mentalidades
Facilidade de formas completas Controlo de Qualidade
Capacidade de absorção de Energia Variedade de critérios de rotura
Poucas peças estruturais necessárias Incompatibilidade de materiais
Múltiplas possibilidades de escolha de materiais
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Leis Constitutivas
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NOV 2004 9
Leis Constitutivas
Teoria clássica vs Teoria 1ª ordem Campo de deslocamentos Campo de deformações Relação Tensão-Extensão TCL Leis Constitutivas TCL Relação Tensão-Extensão 1ª ordem Leis Constitutivas 1ª ordem
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NOV 2004 10
Teoria clássica vs Teoria 1ª ordem
Teoria Clássica Laminados Teoria 1ª ordem
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NOV 2004 11
Campo de Deslocamentos
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, , , , ,
, , ,
x
y
u x y z u x y z z x y
v x y z v x y z z x y
w x y z w x y
axis-x about rotation
axis-y about rotation
z
vy,x
z
uy,x
y
x
Teoria ClássicaLaminados
Teoria 1ª ordem
y
wx
w
y
x
0
0
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NOV 2004 12
Campo de Deformações
Teoria Clássica Laminados Teoria 1ª ordem
0
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y
wz
y
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wz
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NOV 2004 13
Relação Tensão-Extensão TCL
220 00 00 0
0 0 0 00
1 1
2 2x y
xy
w wu v
x x y y
u v w w
y x y x
2 2 20 0 0
2 22x y xy
w w w
x y x y
Teoria Clássica Laminados
0
0
0
i
x x xi
y y y
xy xy xy
z
Q z
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Extensões superfície média
Curvaturas
Relação Tensão/Extensão
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NOV 2004 14
Leis Constitutivas TCL
02
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1 12
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1 1
Moment per unit length:
tk k
tk k
xx x xz zN Ni i
y y y yk kz z
xy xy xyxy
M k
M zdz Q zdz Q k z dz
M k
02
0
1 12
0
1 1
Force per unit length:
tk k
tk k
xx x xz zN Ni i
y y y yk kz z
xy xy xyxy
N k
N dz Q dz Q k zdz
N k
0
DB
BA
M
N
Forças de membrana actuantes no laminado
Momentos actuantes no laminado
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NOV 2004 15
Relação Tensão-Extensão 1ª ordem
220 00 00 0
0 00 0
0 0 0 00
1 1
2 2x y
yz y xz x
xy
w wu v
x x y y
w w
y x
u v w w
y x x y
0
yxx y
yxxy yz xz
x x
y x
0
0
0
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0
i
x x x
y y yi
xy xy xy
yz yz
xz xz
z
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Q z
Extensões superfície média
Curvaturas
Relação Tensão/Extensão
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NOV 2004 16
Leis constitutivas 1ª Ordem
2
2
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2
Transverse shear
force resultants:h
h
h
h
x xz
y yz
Q dz
Q dz
y
wx
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AAK
Q
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NOV 2004 17
Exemplo – Ensaios 3PB
Viga de contraplacado– Comparação entre a TCL e 1ª Ordem
Vigas sandwich faces em GRP núcleo PU – Comparação entre a TCL e 1ª Ordem
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NOV 2004 18
Exemplo – Ensaios 3PB
Deslocamento a meio vão: 3
48 4
PL PLw
D U
TCL (bending)
Corte
1ª Ordem
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NOV 2004 19
Viga de contraplacado 18.2 mm
Contraplacado de madeira de vidoeiro – 13 camadas
[0º,90º,0º...,0º,90º,0º]– Material Ortotrópico– Vão 1000 mm– Resultados Força vs
Deslocamento
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NOV 2004 20
Viga de contraplacado 18.2 mm
0
0.2
0.4
0.6
0.8
1
1.2
0 5 10 15 20Deslocamento [mm]
Fo
rça
[k
N]
TCL
FEM
CNTPL 18
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NOV 2004 21
Viga sandwich em GRP + PU
Viga sandwich – Faces em fibra de vidro
em matriz de poliéster Espessura de 2.5 mm Gramagem de 900 g/m2
– Núcleo em espuma de poliuretano
Espessura de 50 mm Densidade de 40 kg/m3
Materiais Isotrópicos– Faces
E = 6100 MPa = 0.33
– Núcleo E = 7.5 Mpa = 0.33
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NOV 2004 22
Vigas sandwich em GRP + PU
0
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1
1.5
2
2.5
3
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0 10 20 30 40 50 60Deslocamento [mm]
Fo
rça
(k
N)
Painel 1-A Painel 2-APainel 1-B Painel 2-BPainel 3-B Painel 4-BPainel 5-B Painel 6-BTCL FEM ANA
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Design procedures
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NOV 2004 24
Design procedures
Vários envelopes de rotura concorrentes
Altamente dependente da geometria e do carregamento
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NOV 2004 25
Design procedures
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NOV 2004 26
Design procedures
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NOV 2004 27
Design procedures
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Aplicações
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NOV 2004 29
Aplicações
Aeroespacial Aeronáutico Construção Desporto Naval Automóvel Veículos Ferroviários etc
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NOV 2004 30
Satélites
1 Solar Panels : Epoxy carbon prepregs, aluminum honeycomb, film adhesive
2 Reflectors Antennae : Epoxy/aramid prepreg, cyanate carbon prepreg, aramid/aluminum honeycomb
3 Satellite Structures : Carbon prepreg, aluminum honeycomb, film adhesive
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NOV 2004 31
Aeroespacial
1 Fairings: Carbon prepregs. Aluminium honeycomb and adhesives.
2 External Payload Carrier Assembly (SPELTRA): Carbon prepregs, aluminium honeycombs and adhesives.
3 EPS Ring: Epoxy/carbon prepreg or RTM.
4 Front Skirt: Carbon prepreg.
5 Booster Capotage: Epoxy glass/non-metallic honeycomb.
6 Yoke: Epoxy carbon filament winding.
7 Heat Shield: Carbon prepreg/high temperature resistant glass fabric.
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NOV 2004 32
Aeronautico
1 Radar Transparent Radome: Epoxy or BMI Prepreg or RTM resins and woven preforms (socks)
6 Wing Skins and Ribs: Epoxy carbon and glass Prepregs
2 Foreplane Canard Wings: Epoxy carbon Prepregs
7 Fin Tip: Epoxy/quartz Prepregs
3 Fuselage Panel Sections: Epoxy carbon Prepregs. Non-metallic honeycomb core and Redux adhesives
8 Rudder: Epoxy carbon Prepreg
4 Leading Edge Devices: Epoxy carbon and glass Prepregs
9 Fin: Epoxy carbon/glass Prepreg
5 Fin Fairings: Epoxy glass and carbon Prepregs
10 Flying Control Surfaces: Epoxy carbon and glass Prepregs. Honeycomb core material and Redux adhesives
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NOV 2004 33
Pás do rotor de um helicóptero Sea King, mostrando a estrutura interna em compósito. Com a aplicação de compósitos consegue-se maior velocidade das pás e menor transmissão de vibrações à estrutura.
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NOV 2004 34
Naval
1 Decking: Heavy duty structural sandwich panels 9 Weather Shield: Prepregs and honeycombs.
2 Hull Skin Structure: Prepregs, engineered fabrics, honeycombs.
10 Communications Equipment : Prepregs and honeycombs.
3 Lightweight Floor Structure: Sandwich panels. 11 Companionway Stairs : Structural sandwich
panels
4 Suspended Ceilings : Lightweight sandwich panels/honeycombs. 12 Partitions: Lightweight sandwich panels.
5 Interior Furnishings : Lightweight stiff sandwich panels suitable for fabrication. Prepregs and fabrics.
13 Lightweight Superstructure: Sandwich panels and Prepregs.
6 Hull Skin Structure: Prepregs, engineered fabrics, honeycombs.
14 Engine Room : Sandwich panels and special products for FST and sound attenuation..
7 Accommodation Cabin Units: Lightweight sandwich panels, Prepregs and honeycombs.
15 Drive Shafts & Couplings: Epoxy Prepregs and fabrics
8 Bridge Deck Consoles: Lightweight sandwich panels.
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NOV 2004 35
Naval
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NOV 2004 36
Desporto
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NOV 2004 37
O quadro (que já nem sequer tem a forma tradicional de um quadro...) da bicicleta da figura é feito em carbono/ epoxy, bem como as jantes das rodas. Consegue-se maior rigidez e menor peso em relação às estruturas de alumínio. Além disso, o design pode e deve ser alterado para maximizar os benefícios do novo material.
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NOV 2004 38
Aplicações diversas de compósitos em artigos de desporto e lazer. A sua utilização destina-se, em geral, a poupar peso, ganhando rigidez e resistência e, por vezes, permitindo um
design mais atractivo que as ligas metálicas, devido à facilidade de moldagem.
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NOV 2004 39
Construção civil
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NOV 2004 40
Sandwich technology:The sandwich principle has been successfully used in the marine and aerospace industries. Now, Bombardier's new Fully Integrated Carbody Assembly System (FICAS) revolutionizes manufacturing in the rail industry.
FICAS consists of a thin sandwich construction comprising a steel skin bonded to a rigid core. The advantage of this approach to the overall space saving equation is that the sidewalls become significantly thinner than a conventional wall, with possible savings of up to 120 millimeters in wall thickness. (May 2003)
Comboios
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NOV 2004 41
Automóvel
With the long version, the A-class sets a new record for compact cars, for no other automobile in this market segment offers so much cubic capacity, as much as 68.2 cubic feet – which is 11 percent more than the unchanged current standard version.
The spatial economy of the new body variant is equally commendable: since the drive units, thanks to the sandwich concept, are positioned partly in front of and partly beneath the passenger cell, 53 percent of the 12 foot 5 inch body is available to the passengers …
“With the new variant we can now also satisfy prospective customers who were already convinced by the A-Class design and concept but wanted to have more room,” emphasized D. Joachim Schmidt, member of divisional management…
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NOV 2004 42
Automóvel
Therefore, American's steel manufacturers hired Porsche Engineering Services to develop a new kind of steel monocoque technology calls Ultra Light Steel Auto Body (ULSAB). As shown in the picture, basically it has the same structure as a conventional monocoque. What it differs from its donor is in minor details - the use of "Hydroform" parts, sandwich steel and laser
beam welding. Sandwich steel is made from a thermoplastic (polypropylene) core in
between two very thin steel skins. This combination is up to 50 percent lighter compared with a piece of homogenous steel without a penalty in performance. Because it shows excellent rigidity, it is applied in areas that call for high bending stiffness. However, it cannot be used in everywhere because it needs adhesive bonding or
riveting instead of welding.
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NOV 2004 43
Transporte Isotérmico
Vantagem da construção sandwich:Alto isolamento térmico aliado ao desempenho estrutural
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Bibliografia
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NOV 2004 45
Bibiografia
Plantema, F.J., Sandwich construction; the bending and buckling of sandwich beams, plates, and shells. 1966, New York,: Wiley. xx, 246.
Allen, H.G., Analysis and design of structural sandwich panels. 1st ed. 1969, Oxford New York: Pergamon. xvi, 283.
Forest Products, L., Wood handbook : wood as an engineering material. General technical report (Forest Products Laboratory) ; FPL-GTR-113. 1999, Madison: The Laboratory.
Gay, D., Matériaux composites. 4e éd. rev. et augm. ed. Collection Matériaux. 1997, Paris: Hermès,. 672.
Gibson Lorna, J. and F. Ashby Michael, Cellular solids : structure & properties. International series on materials science & technology. 1988, Oxford: Pergamon 1988.
Metzger, D.J., The selection of sandwich panels. 1970: Ithaca, N.Y. p. x, 142 l. Middleton, D.H., Composite materials in aircraft structures. 1990, Harlow: Longman Scientific
& Technical. Vinson, J.R., The behavior of sandwich structures of isotropic and composite materials. 1999,
Lancaster, Pa.: Technomic Publishing Co. Zenkert, D., An introduction to sandwich construction. 1997, Warley: Emas. Zenkert, D. and F. Nordic Industrial, The handbook of sandwich construction. North European
engineering and science conference series. 1997, Cradley Heath: EMAS Publishing.
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FIM