Quasi-static impact of foldcore sandwich panels

This thesis considered the design of new and improved foldcore sandwich panels suitable for high-performance energy absorption applications. This was achieved by utilising origami geometry design techniques to alter foldcore structures such that they possessed different mechanical behaviours and failure modes. The major findings of this thesis were in three areas as follows. First, a modified planar foldcore geometry was developed by introducing sub-folds into a standard foldcore pattern. The new geometry, deemed the indented foldcore, successfully triggered a high-order failure mode known as a travelling hinge line failure mode. This was found to have a much higher energy absorption than the plate buckling failure mode seen in an unmodified foldcore structure. A comprehensive numerical, theoretical, and experimental analysis was conducted on the indented core, which included the development of a new foldcore prototyping method that utilised 3D printed moulds. It was shown that compared to available commercial honeycomb cores, the indented foldcore had an improved uniformity of energy absorption, but weaker overall peak and crushing stresses. Second, rigid origami design principles were used to develop extended foldcore geometries. New parametrisations were presented for three patterns, to complete a set of Miura-derivative geometries termed first-level derivatives. The first-level derivative parametrisations were then combined to create complex, piecewise geometries, with compatible faceted sandwich face geometry also developed. Finally, a method to generate rigid-foldable, curved-crease geometry from Miura-derivative straight-crease geometry was presented. All geometry was validated with physical prototypes and was compiled into a MATLAB Toolbox. Third, the performance of these extended foldcore geometries under impact loadings was investigated. An investigation of curved-crease foldcores showed that they were stronger than straight-crease foldcores, and at certain configurations can potentially match the strength, energy-absorption under quasi-static impact loads, and out-of-plane stiffness of a honeycomb core. A brief investigation of foldcores under low-velocity impact loadings showed that curved-crease foldcores, unlike straight-crease foldcores, strengthened under dynamic loadings, however not to the same extent as honeycomb. Finally, an investigation of single-curved foldcore sandwich shells was conducted. It was seen that foldcore shells could not match the energy-absorption capability of an over-expanded honeycomb shell, but certain core types did exhibit other attributes that might be exploitable with future research, including superior initial strength and superior uniformity of response.