Numerical and experimental torsional analysis of honeycomb structures for automotive applications

Abstract

In this research, a numerical and experimental analysis of honeycomb structures was developed based on a torsional study, with the objective of taking advantage of their load-supporting potential to contribute to the understanding of the complete mechanical behavior of the honeycomb structure. The analyses were performed based on the design of experiments. This seeks the relation between the geometrical parameters of a regular hexagonal honeycomb pattern with an out-plane torsional load. Also, a numerical model was implemented using a representative volume element approach (RVE) to calculate the orthotropic equivalent properties and compare the accuracy with the new analytical model of Gibson and Malek. Additionally, a comparative study was developed with a frame chassis made by a honeycomb core and a rectangular tubular profile with the final objective of evaluating the potential of the honeycomb pattern to support bending and torsional loads used in the validation of electric vehicles.

As a result, some important correlations were found between the RVE numerical approach and the analytical model of Gibson-Malek, and between the torsional behavior and the honeycomb geometrical parameters. Finally, the comparative study between both chassis might indicate a potential field of design for automotive applications using honeycomb patterns.