Foam core composite sandwich beam under bending (Analyse the behaviour of sandwich beam under three points bending)

Abstract

This study investigates the bending performance of foam core composite sandwich beams through combined experimental testing and finite element analysis (FEA). Sandwich beams are widely used in aerospace, automotive, and civil engineering due to their high strength-to weight ratio. The research involved three-point bending experiments on beams with varying core densities and face sheet thicknesses, providing insight into load–displacement behaviour, stiffness, and failure mechanisms. Observed failure modes included core shear, face wrinkling, indentation, and delamination. Complementary FEA models were developed in ABAQUS to simulate the bending response, with predicted results showing strong correlation to experimental data in terms of stiffness, ultimate load, and failure locations. Minor discrepancies arose from idealised modelling assumptions such as perfect bonding and uniform material properties. The findings highlight the significant influence of core density, face sheet thickness, and interface integrity on structural performance. Increasing core density enhanced stiffness and delayed failure, while thicker face sheets reduced wrinkling but added weight. Recommendations include optimising material selection, improving bonding techniques, and incorporating advanced modelling for defect prediction. The validated experimental–numerical approach presented here offers a reliable framework for optimising sandwich structures in weight-critical applications, enabling improved durability, performance, and efficiency in demanding engineering environments.