Virtual Design Method for Controlled Failure in Foldcore Sandwich Panels

For certification, novel fuselage concepts have to prove equivalent crashworthiness standards compared to the existing metal reference design. Due to the brittle failure behaviour of CFRP this requirement can only be fulfilled by a controlled progressive crash kinematics. Experiments showed that the failure of a twin-walled fuselage panel can be controlled by a local modification of the core through-thickness compression strength. For folded cores the required change in core properties can be integrated by a modification of the fold pattern. However, the complexity of folded cores requires a virtual design methodology for tailoring the fold pattern according to all static and crash relevant requirements. In this context a foldcore micromodel simulation method is presented to identify the structural response of a twin-walled fuselage panels with folded core under crash relevant loading condition. The simulations showed that a high degree of correlation is required before simulation can replace expensive testing. In the presented studies, the necessary correlation quality could only be obtained by including imperfections of the core material in the micromodel simulation approach.