Simulation-Based Analysis of Hybrid Architectural and Laminate Honeycomb Structures Under In-Plane Compression Loading
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Honeycomb structures are widely used as crashworthiness components in automotive, aerospace, and packaging applications due to their excellent energy absorption efficiency [1]. They are typically made from metallic, polymeric, or fiber-reinforced polymer (FRP) materials. Fiber metal laminates (FMLs), combining alternating metal and FRP layers, offer an attractive balance between metal ductility and composite strength. While most studies focus on FMLs as facesheets in sandwich structures [2,3], their application as the primary material of honeycomb cell walls remains largely unexplored. Hybridizing honeycomb structures using FML concepts therefore provides a promising strategy to enhance compressive performance. This study numerically investigated the in-plane compressive behavior of hybrid honeycomb panels combining aluminum and glass fiber-reinforced polymer (GFRP). Two hybridization strategies were explored. The first involved a hybrid architectural design, varying the distribution of aluminum and GFRP within the cell walls, resulting in two distinct configurations. The second employed hybrid laminate cell walls based on fiber metal laminates (FMLs), with four stacking sequence configurations analyzed. All honeycomb panels were modeled according to ISO standards, with material properties obtained from validated experimental data [4]. The compressive behavior of hybrid honeycomb panels was evaluated under quasi-static and dynamic loading, with monolithic aluminum and glass fiber panels serving as benchmarks. Under quasi-static loading, aluminum exhibited higher stiffness and a stable plateau, while glass fiber showed higher mean crushing force (MCF). Hybrid architectural designs provided moderate improvements but remained inferior to pure glass fiber. In contrast, FML configurations significantly enhanced MCF and specific energy absorption, particularly for full thickness FML and half aluminum thickness FML. Under dynamic loading, similar trends were observed, with FML-based designs outperforming monolithic structures while maintaining high specific energy absorption. In conclusion, hybrid honeycomb structures incorporating FML concepts demonstrate superior compressive performance, making them promising candidates for lightweight structural and energy-absorbing applications.
