Numerical analysis of curved honeycomb and metastructure panels

  • Augello, Riccardo (Politecnico di Torino)
  • Carrera, Erasmo (Politecnico di Torino)

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Architected cellular metastructures – such as honeycomb lattices and auxetic (re-entrant) geometries – have emerged as key enablers of lightweight, high-performance designs. These engineered materials offer exceptional stiffness- and strength-to-weight ratios and energy absorption capabilities, far surpassing those of conventional solids [1]. Moreover, auxetic structures (with negative Poisson’s ratio) exhibit novel deformation behavior beneficial for impact resistance and flexibility. As a result, architected materials are increasingly integrated into modern aerospace, automotive, and civil structures to achieve unprecedented mechanical properties and multifunctionality. When incorporated into curved panels (shells), these periodic architectures can significantly influence the panel’s static, dynamic, and buckling response, necessitating advanced analytical approaches. This work presents a high-fidelity finite element analysis of curved panels featuring various periodic core architectures – including standard hexagonal honeycombs, re-entrant auxetics, and other novel lattices. The static, free-vibration (dynamic), and buckling behaviors of these architected panels are investigated in detail, with attention to geometric nonlinearity (large deflections). The models are formulated using the Carrera Unified Formulation (CUF) [2] in conjunction with refined shell finite elements. This CUF-based approach enables an exact geometric representation of the curved structure and a hierarchical expansion of the displacement field through the thickness, yielding lower- to higher-order shell models without ad hoc assumptions. Such a highly accurate finite element formulation effectively captures complex mechanical phenomena in the panels, from local cell deformations to global instability modes. The results demonstrate that the proposed modeling strategy can predict the stiffness, natural frequencies, buckling loads, and post-buckling nonlinear behavior of curved metastructure panels with excellent accuracy. The study underlines the importance of advanced computational formulations for architected materials, offering new insights for the design of next-generation lightweight structures with enhanced performance and reliability.