Meso-scale finite element modeling of Nomex™ honeycomb cores

Nomex(TM) honeycomb core composite sandwich panels are widely used in aircraft structures. Detailed meso-scale finite element modeling of the honeycomb geometry can be used to analyze sandwich inserts, vibration response, and complex combined loading cases. The accuracy of a meso-scale honeycomb modeling technique for static load cases was evaluated. A rectangular honeycomb core was modeled with perfect hexagon honeycomb cells. Compression and shear tests simulations with linear and non-linear solutions were performed for four core densities. The simulated moduli and buckling strengths were recorded. These results were compared to property data published by honeycomb manufacturers. The simulated maximum honeycomb wall stresses at the manufacturer predicted core strengths were also recorded. The honeycomb walls' first compression deformation mode shape was observed. Sinusoidal small imperfections were then introduced in the honeycomb geometry based on that deformation mode shape. These imperfections provided a better match to manufacturer compressive modulus data while having a limited impact on the shear moduli. The simulated properties did not exactly match manufacturers' shear and compression data together for all the core densities. Modeling the honeycomb cells with rounded corners and with increased thickness at the cell junctions are potential strategies to improve the accuracy.