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International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
1
DESIGN AND FABRICATION OF CORRUGATED SANDWICH
PANEL USING TAGUCHI METHOD
V.Diwakar Reddy1
, A. Gopichand2
, G. Nirupama3
, G. Krishnaiah4
1
Associate Professor, 2,3
Research Scholar, 4
Professor
Department of Mechanical Engineering,
Sri Venkateswara University College of Engineering, Tirupati
ABSTRACT
Open core metallic sandwich panels are novel type of structures, enabled by
innovative fabrication and topology design tools. Flexural modulus is a basic property of the
material in such fabricated open core structures welding by spot welding. In the present
work spot welded metallic panels are used to optimize the geometry. Based on the analysis,
panel structure parameters considered are Thickness of the sheet, Core height, Core shape,
Panel size and Material constituents of panel face sheet, bottom sheet and core. The
parameters are analyzed by Taguchi design of experiments by considering orthogonal array
of L36.The main aim is to optimize the panel dimensions on flexural modulus of a fabricated
metallic panel, using Finite Element Analysis. The problem is modeled in ANSYS and the
flexural modulus is evaluated in the transverse direction by three point bending test (ASTM
D790). The optimum dimensions are evaluated by Taguchi Analysis. The results show that
the proposed approach can find optimal dimensions considering both better and more robust
design.
Key Words: Taguchi, Corrugated panel, Sandwich panels, Flexural modulus
1. INTRODUCTION
The design of structures with optimal geometry includes sizing, shape and topology
optimization. Extensive research is focused on shape optimization in the process of
engineering design which has ample contribution towards cost, selection of material and time
saving. The purpose of dimensional and shape optimization is to determine the optimal shape
and dimensions of a continuum medium to maximize or minimize a given criterion such as
INTERNATIONAL JOURNAL OF DESIGN AND MANUFACTURING
TECHNOLOGY (IJDMT)
ISSN 0976 – 6995 (Print)
ISSN 0976 – 7002 (Online)
Volume 4, Issue 2, May - August (2013), pp. 01-13
© IAEME: www.iaeme.com/ijdmt.html
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International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
2
weight to volume ratio, minimization of stresses, minimum deflection etc. Researchers are
extensively adopting the computer aided optimization in solving such problems. Earlier
methods are various mathematical techniques which are complex and cumbersome. In the
past few decades a number of innovative approaches are developed and widely applied in the
design optimization such as genetic algorithms, practical swam analysis, Ant colony
algorithm and many more.
Design of experiments (DOE) has become an important methodology that maximizes
the knowledge gained for experimental data by using a smart positioning of points in the
space. The methodology provides a strong tool to design and analyze experiments; it
eliminates redundancy observations and reduces the time and resources to make experiments.
Therefore, DOE statistical techniques useful in complex physical processes, such as
determination of geometrical dimensions, Shapes, selection of material combination in many
design processes. In the present study one such technique adopted is Taguchi method. In this
method, the parameters identified for fabrication of corrugated panels are metal sheet gauge,
core height, core materials, and core shape. The effect of individual parameters under three
point bending is tested using Ansys workbench.
2. LITERATURE REVIEW
Ziad K. Awad, et al [4] presented his research aimed to develop an optimum design of
the new FRP sandwich floor panel by using Finite Element (FE) and Genetic Algorithm (GA)
method. The panel consisted of GFRP skin and Phenolic core. The problem formulation and
solution are described in detail.
James B. Min, et al [10] investigated the use of sandwich panels with solidface sheet
and metal foam core for air plane rotor blades. The face sheets and metal foam core were
made of high strength and high toughness aerospace grade precipitation hardened 17-4PH SS.
Stress analysis results showed that under combined impact, rotation and pressure loading
condition the sandwich panel resulted in lower von Mises stresses in face sheets compared to
other blade conditions. The max displacement was also found lower than the solid Ti-6Al-4V
blade.
Important and that panels is a non-polluting material. Sandwiches-panels on the
equipment which also corresponds to all norms operating in territory of the Russian
federation. Manufacturing of sandwich panels using bolted connections discussed in [11].
Detailed guidelines and numerical formulations to be used are given in [15]. The
numerical formulations are given for various conditions like for studying Linear Elastic
Response, Ultimate Strength, Fatigue analysis, vibration analysis, impact analysis. With
small changes in constants the relations proved good for the current case study. This is
proved though the comparison of analytical results and the results predicted though FEA.
Calculations are given in the next chapter. It may be noted that MathCAD 14.0 was used to
do the calculations.
Krzysztof Magnucki, et al [1] investigated pure bending and axial compression of all
steel sandwich panels. The relationship between the applied bending moment and the
deflection of the beam under four-point bending is discussed. The analytical and numerical
(FEM) calculations as well as experimental results are described and compared. Moreover,
for the axial compression, the elastic global buckling problem of the analyzed beams is
presented
International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
3
Z. Aboura, et al [2] proposed an analytical model for assesing the behaviour of
corrugated cardboard. Computed homogeneous of linear corrugated cardboard behavior is
made use in this model. Experimental method for validating the same is described. A
parametric study is conducted studying the effect of geometrical parameters on in-plane
elastic properties. FE method used to study the relevance of homogenization method. FE
modeling is done in two ways: 1. As 3D solid model, 2. As Shell Model. Shell model is easier
and quicker to solve but the results in both the cases were comparable.
L. St-Pierre, et al [3] carried out FE simulations on corrugated sandwich panels with
top and bottom facing present and only top facing present. 3-Point being was simulated. 3-
Point being tests were performed experimentally also. Experimental and analytical
predictions are in good agreement with each other. During experimentation, it was found that
sandwich beams with front-and-back faces present collapsed by indentation whereas
structures without a back face collapsed by Brazier plastic buckling.
A lightweight sandwich panel construction with a thin-walled core provides a system
to use undervalued lingo-cellulosic based materials for production of structural and non-
structural panels is investigated by Cristopher Ray Voth [5]. Analysis of the core design is
performed to investigate the process that can be utilized for engineering design of future
sandwich panel cores. Small-diameter Ponderosa Pine wood-strands were utilized in
fabrication of a lightweight sandwich panel that has a specific bending stiffness (D, lb-in2/in)
88% stiffer than commercial OSB. The sandwich panels designed within this study utilize
60% less wood-strands and resin by weight compared to OSB panels of equivalent thickness.
A case study was performed on the wood-strand sandwich panels to determine their potential
in structural flooring as an alternative for OSB. The sandwich panel can support a 40 psf live
load and a 20 psf dead load without exceeding IBC (2006) deflection limits. Mathematical
formulation is presented. The theoretical results are verified experimentally by conducting
various tests like 3-point bending tests, Flatwise compression tests, and core shear flexure
tests. Various applications are studied practically like for flooring applications, book shelf
etc.
Haydn N. G. Wadley, et al [6] investigated the use of sandwich structures for
underwater applications. During the investigations, it was found that significant reductions in
the fluid structure interaction regulated transfer of impulse occur when sandwich panels with
thin (light) front faces are impulsively loaded in water.Combined experimental and
computational simulation approach has been used to investigate this phenomenon during the
compression of honeycomb core sandwich panels. Square cell honeycomb panels with a core
relative density of 5% have been fabricated from 304 stainless steel.
Amit Kumar Jha [7], in his thesis investigated the use of sandwich panels for
aerospace applications. In his thesis, free vibration analysis of aluminum honeycomb
structure performed. FEA Software ANSYS used to obtain the natural frequencies. Eight
nodded isoparametric shell element is used for FEA (ANSYS). A detailed parameter study
has been carried out of a simply supported sandwich panel by increasing the core depth as a
percentage of its total thickness, while maintaining a constant mass. Experimental setup used
to validate the simulation results. The results showed that the fundamental natural frequency
of the sandwich panel is 1.4 times more than that of a plain panel. The difference increases
with increase in modes. Increase in thickness of core increases natural frequency and increase
is more at higher modes. Increase in density of the core decreases the natural frequency of the
sandwich plate. Theoretically natural frequency is inversely proportional to density of the
sandwich plate hence density increase natural frequency decreases.
International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
4
An experimental and computational study of the bending response of steel sandwich
panels with corrugated cores in both transverse and longitudinal loading orientations has been
performed by L. Valdevit, et al [8]. Panel designs were chosen on the basis of failure
mechanism maps, constructed using analytic models for failure initiation it was found that
that the analytic models provide accurate predictions when failure initiation is controlled by
yielding. However, discrepancies arise when failure initiation is governed by other
mechanisms. One difficulty is related to the sensitivity of the buckling loads to the rotational
constraints of the nodes, as well as to fabrication imperfections. The second relates to the
compressive stresses beneath the loading pattern. To address these deficiencies, existing
models for core failure have been expanded.The new results have been validated by
experimental measurements and finite element simulations.
Shawn R. McCullough [12] investigated the behavior of LASER welded corrugated
sandwich panels stiffened with concrete. The panel tested is a corrugated sandwich panel
with top and bottom steel facing separated by steel corrugation. Welding is done at both
crests and troughs. Concrete layer is placed on the top of the sheet utilizing shear connector
to ensure composite action. Structural behavior of these composites was evaluated.
Investigations showed a high increase in stiffness of the sandwich panel when concrete is
used. When 1.5” thick concrete is used, there is a 140% increase in stiffness recorded while
240% increase in stiffness is observed when 2.5” thick concrete is used. Main applications of
these sandwich panels include emergency bridge repair, building floors, fire walls etc. Beam
Theory (for narrow panels) and classical theory of orthotropic plates used for analyzing the
plates. Experimental testing used to prove the results. Results are verified for both 3-Point
and 4-Point loading.
3. FABRICATION OF CORRUGATED PANELS
The method of fabrication of panels consists of two stainless steel sheets and in
between a corrugated core is inserted and these panels are joined by means of spot welding
which is as shown in the Figure - 1 below. The geometrical specification of the panel is also
shown in the Figure.-2
Figure – 1 Panel structure of R2 Shape
International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
5
Figure – 2 Nomenclature of the corrugated panel
Design of Experiments by Taguchi method
Taguchi method is a method that chooses the most suitable combination of the levels
of controllable factors by using S/N tables and orthogonal arrays against the factor that form
the variation in product and process. Hence, it tries to reduce the variation in product and
process. Hence, it tries to reduce the variation in product and process. Hence, it tries to reduce
the variation in product and process to least. Taguchi uses statistical performance measure
which is known as S/N ration that takes both medium and variation into consideration.
Design optimization problems in automotive industries are usually complex in formulation of
objective functions and problems have uncontrollable variations in parameters. To overcome
this issue, Taguchi method is adopted in solving the shape design optimization. The
architecture of the proposed approach is given in Figure – 3.
In this study, determination of shape of the panel and core geometry is most important
parameters in design of corrugated panels. For the analysis purpose the material selected for
face sheet is Stainless steel AISI – 304 and for core two different materials are considered
one is Mild steel and other one is parent material i.e Stainless steel. As said above for the
analysis three types of panel shapes are considered in the present case, in which two are
rectangular panels and one is square panel. The two rectangular panels are of same size but
lay of core is in transverse and longitudinal direction along the width as shown in the Figure
– 4. Along with these parameters, the other three are the corrugated shape, height of the core
and face sheet gauge. The design parameters and their levels are shown in the Table – 1.
International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
6
Figure – 3 Design Optimization approach
Modeling in Pro-E
Finite Element Methods
Design Parameters
Material Combination
Core Shape
Face sheet Gauge
Core height
Panel shape
Design of
Experiments by
Taguchi L36
Compute Deformation, Von-Mises
Stress and Shear Stress.
Compute S/N ratios and conduct
ANOVA analysis
Optimized Design
variables
Optimum settings of
Design variables
Fabrication of Panels
using Spot welding
International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
7
Table – 1 Parametric investigation
S.No Parameter Level – 1 Level – 2 Level – 3
1 Material Combination
(MC):
SSMS-
Face sheet x
Core
SSSS-
Face sheet x
Core
2 core shape (CS) R-Rectangular
core
V-Shape core
3 Face sheet thickness
(FS)
20 gauge 18 gauge
4 Core height (CH) 18mm 20mm 24mm
5 Panel Shape (PS) R1-
Rectangular
panel of length
500(L)
X250(W)
R2-Rectangular
panel of length
250(L) X
500(W)
SQ-Square
panel of
350mm X
350mm
Material combination, core shape, Face sheet thickness, Core height and Panel shape
are considered as design parameters to determine their effect on the Flexural Modulus of the
Sandwich panel.
A total of 36 experiments based on Taguchi L36 mixed level orthogonal array were
carried out with mixed combinations of the input parameters which are shown in Table -2,
from this table the material combinations presented are “SSMS” & “SSSS” in which the first
two letters indicates face plates and the next two letters indicate core material (i.e., SSMS
indicates-Stainless Steel face plates & Mild steel core material; Similarly, SSSS indicates
both core and face plates are made of stainless steel). The second parameter considered is
core shape which is Rectangular (R) and Dove-tail(V) corrugated sheets as the core materials
for the panel. Gauge of the sheets were also considered as one of the parameter for the
analysis. Two gauges were considered i.e. 20 and 18. The other important parameters for
minimizing the volume fraction are the core height (20, 24 & 28 mm) and the panel shapes
are rectangular & square as explained in the previous session.
The Considered models using Taguchi method (L36) were analyzed by three point bending
test using ANSYS Work Bench. In the present analysis the model was developed by
considering the spot-welding of face-plate and core.
International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
8
Table -2: Orthogonal Array of L36 of TaguchiModelNo
Material
Combination
Core
Shape
Facesheet
Gauge
Core
Height
Panelshape
ModelNo
Material
Combination
Core
Shape
Facesheet
Gauge
Core
height
Panelshape
1 SSMS R 20 20 R1 19 SSSS R 18 20 R2
2 SSMS R 20 24 R2 20 SSSS R 18 24 SQ
3 SSMS R 20 28 SQ 21 SSSS R 18 28 R1
4 SSMS R 20 20 R1 22 SSSS R 18 20 R2
5 SSMS R 20 24 R2 23 SSSS R 18 24 SQ
6 SSMS R 20 28 SQ 24 SSSS R 18 28 R1
7 SSMS R 18 20 R1 25 SSSS R 20 20 SQ
8 SSMS R 18 24 R2 26 SSSS R 20 24 R1
9 SSMS R 18 28 SQ 27 SSSS R 20 28 R2
10 SSMS V 20 20 R1 28 SSSS V 18 20 SQ
11 SSMS V 20 24 R2 29 SSSS V 18 24 R1
12 SSMS V 20 28 SQ 30 SSSS V 18 28 R2
13 SSMS V 18 20 R2 31 SSSS V 20 20 SQ
14 SSMS V 18 24 SQ 32 SSSS V 20 24 R1
15 SSMS V 18 28 R1 33 SSSS V 20 28 R2
16 SSMS V 18 20 R2 34 SSSS V 20 20 SQ
17 SSMS V 18 24 SQ 35 SSSS V 20 24 R1
18 SSMS V 18 28 R1 36 SSSS V 20 28 R2
A series of models as mentioned in table -2 were analyzed to determine the Flexural rigidity
of the panel by considering the mode of failures as Shear, Von-mises stresses and the lateral
deflection by Three Point Bending Test. A constant load of 5000N was applied in
determination of the above stresses and deflections. The goal of this analysis work was to
investigate the effects of Flexural Rigidity and observed deflection of the panel. In Taguchi
there are three categories of quality characteristics in the analysis of S/N ratio are lower the
better, Higher the better and Nominal the better. Regardless of the category of the quality
characteristic, process parameter settings with the highest S/N ratio always yield the optimum
quality with minimum variance. The category the –lower-the-better was used to calculate the
S/N ratio for all the observed parameters.
4. RESULTS:
The measured values of the Flexural-Rigidity and deflection for the models corresponding to
all the experimental runs are given Table -3.
Signal to Noise ratio: Analysis of influence of each control factor on the flexural rigidity and
deflection has been performed is so called Signal to Noise ratio response Table.
Response table of S/N ratio for Von-mises, Shear stresses and Deflections are shown in the
Tables -4, 5, 6 respectively. The influence of each control factor can be clearly presented with
the response graphs. The slope of the line which connects between the levels can clearly
show the power of the influence of each control factor.
International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
9
Table -3: Experimental Results
ModelNo
Von
Mises
Stress
(MPa)
Shear
Stress
(Mpa)
Deformation
(mm)
ModelNo
Von
Mises
Stress
(MPa)
Shear Stress
(MPa)
Deformation
(mm)
1 137.71 75.328 0.3332 19 15.769 8.741 0.017551
2 105.69 59.709 0.22843 20 94.987 53.981 0.19447
3 137.68 77.523 0.45744 21 96.627 47.949 0.50398
4 137.71 75.328 0.33324 22 15.769 8.741 0.017551
5 105.69 59.709 0.22843 23 94.987 53.981 0.19447
6 137.68 77.523 0.45744 24 96.627 47.949 0.50398
7 137.29 75.096 0.33028 25 73.927 38.167 0.10313
8 25.394 14.164 0.094139 26 233.99 132.31 0.69529
9 68.8 38.264 0.23172 27 73.383 41.97 0.19827
10 113.26 59.884 0.39075 28 49.818 26.358 0.14367
11 49.454 27.431 0.13016 29 105.45 54.884 0.37319
12 60.302 34.228 0.14519 30 23.958 13.742 0.19047
13 22.075 11.944 0.09827 31 89.815 50.304 0.17262
14 43.272 22.846 0.13129 32 116.67 60.287 0.46334
15 89.842 46.983 0.33685 33 40.6 22.81 0.12289
16 22.075 11.944 0.09827 34 89.815 50.304 0.17262
17 43.272 22.846 0.13129 35 116.67 60.287 0.46334
18 89.842 46.983 0.33685 36 40.6 22.81 0.12289
Table-4:Response table for S/N Ratios (Smaller is better) for Von-mises stresses
Level Material
Combination
Core
Shape
Face sheet
Gauge
Core
Height
Panel shape
1 -36.91 -38.24 -39.27 -35.98 -41.82
2 -36.65 -35.32 -34.29 -37.99 -31.30
3 -36.37 -37.23
Delta 0.25 2.93 4.98 2.01 10.53
Rank 5 3 2 4 1
Table-5:Response table for S/N Ratios (Smaller is better) for Shear stresses
Level Material
Combination
Core
Shape
Face sheet
Gauge
Core
Height
Panel shape
1 -31.68 -33.05 -34.10 -30.63 -36.31
2 -31.37 -29.99 -28.05 -32.74 -26.26
3 -31.20 -32.00
Delta 0.32 3.06 5.15 2.11 10.05
Rank 5 3 2 4 1
International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
10
Table-6: Response table for S/N Ratios (Smaller is better) for Deformation
Level Material
Combination
Core
Shape
Face sheet
Gauge
Core
Height
Panel shape
1 13.490 13.687 12.408 16.805 7.642
2 14.350 14.153 15.433 12.665 19.124
3 12.291 14.995
Delta 0.860 0.466 3.025 4.514 11.483
Rank 4 5 3 2 1
Figure – 4: Main Effects plot for S-N Ratio
for Von-Misses stress
Figure – 5: Main Effects plot for S-N
Ratio for Shear stress
A- Material Combination
B- Core Shape
C- Face sheet Gauge
D- Core Height
E- Panel shape
Figure – 6: Main Effects plot for S-N Ratio
for Deformation
International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
11
5. DISCUSSION
It is seen from the response Tables and according to the Rank for each control factor
that the panel shape had the strongest influence on Von-misses stresses and Shear Stresses
followed by face sheet gauge, Core Shape, Core height and least influence on Material
combination. Similarly from the response table of Deformation and according to the Rank for
each control factor that the panel shape had the strongest influence on Deformation followed
by Core height, face sheet gauge, Material combination and least influence on Core Shape.
From the Main effects plot for S/N ratio for Von-Misses Stresses Fig.4 the Von-
Misses Stresses appears to be linear increasing function for Material Combination(A), Core
Shape(B) and Face sheet Gauge (C) and variation in the levels for core height (D) and panel
shape (E).
Thus in order to reduce the von-Misses stresses under particular loading condition the
following levels has to be considered(Refer Table - 7).
Table - 7: Selected levels for the fabrication of the corrugated panel
Parameter Level
A- Material Combination SSSS-Face and core material as Stainless steel
B- Core Shape V-Dove-Tail corrugated sheet
C- Face sheet Gauge 18 gauge stainless steel
D- Core Height 20mm
E- Panel shape Rectangular
It is observed that the core height is being considered as 20mm since as height
increases the possibility of sliding failure of the panel may occur and V-Dove-Tail corrugated
sheet is considered from the analysis instead of rectangular section since the rectangular
section is taking the direct load while the Dove-Tail is taking resultant load. From the Main
effects plot for S/N ratio for Deformation Fig.6, the Deflection appears to be linear similar to
Von-Misses stresses as explained above.
5.1 Experimental Results: The corrugated Panel is fabricated for the above optimum levels
of the considered parameters and tested for Three-Point Bending. In the Analysis the
maximum load applied is 5kN and the results were drawn which are shown in Figure 7 & 8.
From the experiments, the corrugated panel has endured a maximum load of 15kN. Hence the
model is recommended up to 10kN.Fig 9 and Fig 10 shows the experimental testing of
fabricated corrugated sandwich under three point bending test.
International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
12
Figure -7: FEA Results for Max shear stress Figure - 8: FEA Results for Max Von-misses
stress
Figure - 9: Experimental test of three point
bending test
Figure - 10: Tested panel in three point
bending test.
.
6. CONCLUSIONS
This Study discussed an application of the Taguchi-Method for Dimensional
optimization of corrugated panel using performance measures of Three-Point Bending Test.
From this Research conclusions could be reached with a fair amount of confidence. From the
Taguchi Analysis the optimum levels decided is not modeled in L36 models. Hence for
validation of the above said result is carried out. And it is observed that the maximum shear
stress, Von-Misses stresses and deflections are 11.882Mpa,22.161 Mpa,0.09mm respectively.
From the experiments the maximum load endured by the panel is three times more than the
considered load. Finally for minimum stress induced and deflection, core and face plate are
made of stainless steel of gauge 18, core height as 20mm, core shape as Dove-tailed
corrugated sheet and the panel shape is rectangular with corrugations along the width is
considered for fabrication.
International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 –
6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME
13
7. REFERENCES
[1] Krzysztof Magnucki, PawełJasion, MarcinKrus, PawełKuligowski, Leszek
Wittenbeck, Strength and Buckling of Sandwich Beams with corrugated cores,
Journal of Theoretical and Applied Mechanics,2013,51(1), pp. 15-24
[2] Z. Aboura, N. Talbi, S. Allaoui, M.L Benzeggagh, Elastic behavior of corrugated
cardboard: Experiments and Modeling, Composite Structures, 2013,63(1), pp. 53-62
[3] L. St-Pierre, N. A. Fleck, V. S. Deshpande, Sandwich Beams With Corrugated and Y-
frame Cores: Does the Back Face Contribute to the Bending Response, Journal of
Applied Mechanics, 2012,79, pp. 011002-1 - 011002-13
[4] Ziad K. Awad, ThiruAravinthan, Yan Zhuge, Cost Optimum Design of Structural
Fiber Composite Sandwich Panel for Flooring Applications, CICE 2010 - The 5th
International Conference on FRP Composites in Civil Engineering, 2010.
[5] Cristopher Ray Voth,Ligth Weight Sandwich Panels Using Small-Diameter Timber
Wood-Strands And Recycled Newsprint Cores,MS Thesis, Washington State
University,2009
[6] Haydn n. G. Wadley, Kumar P. Dharmasena, Doug T. Queheillalt, Yungchia Chen,
Philip Dudt, David Knight, Ken Kiddy, ZhenyuXue, AshkanVaziri,Dynamic
compression of square honeycomb structures during underwater impulsive
loading,Journal Of Mechanics Of Materials And Structures,2007,2(10), pp. 2025 -
2048
[7] Amit Kumar Jha,Free Vibration Analysis of Sandwich Panel,M.Tech. Thesis,
National Institute of Technology, Rourkela,2007
[8] L. Valdevit, Z. Wei, C. Mercer, F.W. Zok, A.G. Evans, Structural performance of
near-optimal sandwich panels with corrugated cores, International Journal of Solids
and Structures,2006,43(16), pp. 4888–4905
[9] Pentti KUJALA, Alan KLANAC,Steel Sandwich Panels in Marine
Applications,BrodoGradnja,2005,56 (4), pp. 305 - 314
[10] James B. Min, Louis J. Ghosn, Bradley A. Lerch, Sai V. Raj, Fredic A. Holland Jr.,
Mohan G. Hebsur,Analysis of Stainless steel sandwich panels with metal foam core
for lightweight fan blade design, 45th
AIAA/ASME/ASCE/AHS/ASC Structures,
Structural Dynamics and Materials Conference,2004
[11] COLD-FORMED CONNECTIONS,Chapter 11, Structural Connections according to
Eurocode 3 - Frequently Asked Questions, Project Continuing Education in Structural
Connections, Leonardo da Vinci Programme No. CZ/00/B/F/PP-134049, Czech
Technical University in Prague,2003, pp. 103-110
[12] Shawn R. McCullough,An Investigation of LASER welded corrugated-core sandwich
beams and plates stiffened with concrete, PhD Thesis, Rice University,2000

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Design and fabrication of corrugated sandwich panel using taguchi method 2

  • 1. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 1 DESIGN AND FABRICATION OF CORRUGATED SANDWICH PANEL USING TAGUCHI METHOD V.Diwakar Reddy1 , A. Gopichand2 , G. Nirupama3 , G. Krishnaiah4 1 Associate Professor, 2,3 Research Scholar, 4 Professor Department of Mechanical Engineering, Sri Venkateswara University College of Engineering, Tirupati ABSTRACT Open core metallic sandwich panels are novel type of structures, enabled by innovative fabrication and topology design tools. Flexural modulus is a basic property of the material in such fabricated open core structures welding by spot welding. In the present work spot welded metallic panels are used to optimize the geometry. Based on the analysis, panel structure parameters considered are Thickness of the sheet, Core height, Core shape, Panel size and Material constituents of panel face sheet, bottom sheet and core. The parameters are analyzed by Taguchi design of experiments by considering orthogonal array of L36.The main aim is to optimize the panel dimensions on flexural modulus of a fabricated metallic panel, using Finite Element Analysis. The problem is modeled in ANSYS and the flexural modulus is evaluated in the transverse direction by three point bending test (ASTM D790). The optimum dimensions are evaluated by Taguchi Analysis. The results show that the proposed approach can find optimal dimensions considering both better and more robust design. Key Words: Taguchi, Corrugated panel, Sandwich panels, Flexural modulus 1. INTRODUCTION The design of structures with optimal geometry includes sizing, shape and topology optimization. Extensive research is focused on shape optimization in the process of engineering design which has ample contribution towards cost, selection of material and time saving. The purpose of dimensional and shape optimization is to determine the optimal shape and dimensions of a continuum medium to maximize or minimize a given criterion such as INTERNATIONAL JOURNAL OF DESIGN AND MANUFACTURING TECHNOLOGY (IJDMT) ISSN 0976 – 6995 (Print) ISSN 0976 – 7002 (Online) Volume 4, Issue 2, May - August (2013), pp. 01-13 © IAEME: www.iaeme.com/ijdmt.html Journal Impact Factor (2013): 4.2823 (Calculated by GISI) www.jifactor.com IJDMT © I A E M E
  • 2. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 2 weight to volume ratio, minimization of stresses, minimum deflection etc. Researchers are extensively adopting the computer aided optimization in solving such problems. Earlier methods are various mathematical techniques which are complex and cumbersome. In the past few decades a number of innovative approaches are developed and widely applied in the design optimization such as genetic algorithms, practical swam analysis, Ant colony algorithm and many more. Design of experiments (DOE) has become an important methodology that maximizes the knowledge gained for experimental data by using a smart positioning of points in the space. The methodology provides a strong tool to design and analyze experiments; it eliminates redundancy observations and reduces the time and resources to make experiments. Therefore, DOE statistical techniques useful in complex physical processes, such as determination of geometrical dimensions, Shapes, selection of material combination in many design processes. In the present study one such technique adopted is Taguchi method. In this method, the parameters identified for fabrication of corrugated panels are metal sheet gauge, core height, core materials, and core shape. The effect of individual parameters under three point bending is tested using Ansys workbench. 2. LITERATURE REVIEW Ziad K. Awad, et al [4] presented his research aimed to develop an optimum design of the new FRP sandwich floor panel by using Finite Element (FE) and Genetic Algorithm (GA) method. The panel consisted of GFRP skin and Phenolic core. The problem formulation and solution are described in detail. James B. Min, et al [10] investigated the use of sandwich panels with solidface sheet and metal foam core for air plane rotor blades. The face sheets and metal foam core were made of high strength and high toughness aerospace grade precipitation hardened 17-4PH SS. Stress analysis results showed that under combined impact, rotation and pressure loading condition the sandwich panel resulted in lower von Mises stresses in face sheets compared to other blade conditions. The max displacement was also found lower than the solid Ti-6Al-4V blade. Important and that panels is a non-polluting material. Sandwiches-panels on the equipment which also corresponds to all norms operating in territory of the Russian federation. Manufacturing of sandwich panels using bolted connections discussed in [11]. Detailed guidelines and numerical formulations to be used are given in [15]. The numerical formulations are given for various conditions like for studying Linear Elastic Response, Ultimate Strength, Fatigue analysis, vibration analysis, impact analysis. With small changes in constants the relations proved good for the current case study. This is proved though the comparison of analytical results and the results predicted though FEA. Calculations are given in the next chapter. It may be noted that MathCAD 14.0 was used to do the calculations. Krzysztof Magnucki, et al [1] investigated pure bending and axial compression of all steel sandwich panels. The relationship between the applied bending moment and the deflection of the beam under four-point bending is discussed. The analytical and numerical (FEM) calculations as well as experimental results are described and compared. Moreover, for the axial compression, the elastic global buckling problem of the analyzed beams is presented
  • 3. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 3 Z. Aboura, et al [2] proposed an analytical model for assesing the behaviour of corrugated cardboard. Computed homogeneous of linear corrugated cardboard behavior is made use in this model. Experimental method for validating the same is described. A parametric study is conducted studying the effect of geometrical parameters on in-plane elastic properties. FE method used to study the relevance of homogenization method. FE modeling is done in two ways: 1. As 3D solid model, 2. As Shell Model. Shell model is easier and quicker to solve but the results in both the cases were comparable. L. St-Pierre, et al [3] carried out FE simulations on corrugated sandwich panels with top and bottom facing present and only top facing present. 3-Point being was simulated. 3- Point being tests were performed experimentally also. Experimental and analytical predictions are in good agreement with each other. During experimentation, it was found that sandwich beams with front-and-back faces present collapsed by indentation whereas structures without a back face collapsed by Brazier plastic buckling. A lightweight sandwich panel construction with a thin-walled core provides a system to use undervalued lingo-cellulosic based materials for production of structural and non- structural panels is investigated by Cristopher Ray Voth [5]. Analysis of the core design is performed to investigate the process that can be utilized for engineering design of future sandwich panel cores. Small-diameter Ponderosa Pine wood-strands were utilized in fabrication of a lightweight sandwich panel that has a specific bending stiffness (D, lb-in2/in) 88% stiffer than commercial OSB. The sandwich panels designed within this study utilize 60% less wood-strands and resin by weight compared to OSB panels of equivalent thickness. A case study was performed on the wood-strand sandwich panels to determine their potential in structural flooring as an alternative for OSB. The sandwich panel can support a 40 psf live load and a 20 psf dead load without exceeding IBC (2006) deflection limits. Mathematical formulation is presented. The theoretical results are verified experimentally by conducting various tests like 3-point bending tests, Flatwise compression tests, and core shear flexure tests. Various applications are studied practically like for flooring applications, book shelf etc. Haydn N. G. Wadley, et al [6] investigated the use of sandwich structures for underwater applications. During the investigations, it was found that significant reductions in the fluid structure interaction regulated transfer of impulse occur when sandwich panels with thin (light) front faces are impulsively loaded in water.Combined experimental and computational simulation approach has been used to investigate this phenomenon during the compression of honeycomb core sandwich panels. Square cell honeycomb panels with a core relative density of 5% have been fabricated from 304 stainless steel. Amit Kumar Jha [7], in his thesis investigated the use of sandwich panels for aerospace applications. In his thesis, free vibration analysis of aluminum honeycomb structure performed. FEA Software ANSYS used to obtain the natural frequencies. Eight nodded isoparametric shell element is used for FEA (ANSYS). A detailed parameter study has been carried out of a simply supported sandwich panel by increasing the core depth as a percentage of its total thickness, while maintaining a constant mass. Experimental setup used to validate the simulation results. The results showed that the fundamental natural frequency of the sandwich panel is 1.4 times more than that of a plain panel. The difference increases with increase in modes. Increase in thickness of core increases natural frequency and increase is more at higher modes. Increase in density of the core decreases the natural frequency of the sandwich plate. Theoretically natural frequency is inversely proportional to density of the sandwich plate hence density increase natural frequency decreases.
  • 4. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 4 An experimental and computational study of the bending response of steel sandwich panels with corrugated cores in both transverse and longitudinal loading orientations has been performed by L. Valdevit, et al [8]. Panel designs were chosen on the basis of failure mechanism maps, constructed using analytic models for failure initiation it was found that that the analytic models provide accurate predictions when failure initiation is controlled by yielding. However, discrepancies arise when failure initiation is governed by other mechanisms. One difficulty is related to the sensitivity of the buckling loads to the rotational constraints of the nodes, as well as to fabrication imperfections. The second relates to the compressive stresses beneath the loading pattern. To address these deficiencies, existing models for core failure have been expanded.The new results have been validated by experimental measurements and finite element simulations. Shawn R. McCullough [12] investigated the behavior of LASER welded corrugated sandwich panels stiffened with concrete. The panel tested is a corrugated sandwich panel with top and bottom steel facing separated by steel corrugation. Welding is done at both crests and troughs. Concrete layer is placed on the top of the sheet utilizing shear connector to ensure composite action. Structural behavior of these composites was evaluated. Investigations showed a high increase in stiffness of the sandwich panel when concrete is used. When 1.5” thick concrete is used, there is a 140% increase in stiffness recorded while 240% increase in stiffness is observed when 2.5” thick concrete is used. Main applications of these sandwich panels include emergency bridge repair, building floors, fire walls etc. Beam Theory (for narrow panels) and classical theory of orthotropic plates used for analyzing the plates. Experimental testing used to prove the results. Results are verified for both 3-Point and 4-Point loading. 3. FABRICATION OF CORRUGATED PANELS The method of fabrication of panels consists of two stainless steel sheets and in between a corrugated core is inserted and these panels are joined by means of spot welding which is as shown in the Figure - 1 below. The geometrical specification of the panel is also shown in the Figure.-2 Figure – 1 Panel structure of R2 Shape
  • 5. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 5 Figure – 2 Nomenclature of the corrugated panel Design of Experiments by Taguchi method Taguchi method is a method that chooses the most suitable combination of the levels of controllable factors by using S/N tables and orthogonal arrays against the factor that form the variation in product and process. Hence, it tries to reduce the variation in product and process. Hence, it tries to reduce the variation in product and process. Hence, it tries to reduce the variation in product and process to least. Taguchi uses statistical performance measure which is known as S/N ration that takes both medium and variation into consideration. Design optimization problems in automotive industries are usually complex in formulation of objective functions and problems have uncontrollable variations in parameters. To overcome this issue, Taguchi method is adopted in solving the shape design optimization. The architecture of the proposed approach is given in Figure – 3. In this study, determination of shape of the panel and core geometry is most important parameters in design of corrugated panels. For the analysis purpose the material selected for face sheet is Stainless steel AISI – 304 and for core two different materials are considered one is Mild steel and other one is parent material i.e Stainless steel. As said above for the analysis three types of panel shapes are considered in the present case, in which two are rectangular panels and one is square panel. The two rectangular panels are of same size but lay of core is in transverse and longitudinal direction along the width as shown in the Figure – 4. Along with these parameters, the other three are the corrugated shape, height of the core and face sheet gauge. The design parameters and their levels are shown in the Table – 1.
  • 6. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 6 Figure – 3 Design Optimization approach Modeling in Pro-E Finite Element Methods Design Parameters Material Combination Core Shape Face sheet Gauge Core height Panel shape Design of Experiments by Taguchi L36 Compute Deformation, Von-Mises Stress and Shear Stress. Compute S/N ratios and conduct ANOVA analysis Optimized Design variables Optimum settings of Design variables Fabrication of Panels using Spot welding
  • 7. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 7 Table – 1 Parametric investigation S.No Parameter Level – 1 Level – 2 Level – 3 1 Material Combination (MC): SSMS- Face sheet x Core SSSS- Face sheet x Core 2 core shape (CS) R-Rectangular core V-Shape core 3 Face sheet thickness (FS) 20 gauge 18 gauge 4 Core height (CH) 18mm 20mm 24mm 5 Panel Shape (PS) R1- Rectangular panel of length 500(L) X250(W) R2-Rectangular panel of length 250(L) X 500(W) SQ-Square panel of 350mm X 350mm Material combination, core shape, Face sheet thickness, Core height and Panel shape are considered as design parameters to determine their effect on the Flexural Modulus of the Sandwich panel. A total of 36 experiments based on Taguchi L36 mixed level orthogonal array were carried out with mixed combinations of the input parameters which are shown in Table -2, from this table the material combinations presented are “SSMS” & “SSSS” in which the first two letters indicates face plates and the next two letters indicate core material (i.e., SSMS indicates-Stainless Steel face plates & Mild steel core material; Similarly, SSSS indicates both core and face plates are made of stainless steel). The second parameter considered is core shape which is Rectangular (R) and Dove-tail(V) corrugated sheets as the core materials for the panel. Gauge of the sheets were also considered as one of the parameter for the analysis. Two gauges were considered i.e. 20 and 18. The other important parameters for minimizing the volume fraction are the core height (20, 24 & 28 mm) and the panel shapes are rectangular & square as explained in the previous session. The Considered models using Taguchi method (L36) were analyzed by three point bending test using ANSYS Work Bench. In the present analysis the model was developed by considering the spot-welding of face-plate and core.
  • 8. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 8 Table -2: Orthogonal Array of L36 of TaguchiModelNo Material Combination Core Shape Facesheet Gauge Core Height Panelshape ModelNo Material Combination Core Shape Facesheet Gauge Core height Panelshape 1 SSMS R 20 20 R1 19 SSSS R 18 20 R2 2 SSMS R 20 24 R2 20 SSSS R 18 24 SQ 3 SSMS R 20 28 SQ 21 SSSS R 18 28 R1 4 SSMS R 20 20 R1 22 SSSS R 18 20 R2 5 SSMS R 20 24 R2 23 SSSS R 18 24 SQ 6 SSMS R 20 28 SQ 24 SSSS R 18 28 R1 7 SSMS R 18 20 R1 25 SSSS R 20 20 SQ 8 SSMS R 18 24 R2 26 SSSS R 20 24 R1 9 SSMS R 18 28 SQ 27 SSSS R 20 28 R2 10 SSMS V 20 20 R1 28 SSSS V 18 20 SQ 11 SSMS V 20 24 R2 29 SSSS V 18 24 R1 12 SSMS V 20 28 SQ 30 SSSS V 18 28 R2 13 SSMS V 18 20 R2 31 SSSS V 20 20 SQ 14 SSMS V 18 24 SQ 32 SSSS V 20 24 R1 15 SSMS V 18 28 R1 33 SSSS V 20 28 R2 16 SSMS V 18 20 R2 34 SSSS V 20 20 SQ 17 SSMS V 18 24 SQ 35 SSSS V 20 24 R1 18 SSMS V 18 28 R1 36 SSSS V 20 28 R2 A series of models as mentioned in table -2 were analyzed to determine the Flexural rigidity of the panel by considering the mode of failures as Shear, Von-mises stresses and the lateral deflection by Three Point Bending Test. A constant load of 5000N was applied in determination of the above stresses and deflections. The goal of this analysis work was to investigate the effects of Flexural Rigidity and observed deflection of the panel. In Taguchi there are three categories of quality characteristics in the analysis of S/N ratio are lower the better, Higher the better and Nominal the better. Regardless of the category of the quality characteristic, process parameter settings with the highest S/N ratio always yield the optimum quality with minimum variance. The category the –lower-the-better was used to calculate the S/N ratio for all the observed parameters. 4. RESULTS: The measured values of the Flexural-Rigidity and deflection for the models corresponding to all the experimental runs are given Table -3. Signal to Noise ratio: Analysis of influence of each control factor on the flexural rigidity and deflection has been performed is so called Signal to Noise ratio response Table. Response table of S/N ratio for Von-mises, Shear stresses and Deflections are shown in the Tables -4, 5, 6 respectively. The influence of each control factor can be clearly presented with the response graphs. The slope of the line which connects between the levels can clearly show the power of the influence of each control factor.
  • 9. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 9 Table -3: Experimental Results ModelNo Von Mises Stress (MPa) Shear Stress (Mpa) Deformation (mm) ModelNo Von Mises Stress (MPa) Shear Stress (MPa) Deformation (mm) 1 137.71 75.328 0.3332 19 15.769 8.741 0.017551 2 105.69 59.709 0.22843 20 94.987 53.981 0.19447 3 137.68 77.523 0.45744 21 96.627 47.949 0.50398 4 137.71 75.328 0.33324 22 15.769 8.741 0.017551 5 105.69 59.709 0.22843 23 94.987 53.981 0.19447 6 137.68 77.523 0.45744 24 96.627 47.949 0.50398 7 137.29 75.096 0.33028 25 73.927 38.167 0.10313 8 25.394 14.164 0.094139 26 233.99 132.31 0.69529 9 68.8 38.264 0.23172 27 73.383 41.97 0.19827 10 113.26 59.884 0.39075 28 49.818 26.358 0.14367 11 49.454 27.431 0.13016 29 105.45 54.884 0.37319 12 60.302 34.228 0.14519 30 23.958 13.742 0.19047 13 22.075 11.944 0.09827 31 89.815 50.304 0.17262 14 43.272 22.846 0.13129 32 116.67 60.287 0.46334 15 89.842 46.983 0.33685 33 40.6 22.81 0.12289 16 22.075 11.944 0.09827 34 89.815 50.304 0.17262 17 43.272 22.846 0.13129 35 116.67 60.287 0.46334 18 89.842 46.983 0.33685 36 40.6 22.81 0.12289 Table-4:Response table for S/N Ratios (Smaller is better) for Von-mises stresses Level Material Combination Core Shape Face sheet Gauge Core Height Panel shape 1 -36.91 -38.24 -39.27 -35.98 -41.82 2 -36.65 -35.32 -34.29 -37.99 -31.30 3 -36.37 -37.23 Delta 0.25 2.93 4.98 2.01 10.53 Rank 5 3 2 4 1 Table-5:Response table for S/N Ratios (Smaller is better) for Shear stresses Level Material Combination Core Shape Face sheet Gauge Core Height Panel shape 1 -31.68 -33.05 -34.10 -30.63 -36.31 2 -31.37 -29.99 -28.05 -32.74 -26.26 3 -31.20 -32.00 Delta 0.32 3.06 5.15 2.11 10.05 Rank 5 3 2 4 1
  • 10. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 10 Table-6: Response table for S/N Ratios (Smaller is better) for Deformation Level Material Combination Core Shape Face sheet Gauge Core Height Panel shape 1 13.490 13.687 12.408 16.805 7.642 2 14.350 14.153 15.433 12.665 19.124 3 12.291 14.995 Delta 0.860 0.466 3.025 4.514 11.483 Rank 4 5 3 2 1 Figure – 4: Main Effects plot for S-N Ratio for Von-Misses stress Figure – 5: Main Effects plot for S-N Ratio for Shear stress A- Material Combination B- Core Shape C- Face sheet Gauge D- Core Height E- Panel shape Figure – 6: Main Effects plot for S-N Ratio for Deformation
  • 11. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 11 5. DISCUSSION It is seen from the response Tables and according to the Rank for each control factor that the panel shape had the strongest influence on Von-misses stresses and Shear Stresses followed by face sheet gauge, Core Shape, Core height and least influence on Material combination. Similarly from the response table of Deformation and according to the Rank for each control factor that the panel shape had the strongest influence on Deformation followed by Core height, face sheet gauge, Material combination and least influence on Core Shape. From the Main effects plot for S/N ratio for Von-Misses Stresses Fig.4 the Von- Misses Stresses appears to be linear increasing function for Material Combination(A), Core Shape(B) and Face sheet Gauge (C) and variation in the levels for core height (D) and panel shape (E). Thus in order to reduce the von-Misses stresses under particular loading condition the following levels has to be considered(Refer Table - 7). Table - 7: Selected levels for the fabrication of the corrugated panel Parameter Level A- Material Combination SSSS-Face and core material as Stainless steel B- Core Shape V-Dove-Tail corrugated sheet C- Face sheet Gauge 18 gauge stainless steel D- Core Height 20mm E- Panel shape Rectangular It is observed that the core height is being considered as 20mm since as height increases the possibility of sliding failure of the panel may occur and V-Dove-Tail corrugated sheet is considered from the analysis instead of rectangular section since the rectangular section is taking the direct load while the Dove-Tail is taking resultant load. From the Main effects plot for S/N ratio for Deformation Fig.6, the Deflection appears to be linear similar to Von-Misses stresses as explained above. 5.1 Experimental Results: The corrugated Panel is fabricated for the above optimum levels of the considered parameters and tested for Three-Point Bending. In the Analysis the maximum load applied is 5kN and the results were drawn which are shown in Figure 7 & 8. From the experiments, the corrugated panel has endured a maximum load of 15kN. Hence the model is recommended up to 10kN.Fig 9 and Fig 10 shows the experimental testing of fabricated corrugated sandwich under three point bending test.
  • 12. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 12 Figure -7: FEA Results for Max shear stress Figure - 8: FEA Results for Max Von-misses stress Figure - 9: Experimental test of three point bending test Figure - 10: Tested panel in three point bending test. . 6. CONCLUSIONS This Study discussed an application of the Taguchi-Method for Dimensional optimization of corrugated panel using performance measures of Three-Point Bending Test. From this Research conclusions could be reached with a fair amount of confidence. From the Taguchi Analysis the optimum levels decided is not modeled in L36 models. Hence for validation of the above said result is carried out. And it is observed that the maximum shear stress, Von-Misses stresses and deflections are 11.882Mpa,22.161 Mpa,0.09mm respectively. From the experiments the maximum load endured by the panel is three times more than the considered load. Finally for minimum stress induced and deflection, core and face plate are made of stainless steel of gauge 18, core height as 20mm, core shape as Dove-tailed corrugated sheet and the panel shape is rectangular with corrugations along the width is considered for fabrication.
  • 13. International Journal of Design and Manufacturing Technology (IJDMT), ISSN 0976 – 6995(Print), ISSN 0976 – 7002(Online) Volume 4, Issue 2, May - August (2013), © IAEME 13 7. REFERENCES [1] Krzysztof Magnucki, PawełJasion, MarcinKrus, PawełKuligowski, Leszek Wittenbeck, Strength and Buckling of Sandwich Beams with corrugated cores, Journal of Theoretical and Applied Mechanics,2013,51(1), pp. 15-24 [2] Z. Aboura, N. Talbi, S. Allaoui, M.L Benzeggagh, Elastic behavior of corrugated cardboard: Experiments and Modeling, Composite Structures, 2013,63(1), pp. 53-62 [3] L. St-Pierre, N. A. Fleck, V. S. Deshpande, Sandwich Beams With Corrugated and Y- frame Cores: Does the Back Face Contribute to the Bending Response, Journal of Applied Mechanics, 2012,79, pp. 011002-1 - 011002-13 [4] Ziad K. Awad, ThiruAravinthan, Yan Zhuge, Cost Optimum Design of Structural Fiber Composite Sandwich Panel for Flooring Applications, CICE 2010 - The 5th International Conference on FRP Composites in Civil Engineering, 2010. [5] Cristopher Ray Voth,Ligth Weight Sandwich Panels Using Small-Diameter Timber Wood-Strands And Recycled Newsprint Cores,MS Thesis, Washington State University,2009 [6] Haydn n. G. Wadley, Kumar P. Dharmasena, Doug T. Queheillalt, Yungchia Chen, Philip Dudt, David Knight, Ken Kiddy, ZhenyuXue, AshkanVaziri,Dynamic compression of square honeycomb structures during underwater impulsive loading,Journal Of Mechanics Of Materials And Structures,2007,2(10), pp. 2025 - 2048 [7] Amit Kumar Jha,Free Vibration Analysis of Sandwich Panel,M.Tech. Thesis, National Institute of Technology, Rourkela,2007 [8] L. Valdevit, Z. Wei, C. Mercer, F.W. Zok, A.G. Evans, Structural performance of near-optimal sandwich panels with corrugated cores, International Journal of Solids and Structures,2006,43(16), pp. 4888–4905 [9] Pentti KUJALA, Alan KLANAC,Steel Sandwich Panels in Marine Applications,BrodoGradnja,2005,56 (4), pp. 305 - 314 [10] James B. Min, Louis J. Ghosn, Bradley A. Lerch, Sai V. Raj, Fredic A. Holland Jr., Mohan G. Hebsur,Analysis of Stainless steel sandwich panels with metal foam core for lightweight fan blade design, 45th AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics and Materials Conference,2004 [11] COLD-FORMED CONNECTIONS,Chapter 11, Structural Connections according to Eurocode 3 - Frequently Asked Questions, Project Continuing Education in Structural Connections, Leonardo da Vinci Programme No. CZ/00/B/F/PP-134049, Czech Technical University in Prague,2003, pp. 103-110 [12] Shawn R. McCullough,An Investigation of LASER welded corrugated-core sandwich beams and plates stiffened with concrete, PhD Thesis, Rice University,2000