Thermomechanical Analysis of Thermoplastic Mono-Material Sandwich Structures with Honeycomb Core

The application of fiber-reinforced thermoplastic mono-material sandwich panels has many advantages, such as recyclability, reduction in processing cycle times, integration of additional elements by means of welding, and a great potential for in-line production. The most efficient way to produce a curved thermoplastic sandwich panel is thermoforming, which has several challenges. One of them is to achieve a higher thermal gradient in the panel. On the one hand, the temperature at the skin–core interface must exceed the softening point of the polymer to reach a sufficient bonding degree. On the other hand, the core should not be overheated and overloaded to avoid its collapse. Furthermore, several fiber distortions, such as wrinkles or buckles, can be developed during thermoforming. All these flaws have a negative impact on the mechanical performance of the sandwich structure. The objective of this study is the development of a simulation tool for the thermoforming process, which can replace the time-consuming trial-and-error-based method. Therefore, a coupled thermomechanical model was developed for a novel thermoplastic sandwich structure, which is able to predict the temperature distribution and its influence on the mechanical properties of the panel. Experimental trials were conducted to validate the thermomechanical forming model, which demonstrated a good agreement with numerical results.