Development Of Honeycomb Structure With Aluminium Skin For Light Weight Structural Application.

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KUTKM Library (Pind.l/2005)

KOLEJ UNIVERSITI TEKNIKAL KEBANGSAAN MALAYSIA

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DECLARATION

I hereby, declared this thesis entitled" Development ofHoneycomb Structure With Aluminium Skin For Light Weight Structural Application" is the results of my own research except as cited in references .

Signature Author's Name Date

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Mahamad Gaos

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ABSTRACT

This study on honeycomb structure is done to find the best materials for honeycomb structure that have the outstanding properties. Firstly the previous researches about honeycomb properties and materials are studied. lbis is to get a better knowledge on this study. Besides that the product that uses this sandwich structures are identified. This study of honeycomb is for the usage in the aircraft industry. It is studied in which part of the aircraft is the sandwich structure applied.

lbis study to frnd the best material for lightweight application will use 3 types of material. Among the three materials are aluminium cans, aluminium sheet and straw. Before carrying out the study the physical properties of those materials are studied. The honeycomb structures are built using the materials. The composition of each material had been planned first. After each model has been constructed it will be tested. The testing is done according to ASTM standard (American Society for Testing and Materials).

There were 3 test conducted which is the bending test, compression test, and tensile test. For the tensile test the mechanical properties obtained are yield strength, tensile strength and modulus of elasticity. For the bending test the mechanical properties obtained are flexural modulus and flexural yield strength. Lastly for the compression test the mechanical properties obtained are compressive strength and modulus of compression. Between the two materials which are aluminium can and straw it is proved that the aluminium can is better than the straw. lbis is due to the good results of compressive, yield and tensile strength.

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ACKNOWLEDGEMENTS

I would like to convey my sincere appreciation and my utmost gratitude to my project supervisor, Miss Zaleha Mustafa for her support ,guidance and advise throughout the process of completing my research. I would also like to thank the management of 'Perpustakaan Sultanah Zanariah' , in Universiti Teknologi Malaysia for giving me access to find sources for my project. My deepest appreciation to my parents, En. Mahamad Gaos and Puan Rahimah Ghouse who had given me non-stop inspiration and also supported me financially . A special thanks to all my family members who have spend their precious time helping me in completing this project. I would also like to express my sincere appreciation to my colleagues for their support and especially to En.Hazman Hasib who had helped me a lot throughout my project. I also thank En. Jeffery who provided thoughtful reviews on improving this research .

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CHAPTER 3 METHODOLOGY

3.0 Flow chart

3.1 The process 3.2 Testing

3.2.1 Tensile test 3.2.2 Compression test 3.2.3 Bending test

CHAPTER 4 RESULTS

4.1 Tensile test 4.2 Bending test 4.3 Compression test

CHAPTERS DISCUSSION

5.1 Compressive properties 5.2 Tensile properties 5.3 Flexural properties

CHAPTER 6 CONCLUSION

6.1 Conclusion

6.2 Recommendation for further work

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LIST OF FIGURES

2.1

Sandwich panel with a honeycomb core

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2.2

Basic components of an aircraft

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2.3

Aircraft control surfaces and axes of motion

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2.4

Topology optimization results

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2.5

Aluminium

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2.6

Polystyrene hydrocarbon chain

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3.0

Flowchart

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3.1

Honeycomb structure using straw

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3.2

Honeycomb structure using aluminium can

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3.3

Compression tester

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4.1

Stress strain curve comparison between aluminium can and straw

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honeycomb for tensile test

4.2

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honeycomb for bending test

4.3

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honeycomb for compression test

5.1

The compression process of aluminium can

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5.2

Specimen after compressed

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5.3

Buckling

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5.4

Material being pulled during the tensile test

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5.5

Plastic deformation

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5.6

The jaw slipping from the specimen (straw honeycomb)

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5.7

The honeycomb structure of aluminium can being bended

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5.8

The specimen after the bending test

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5.9

The specimen (straw) after completing the bending test

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LIST OF TABLES

2.1

Properties of aluminium

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2.2

Properties of polystyrene

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4.1

Yield Strength, Tensile Strength and Modulus of Elasticity for

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aluminium can and straw honeycomb

4.2

Flexural Modulus and Flexural Yield Strength for aluminium can

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and straw honeycomb

4.3

Compressive strength and modulus for aluminium can and straw

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Honeycomb

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