The Application of Sandwich Components in Hybrid Structures

A. Starlinger
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Abstract

A hybrid design concept for body shells has been developed in order to achieve light and stiff structures for state of the art railway and bus vehicles. It uses longitudinal hollow aluminum extrusions combined with foam core sandwich panels of aluminum face layers. In addition to the reduction of mass, hybrid design helps to save production costs. These savings are based on the simplified assembling technique in a modular concept (via corner bolt systems, viscoelastic adhesives, riveting and laser welding), the integration of insulation (by the foam core), and the outstanding impact behavior. The direct joining of the sandwich composite elements to the aluminum extrusions is, however, one of the most challenging steps when designing a hybrid structure. For this reason the hybrid design concept requires a more sophisticated structural analysis approach. In the case of the composite components reduced shear stiffness of the core and local failure mechanisms have to be taken into account. In order to meet all the structural criteria detailed finite element models and analyses have been derived. Several examples of railway structures built in the hybrid design are given to show the development steps and the advantages of this new design concept.
夹层构件在混合动力结构中的应用
车身外壳的混合设计概念已经被开发出来,以便为最先进的铁路和公共汽车车辆实现轻而硬的结构。采用纵向中空铝型材结合铝面层泡沫芯夹芯板。除了减少质量外,混合设计还有助于节省生产成本。这些节省是基于模块化概念中的简化组装技术(通过角螺栓系统、粘弹性粘合剂、铆接和激光焊接)、绝缘集成(通过泡沫芯)以及出色的抗冲击性能。然而,在设计混合结构时,夹层复合材料元件与铝型材的直接连接是最具挑战性的步骤之一。因此,混合设计概念需要更复杂的结构分析方法。在复合构件的情况下,降低了核心的剪切刚度和局部破坏机制必须考虑。为了满足所有的结构标准,推导了详细的有限元模型和分析。文中给出了采用混合设计的铁路结构实例,说明了混合设计的发展步骤和这种新设计理念的优点。
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