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Bonding Aluminium Honeycomb (19.1mm cell size ) to sheet Aluminium.
Bonding Aluminium Honeycomb (19.1mm cell size ) to sheet Aluminium.
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Bonding Aluminium Honeycomb (19.1mm cell size ) to sheet Aluminium.
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NigelGroom
NigelGroom
posted 10 Years Ago
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I am working on the design of an impact attenuator for a Formula Student car.
I am interested in using aluminium honeycomb, specifically the 19.1mm cell size as it is the most cost effective, and I am in the process of testing a design using this in solidworks.
One concern I have is how the sheets and honeycomb layers will be bonded together.
I have attatched an image of the current attenuator design because it is a little bit difficult to explain.
I would like to know, along with what the best resin/adhesive to use is, what material exactly should be selected and used during the cad process.
I can see that it is of the 3003 series, however I am unsure what material out of this series specifically as they are given properties in solid form rather than treated as a honeycomb section.
All help and feedback is greatly appreciated!
I am also open to using a different material providing it is not ridiculously expensive. The budget for this project is around £500 so it is limited.
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aluminium
attenuator
bonding
honeycomb
solidworks
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Warren (Staff)
Warren (Staff)
posted 10 Years Ago
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You will need to be more precise than 0.5mm.
The foil thickness is the figure you are after, and in that case is 50 micron.
Other technical and mechanical data on the honeycomb can be downloaded
here
.
You also will want to consider the cell construction of the sheet. The honeycomb is manufactured, in simple terms, using multiple layers of thin aluminium foil perforated and bonded at the nodes. The critical point here is that 2 faces of each cell are in effect 2 foils bonded together. You would need to take this into account with any modelling you perform.
Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
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NigelGroom
NigelGroom
posted 10 Years Ago
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Ok perfect, I shall use 50 microns in my modelling from now on.
Your description of the cell construction makes sense, I shall ensure that the top and bottom faces (assuming a regular hexagon) are 100 microns in my modelling.
Thank you so much for all your feedback and support, you have been very helpful.
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Bonding Aluminium Honeycomb (19.1mm cell size ) to sheet Aluminium.
NigelGroom
-
10 Years Ago
You can use Permabond ET538 .. this is specifically formulated for bonding Alu honeycomb, both to...
Dravis
-
10 Years Ago
Thank you for your reply and feedback. I feel those materials are a little out of the price range....
NigelGroom
-
10 Years Ago
Dravis is correct. Unless this is a technical exercise, you may well find it cheaper and easier to...
Warren (Staff)
-
10 Years Ago
Yes this is a technical exercise, it is my final year individual project. There already exists an...
NigelGroom
-
10 Years Ago
keying is the process of leaving a rough finish on the surface, in this case usually with sand...
Warren (Staff)
-
10 Years Ago
Oh right I wasn't aware of that but I shall look into it, thanks.
NigelGroom
-
10 Years Ago
The other issue I have is when modelling it, what should the thickness of the aluminium be set at?...
NigelGroom
-
10 Years Ago
You will need to be more precise than 0.5mm. The foil thickness is the figure you are after, and in...
Warren (Staff)
-
10 Years Ago
Ok perfect, I shall use 50 microns in my modelling from now on. Your description of the cell...
NigelGroom
-
10 Years Ago
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