Three-dimensional Composite Lattice Structures Fabricated by Electrical Discharge Machining
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We present a novel method for fabricating carbon fiber composite sandwich panels with lattice core construction by means of electrical discharge machining (EDM). First, flat-top corrugated carbon fiber composite cores were fabricated by a hot press molding method. Then, two composite face sheets were bonded to each corrugated core to create precursor sandwich panels. These panels were transformed into sandwich panels with near-pyramidal truss cores by EDM plunge-cutting the corrugated core between the face sheets with a shaped cuprite electrode. The flat top corrugation permits adhesive to be applied consistently, and the selected dimensions leave a substantial bond area after cutting, resulting in a strong core-to-sheet bond. The crushing behavior of this novel construction was investigated in flatwise compression, and the results were compared to analytical expressions for strength and stiffness.
KeywordsCarbon fiber Lattice structures Sandwich panel Mechanical properties Electrical Discharge Machining
The present work was supported in part by the Major State Basic Research Development Program of China (973 Program) under grant No. 2011CB610303, National Science Foundation of China under grant Nos. 11222216, 11302060 and the Fundamental Research Funds for Central Universities under Grant No. HIT.BRETIV.201301. AV and JP acknowledge the support by the U.S. Air Force Office of Scientific Research under AFOSR YIP grant award, #FA 9550-10-1-0145 and technical direction of Dr. Joycelyn Harrison. JX also gratefully acknowledges support by the Natural Sciences Research Innovation Foundation in Harbin Institute of Technology (HIT.NSRIF.2014025) and Open-ended fund of Science and Technology on Advanced Composites in Special Environments Laboratory.
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