Faculty Publications

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Dynamic impact resistance of composite sandwich panels with 3-D printed polymer syntactic foam cores
(DEStech Publications, 2021) Tewani, H.R.; Bonthu, D.; Bharath, H.S.; Doddamani, M.; Prabhakar, P.
Polymer-based syntactic foams find use in the marine industry as primary structural materials due to their inherent lightweight nature and enhanced mechanical properties relative to pure HDPE. 3-D printing these materials circumvents the use of joining assemblies, enabling the production of complex shapes as standalone structures. Although the quasi-static response of these 3D printed foams has been well studied independently in recent years, their dynamic impact resistance and tolerance as potential core material for sandwich panels have not been the focus. Moreover, 3D printing is known to impart directionality in the printed syntactic foams, which may introduce failure mechanisms typically not observed in molded foams. It is therefore important to investigate the mechanics of 3-D printed syntactic foam core composite sandwich structures under impact loading and characterize their failure mechanisms for establishing dynamic impact resistance. To this end, 3-D printed syntactic foams have been developed using rasters of High-Density Polyethylene (HDPE) and Glass MicroBalloon (GMB) fillers by adopting the Fused Raster Fabrication (FFF) technique. The current study is performed to assess the impact performance of these composite foam cores based on the volume fraction of fillers and print orientation. The weight percentage of GMB fillers in printed specimens ranges from 0% to 60% in increments of 20%. This study presents the impact response of these composite sandwich panels at different energy levels, in compliance with ASTM D7136/D7136M - 20. Observations suggest that an increase in GMB % in HDPE matrix improves the impact performance in terms of the peak load of the material, but the failure behavior becomes brittle to an extent. Observing the failed specimens under a Micro-CT scanner captures the failure morphologies and helps characterize failure processes during impact. It is noticed that core materials with higher GMB content are prone to individual raster breakage and delamination at the back face, in addition to debonding between individual rasters. Specimens printed along the longer dimension (y-direction) impart more warping in the final sandwich structures than that of specimens printed along the shorter dimension (x-direction). Therefore, they are more susceptible to delamination at the back face. Addition of GMB fillers mitigate the tendency of the sandwich panels to warp. Â© 2021 36th Technical Conference of the American Society for Composites 2021: Composites Ingenuity Taking on Challenges in Environment-Energy-Economy, ASC 2021. All Rights Reserved.
Mechanical behavior of 3D printed syntactic foam composites
(Elsevier Ltd, 2020) Bharath, H.S.; Sawardekar, A.; Waddar, S.; Jeyaraj, J.; Doddamani, M.
A three-dimensional printed (3DP), polymer based syntactic foams are developed using hollow glass micro balloons (GMB) dispersed in high density polyethylene (HDPE). This work presents the buckling and vibration response of 3D printed foams subjected to axial compression. The buckling load is estimated using Modified Budiansky Criteria (MBC) and Double Tangent Method (DTM) through the load–deflection plots. The first three natural frequencies and their mode shapes are computed as a function of axial compressive load. It is noted that the natural frequency reduces with an increase in axial compressive load. It is also observed that with an increase in GMB %, the natural frequencies and critical buckling load increases. In mode-1, the natural frequency decreases in pre-buckling regimes and increases exponentially in post-critical loading conditions. Analytical solutions obtained from the Euler-Bernoulli-beam theory are compared with experimental results. It is noted that the fundamental frequency approaches zero when the axial load is equal to the critical load. The critical buckling load is estimated through the vibration correlation technique and compared with the results obtained using DTM and MBC methods. The property map is plotted for buckling load against the density of various composites. © 2020 Elsevier Ltd
Dynamic behavior of concurrently printed functionally graded closed cell foams
(Elsevier Ltd, 2021) Dileep, B.; Prakash, R.; Bharath, H.S.; Jeyaraj, J.; Doddamani, M.
In this work, functionally graded foams (FGFs) of closed cell types are three-dimensionally printed (3DP) concurrently. These closed cell syntactic foams are manufactured by reinforcing 20, 40, and 60 vol% hollow glass microballoons (GMBs) in the high density polyethylene (HDPE) matrix and are investigated for their mechanical buckling and free vibration response. The critical buckling load (Pcr) of the FGFs are evaluated using the Double Tangent Method (DTM), Modified Budiansky Criteria (MBC), and Vibration Correlation Technique (VCT). It is observed that Pcr evaluated by all three methods are in good agreement. Among all FGFs, FGF-2 exhibited higher buckling strength with 22–26% higher than FGF-1 and FGF-3. Under no-load and uniaxial compressive loads, the first three natural frequency of FGFs and their corresponding damping factors are evaluated. At first mode, the natural frequency of FGFs decreases in the pre-buckling zone and started increasing in the post-buckling zone. Damping factor exhibited reverse trend compared to the trend shown by the natural frequencies. Among all FGFs, FGF-2 (20-40-60 GMB gradation) exhibited better natural frequency. Experimental results are compared with a finite element based simulation results. © 2021 Elsevier Ltd

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