Honeycomb core failure mechanism of CFRP/Nomex sandwich panel under multi-angle impact of hail ice

The rudder of an airplane is fabricated as a sandwich panel and can potentially be damaged by hail ice. The dynamic responses of a CFRP/Nomex sandwich panel with barely any visible core damage under multi-angle impact of an ice sphere at various velocities are researched experimentally and by using numerical simulations at the mesoscale. The results show that the honeycomb core represents three types of failure modes: wrinkling, fracture of cell walls, and debonding of cell walls at the interface of two-glued-paper-walls (TGPW) due to resin failure. These failure modes exist at specific impact velocities and angles. This paper proposes a mesoscale numerical modeling method of a honeycomb structure to represent the debonding failure at the TGPW interface. In addition, the mechanical properties of these failures are revealed, as the wrinkling of the cell walls are caused by buckling and the fracture of the cell walls and debonding of the TGPW interface are caused by out-plane and in-plane shearing of cell walls. The results showed that the relationship between the denting and impact kinetic energy under multi-angle impact is linear with respect to the impact angle. The effects of impact angles on the contacting forces on a rigid wall and sandwich panel are presented as the amount of peak impact forces affected by the target material type. However, the intensity of the peak impact forces is rarely affected by the type of the target material. The peak impact force of nonvertical impact is greater than that of the normal impact when the normal components of the impact velocities are the same. This is because the impact angle affects the distribution of ice scatter fragments during the impact, and this generates different pressure distributions on the face sheet of the panel.