KUTKM Library (Pind.l/2005)

KOLEJ UNIVERSITI TEKNIKAL KEBANGSAAN MALAYSIA

BORANG PENGESAHAN STATUS TESIS•

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mengaku membenar1<an tesis lPSMJSarjana/Doktor Falsafah) ini disimpan di Perpustakaan Kolej Universiti ~ikal Kebangsaan Malaysia (KUTKM) dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hak milik Kolej Universiti Teknikal Kebangsaan Malaysia. 2. Perpustakaan Kolej Universiti Teknikal Kebangsaan Malaysia dibenarkan

membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran

antara institusi pengajian tinggi. 4. **SUa tandakan (" )

D SULIT

D TERHAD

0 TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

(fAN&~N PENUUS)

Disahkan oleh:

~VEllA) Alamat Tetap: 54, IR.VIt.J§ ~D 10100 PENMJ9 .

Tarikh:

Cop Rasmi: ZALEHA BINTI MUST J r A

lleloJa JiJbi(llfl (~illl Kejuruteraifl)

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l(ol~l ::;n iefkiiOC 1200 ~Y• ~~..on Mel alia

Tarikh: ~ I Ob

• Tesis cfimaksudkan sebagai tesis bagi ljazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). •• Jika tesls ini SULIT atau TERHAD, sila lampfrkan surat daripada pihak berkuasa/organisasf berkenaan de~an menyatakan sekal1 sebab dan tempoh tesis ini perlu dlkelaskan seba~ai SULIT atau TERHAD.

DECLARATION

I hereby, declared this thesis entitled" Development ofHoneycomb Structure

With Aluminium Skin For Light Weight Structural Application" is the results of my own

research except as cited in references .

Signature

Author's Name

Date

.. ~~ .. ~ ..................................... .. ... .... . ..

S~~ ~t. Mahamad Gaos 6/IVO'

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ABSTRACT

This study on honeycomb structure is done to find the best materials for

honeycomb structure that have the outstanding properties. Firstly the previous researches

about honeycomb properties and materials are studied. lbis is to get a better knowledge

on this study. Besides that the product that uses this sandwich structures are identified.

This study of honeycomb is for the usage in the aircraft industry. It is studied in which

part of the aircraft is the sandwich structure applied.

lbis study to frnd the best material for lightweight application will use 3 types of

material. Among the three materials are aluminium cans, aluminium sheet and straw.

Before carrying out the study the physical properties of those materials are studied. The

honeycomb structures are built using the materials. The composition of each material

had been planned first. After each model has been constructed it will be tested. The

testing is done according to ASTM standard (American Society for Testing and

Materials).

There were 3 test conducted which is the bending test, compression test, and

tensile test. For the tensile test the mechanical properties obtained are yield strength,

tensile strength and modulus of elasticity. For the bending test the mechanical properties

obtained are flexural modulus and flexural yield strength. Lastly for the compression test

the mechanical properties obtained are compressive strength and modulus of

compression. Between the two materials which are aluminium can and straw it is proved

that the aluminium can is better than the straw. lbis is due to the good results of

compressive, yield and tensile strength.

1

ACKNOWLEDGEMENTS

I would like to convey my sincere appreciation and my utmost gratitude to my project

supervisor, Miss Zaleha Mustafa for her support ,guidance and advise throughout the

process of completing my research. I would also like to thank the management of

'Perpustakaan Sultanah Zanariah' , in Universiti Teknologi Malaysia for giving me

access to find sources for my project. My deepest appreciation to my parents, En.

Mahamad Gaos and Puan Rahimah Ghouse who had given me non-stop inspiration and

also supported me financially. A special thanks to all my family members who have

spend their precious time helping me in completing this project. I would also like to

express my sincere appreciation to my colleagues for their support and especially to

En.Hazman Hasib who had helped me a lot throughout my project. I also thank En.

Jeffery who provided thoughtful reviews on improving this research .

u

TABLE OF CONTENTS

Abstract

Acknowledgement

Table of Contents

List of Figures

List ofTables

List of Abbreviations, Symbols

CHAPTER 1 INTRODUCTION

1.1 Background

1.2 Problem Statement

1.3 Objectives of the Research

1.4 Scope ofthe thesis

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction

2.2 Honeycomb panels

2.3 Applications

2.3.1 Parts of an aircraft

2.3.2 Location of honeycomb in an aircraft

2.3.3 Existing product

2.4 Properties of honeycomb structures

2.4.1 Problems relating on existing product

2.5 Properties of Material Used

2.5.1 Properties of Aluminium

2.5.2 Properties of Polystyrene

2.6 Conclusion on Literature Review

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CHAPTER 3 METHODOLOGY

3.0 Flow chart

3.1 The process

3.2 Testing

3.2.1 Tensile test

3.2.2 Compression test

3.2.3 Bending test

CHAPTER 4 RESULTS

4.1 Tensile test

4.2 Bending test

4.3 Compression test

CHAPTERS DISCUSSION

5.1 Compressive properties

5.2 Tensile properties

5.3 Flexural properties

CHAPTER 6 CONCLUSION

6.1 Conclusion

6.2 Recommendation for further work

REFERENCES

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LIST OF FIGURES

2.1 Sandwich panel with a honeycomb core 7

2.2 Basic components of an aircraft 10

2.3 Aircraft control surfaces and axes of motion 12

2.4 Topology optimization results 15

2.5 Aluminium 20

2.6 Polystyrene hydrocarbon chain 22

3.0 Flowchart 24

3.1 Honeycomb structure using straw 25

3.2 Honeycomb structure using aluminium can 27

3.3 Compression tester 29

4.1 Stress strain curve comparison between aluminium can and straw 31

honeycomb for tensile test

4.2 Stress strain curve comparison between aluminium can and straw 32

honeycomb for bending test

4.3 Stress strain curve comparison between aluminium can and straw 33

honeycomb for compression test

5.1 The compression process of aluminium can 36

5.2 Specimen after compressed 36

5.3 Buckling 37

5.4 Material being pulled during the tensile test 38

5.5 Plastic deformation 39

5.6 The jaw slipping from the specimen (straw honeycomb) 40

5.7 The honeycomb structure of aluminium can being bended 41

5.8 The specimen after the bending test 42

5.9 The specimen (straw) after completing the bending test 43

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LIST OF TABLES

2.1 Properties of aluminium 21

2.2 Properties of polystyrene 22

4.1 Yield Strength, Tensile Strength and Modulus of Elasticity for 32

aluminium can and straw honeycomb

4.2 Flexural Modulus and Flexural Yield Strength for aluminium can 33

and straw honeycomb

4.3 Compressive strength and modulus for aluminium can and straw 34

Honeycomb

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