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In this paper, the numerical analysis of a three-point bending test of an aluminum foam sandwich structure is performed with the new extended finite element feature supported by Abaqus 6.9. The sandwich beam consists of two aluminum skins and one aluminum foam core. Three different sets of model dimensions are selected for comparison with the reference results (J. Yu, E. Wang, J. Li, Z. Zheng, “Static and low-velocity impact behavior of sandwich beams with closed-cell aluminum-foam core in three-point bending”, International Journal of Impact Engineering, 35, 2008, pp 885-894). Failure modes in this paper can be categorized into three parts: face yield (FY), indentation (IN), and core shear (CS). Face yield occurs on the surface of the core when the thickness of the skin is small. Indentation and core shear occur if the thickness of the skin is relatively large.

In the current study, thermoforming and compression analysis were carried out for the woven composite egg-box panel with the non-orthogonal constitutive material model, which is proposed by Xue et al (Composites: Part A 34 (2003) 183–193). The material model is implemented in commercial engineering software, LS-DYNA, with user subroutine. Xue et al obtained the nonlinear Young’s modulus and shear modulus from the experiment test, but the constant Young’s modulus and shear modulus for fiber are used in this woven composite egg-panel compression analysis for the convenience. Directional properties in non-orthogonal coordinates are detected using the deformation gradient tensor and the material modulus matrix in local coordinate is updated at each time step. After the implemented non-orthogonal constitutive model was verified by performing bias extension test, the egg-box panel simulation was performed.