Characterization of Nomex honeycomb core constituent material mechanical properties

Nomex honeycomb cores have been widely used in composite sandwich panels. To accomplish meso-scale finite element modeling of these cores, cell wall mechanical properties are required, for which limited data are available. In this work, tensile testing was performed on Nomex paper, phenolic resin, and Nomex paper coated with phenolic resin. Flatwise tension and compression tests were also performed on two types of Nomex honeycomb cores. Test results were calibrated in finite element modeling to account for strain gage local stiffening effects and thickness normalization. Identified cell wall material properties were implemented in a honeycomb core finite element model and further calibrated by matching simulation results to manufacturer test data. The cells’ double-wall thickness was also adjusted. These calibrations and adjustments led to an exact simulation match with test data. Numerically matching cell wall material properties depends on modeling sophistication and is subject to core test result variability and core construction differences among manufacturers.