Research on the Quality Control of Sandwich Structures with High Curvature and Ultra-thick Core Materials

Xueying Zhao; Fuquan Xu; Shengwei Song; Qingwen Yun; Zhigang Wang; Shuhui Tong; Dongmei Dai; Yukui Wang

doi:10.1007/978-981-95-3022-9_48

Research on the Quality Control of Sandwich Structures with High Curvature and Ultra-thick Core Materials

Xueying Zhao^*
, Fuquan Xu
, Shengwei Song
, Qingwen Yun
, Zhigang Wang
, Shuhui Tong
, Dongmei Dai
, Yukui Wang

^*Corresponding author for this work

School of Mechatronics Engineering

Harbin Aircraft Industry(Group) Co. Ltd.
Technology Application and Innovation Center for Resin Matrix Composite Materials
Engineering and Technology Research Center for Aeronautical Composite Materials of Heilongjiang
School of Mechanical Engineering

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

Abstract

This paper focus on the research object of co-curing sandwich structure door with hybrid core materials. A mesoscopic simulation model for resin-based composite honeycomb sandwich structures was established, and the top and bottom surfaces of honeycomb were pre-cured to apply fixed constraints to effectively avoid defects such as slippage and collapse at the chamfer after analyzing. An adjustable mold based on multi-point forming theory was designed and a dynamic real-time tracking device was developed to monitor the deformation of the adjustable mold. Based on macroscopic curing simulation analysis results of resin-based composite sandwich structures, a complete set of deformation control methods for composites were achieved through simulation analysis of curing-induced deformation and compensation adjustment of mold surfaces. These methods were applied to quality optimization in high curvature and ultra-thick core sandwich structures, providing critical support for the application of such high curvature and ultra-thick sandwich structural components on aircraft.

Original language	English
Title of host publication	Proceedings of the 8th China Aeronautical Science and Technology Conference - Volume II
Publisher	Springer Science and Business Media Deutschland GmbH
Pages	555-571
Number of pages	17
ISBN (Print)	9789819530212
DOIs	https://doi.org/10.1007/978-981-95-3022-9_48
State	Published - 2026
Event	8th China Aeronautical Science and Technology Conference, CASTC 2025 - Guangzhou, China Duration: 24 Oct 2025 → 26 Oct 2025

Publication series

Name	Lecture Notes in Mechanical Engineering
ISSN (Print)	2195-4356
ISSN (Electronic)	2195-4364

Conference

Conference	8th China Aeronautical Science and Technology Conference, CASTC 2025
Country/Territory	China
City	Guangzhou
Period	24/10/25 → 26/10/25

Keywords

Cure-induced deformation
Honeycomb delamination
Numerical analysis
Profile-adjustable tooling

Access to Document

10.1007/978-981-95-3022-9_48

Cite this

Zhao, X., Xu, F., Song, S., Yun, Q., Wang, Z., Tong, S., Dai, D., & Wang, Y. (2026). Research on the Quality Control of Sandwich Structures with High Curvature and Ultra-thick Core Materials. In Proceedings of the 8th China Aeronautical Science and Technology Conference - Volume II (pp. 555-571). (Lecture Notes in Mechanical Engineering). Springer Science and Business Media Deutschland GmbH. https://doi.org/10.1007/978-981-95-3022-9_48

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title = "Research on the Quality Control of Sandwich Structures with High Curvature and Ultra-thick Core Materials",

abstract = "This paper focus on the research object of co-curing sandwich structure door with hybrid core materials. A mesoscopic simulation model for resin-based composite honeycomb sandwich structures was established, and the top and bottom surfaces of honeycomb were pre-cured to apply fixed constraints to effectively avoid defects such as slippage and collapse at the chamfer after analyzing. An adjustable mold based on multi-point forming theory was designed and a dynamic real-time tracking device was developed to monitor the deformation of the adjustable mold. Based on macroscopic curing simulation analysis results of resin-based composite sandwich structures, a complete set of deformation control methods for composites were achieved through simulation analysis of curing-induced deformation and compensation adjustment of mold surfaces. These methods were applied to quality optimization in high curvature and ultra-thick core sandwich structures, providing critical support for the application of such high curvature and ultra-thick sandwich structural components on aircraft.",

keywords = "Cure-induced deformation, Honeycomb delamination, Numerical analysis, Profile-adjustable tooling",

author = "Xueying Zhao and Fuquan Xu and Shengwei Song and Qingwen Yun and Zhigang Wang and Shuhui Tong and Dongmei Dai and Yukui Wang",

note = "Publisher Copyright: {\textcopyright} Chinese Society of Aeronautics and Astronautics 2026.; 8th China Aeronautical Science and Technology Conference, CASTC 2025 ; Conference date: 24-10-2025 Through 26-10-2025",

year = "2026",

doi = "10.1007/978-981-95-3022-9\_48",

language = "英语",

isbn = "9789819530212",

series = "Lecture Notes in Mechanical Engineering",

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pages = "555--571",

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}

Zhao, X, Xu, F, Song, S, Yun, Q, Wang, Z, Tong, S, Dai, D & Wang, Y 2026, Research on the Quality Control of Sandwich Structures with High Curvature and Ultra-thick Core Materials. in Proceedings of the 8th China Aeronautical Science and Technology Conference - Volume II. Lecture Notes in Mechanical Engineering, Springer Science and Business Media Deutschland GmbH, pp. 555-571, 8th China Aeronautical Science and Technology Conference, CASTC 2025, Guangzhou, China, 24/10/25. https://doi.org/10.1007/978-981-95-3022-9_48

Research on the Quality Control of Sandwich Structures with High Curvature and Ultra-thick Core Materials. / Zhao, Xueying; Xu, Fuquan; Song, Shengwei et al.
Proceedings of the 8th China Aeronautical Science and Technology Conference - Volume II. Springer Science and Business Media Deutschland GmbH, 2026. p. 555-571 (Lecture Notes in Mechanical Engineering).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

TY - GEN

T1 - Research on the Quality Control of Sandwich Structures with High Curvature and Ultra-thick Core Materials

AU - Zhao, Xueying

AU - Xu, Fuquan

AU - Song, Shengwei

AU - Yun, Qingwen

AU - Wang, Zhigang

AU - Tong, Shuhui

AU - Dai, Dongmei

AU - Wang, Yukui

PY - 2026

Y1 - 2026

N2 - This paper focus on the research object of co-curing sandwich structure door with hybrid core materials. A mesoscopic simulation model for resin-based composite honeycomb sandwich structures was established, and the top and bottom surfaces of honeycomb were pre-cured to apply fixed constraints to effectively avoid defects such as slippage and collapse at the chamfer after analyzing. An adjustable mold based on multi-point forming theory was designed and a dynamic real-time tracking device was developed to monitor the deformation of the adjustable mold. Based on macroscopic curing simulation analysis results of resin-based composite sandwich structures, a complete set of deformation control methods for composites were achieved through simulation analysis of curing-induced deformation and compensation adjustment of mold surfaces. These methods were applied to quality optimization in high curvature and ultra-thick core sandwich structures, providing critical support for the application of such high curvature and ultra-thick sandwich structural components on aircraft.

AB - This paper focus on the research object of co-curing sandwich structure door with hybrid core materials. A mesoscopic simulation model for resin-based composite honeycomb sandwich structures was established, and the top and bottom surfaces of honeycomb were pre-cured to apply fixed constraints to effectively avoid defects such as slippage and collapse at the chamfer after analyzing. An adjustable mold based on multi-point forming theory was designed and a dynamic real-time tracking device was developed to monitor the deformation of the adjustable mold. Based on macroscopic curing simulation analysis results of resin-based composite sandwich structures, a complete set of deformation control methods for composites were achieved through simulation analysis of curing-induced deformation and compensation adjustment of mold surfaces. These methods were applied to quality optimization in high curvature and ultra-thick core sandwich structures, providing critical support for the application of such high curvature and ultra-thick sandwich structural components on aircraft.

KW - Cure-induced deformation

KW - Honeycomb delamination

KW - Numerical analysis

KW - Profile-adjustable tooling

UR - https://www.scopus.com/pages/publications/105030540557

U2 - 10.1007/978-981-95-3022-9_48

DO - 10.1007/978-981-95-3022-9_48

M3 - 会议稿件

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SN - 9789819530212

T3 - Lecture Notes in Mechanical Engineering

SP - 555

EP - 571

BT - Proceedings of the 8th China Aeronautical Science and Technology Conference - Volume II

PB - Springer Science and Business Media Deutschland GmbH

T2 - 8th China Aeronautical Science and Technology Conference, CASTC 2025

Y2 - 24 October 2025 through 26 October 2025

ER -

Zhao X, Xu F, Song S, Yun Q, Wang Z, Tong S et al. Research on the Quality Control of Sandwich Structures with High Curvature and Ultra-thick Core Materials. In Proceedings of the 8th China Aeronautical Science and Technology Conference - Volume II. Springer Science and Business Media Deutschland GmbH. 2026. p. 555-571. (Lecture Notes in Mechanical Engineering). doi: 10.1007/978-981-95-3022-9_48

Research on the Quality Control of Sandwich Structures with High Curvature and Ultra-thick Core Materials

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Keywords

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