Three-dimensional Composite Lattice Structures Fabricated by Electrical Discharge Machining

Xiong, J.; Wang, B.; Ma, L.; Papadopoulos, J.; Vaziri, A.; Wu, L.
March 2014
Experimental Mechanics;Mar2014, Vol. 54 Issue 3, p405
Academic Journal
We present a novel method for fabricating carbon fiber composite sandwich panels with lattice core construction by means of electrical discharge machining (EDM). First, flat-top corrugated carbon fiber composite cores were fabricated by a hot press molding method. Then, two composite face sheets were bonded to each corrugated core to create precursor sandwich panels. These panels were transformed into sandwich panels with near-pyramidal truss cores by EDM plunge-cutting the corrugated core between the face sheets with a shaped cuprite electrode. The flat top corrugation permits adhesive to be applied consistently, and the selected dimensions leave a substantial bond area after cutting, resulting in a strong core-to-sheet bond. The crushing behavior of this novel construction was investigated in flatwise compression, and the results were compared to analytical expressions for strength and stiffness.


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