Strength optimization of metallic sandwich panels subject to bending

A general methodology for the design of strong, lightweight sandwich panels is described and implemented. Several core topologies are considered, including square-section truss members in pyramidal and tetrahedral configurations, square honeycombs, and corrugated sheets. When the number of independent design parameters is restricted to three, closed-form analytical solutions for the optimal design are obtained. Alternatively, when a fourth parameter is added (as needed to fully characterize the panel geometry), numerical routes are required. The results demonstrate that the three parameter optimizations yield design weights that are only slightly heavier than those of the fully optimized panels, provided the value of the fourth parameter is selected judiciously. The weight rankings of the various core topologies change with load capacity, although the differences between them are generally small, particularly upon comparison with the weight of a solid panel.