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Numerous papers deal with the Equivalent Plate Model (EPM) for corrugated panels. Comparison of published formulas for the four relevant equivalent bending stiffnesses D 11 eq , D 22 eq , D 66 eq , and D 12 eq revealed ambiguities: Three different formulas were found for D 22 eq , which describes the bending of the ridges and troughs; for D 66 eq two ‘competing’ formulas emerged. Expressions not converging to the flat-plate values in the limit of vanishing corrugation height were discarded. All discussed formulas are written in a uniform notation for general one-dimensionally periodic shapes. Formulas derived for isotropic panel materials were generalized to the orthotropic case. In order to resolve the ambiguities and assess the EPM with regard to its range of applicability, vibration modes of six rectangular corrugated panels were measured. While agreement with numerical results obtained with COMSOL was fair, the EPM predictions of natural frequencies were satisfactory only for low-order modes. Finally, equivalent bending stiffnesses were determined numerically from COMSOL results for a few low-order modes by inverse methods. Thus the ambiguities with regard to D 22 eq and D 66 eq could be resolved. However, the D 12 eq values determined numerically came out significantly larger than the EPM prediction, in particular for stronger corrugations. Even though this discrepancy had little effect on the natural frequencies tested in the present paper, it remains a theoretical challenge.

Corrugated core steel panels are an effective way to reduce weight and increase stiffness of steel structures. In numerous applications, these panels have shown very promising commercial possibilities. This study presents the design, manufacturing and commercializing process for two practical examples: Case 1) a fly wheel cover for a diesel engine and Case 2) rotationally symmetrical panel for an electric motor. Test materials of various kinds were used for corrugated cores and skin plates: conventional low-carbon steel grade EN 10130 and ferritic stainless steel grade 1.4509 with plate the thicknesses of 0.5, 0.6 and 0.75 mm. To manufacture different kinds of corrugated core steel panels, flexible manufacturing tools and cost-effective processes are needed. The most important criterion for laser welding panels was the capability of forming tools for producing high quality geometry for the core. Laser welding assembly showed that the quality of the core in both studied cases was good enough for welding the lap joints properly. Developed panels have been tested in industrial applications with excellent feedback. If thickness of a corrugated panel structure is not a limiting issue, these panels are good solution on application where stiffness and lighter weight are required as well as vibrational aspect considered.

The design of corrugated panels has wide application in engineering. For example corrugated panels are often used in roof structures in civil engineering. More recently corrugated laminates have been suggested as a good solution for morphing aircraft skins due to their extremely anisotropic behaviour. The optimal design of these structures requires simple models of the panels or skins that may be incorporated into multi-disciplinary system models. Thus equivalent material models are required that retain the dependence on the geometric parameters of the corrugated skins or panels. An homogenisation-based analytical model, which could be used for any corrugation shape, is suggested in this paper. This method is based on a simplified geometry for a unit-cell and the stiffness properties of original sheet. This paper outlines such a modelling strategy, gives explicit expressions to calculate the equivalent material properties, and demonstrates the performance of the approach using two popular corrugation shapes.