The stressed state of three-layer composites with tetrachiral honeycombs under bending conditions: Mathematical modeling and additive manufacturing laboratory experiments.

• The results of FE modeling based on the full-scale 3D model and by solving a plane problem via the algorithms suggested for three-layer plates with a tetrachiral honeycomb core are in good agreement. • The proposed algorithms for solving a plane problem by the finite element method are an effective alternative to full-scale modeling. • Boundary conditions effect the dispersion and regularity of the change in the maximum stresses in honeycombs with different discretization. • Honeycomb core discretization does not affect the values of maximum stresses in the face layers of composite plates. • The results of laboratory tests of composite plates with a tetrachiral honeycomb core prepared via additive technologies are in good agreement with those by mathematical modeling. In the presented paper, three-layer plates with solid face layers and a honeycomb core of the tetrachiral type are investigated. The influence of discretization, relative density and thickness of honeycomb cores on the stress state of composite plates subjected to the static bending is studied for different boundary conditions. In the first formulation of numerical experiments, the thickness of layers of composite plates remains constant with a variation in the relative density of the honeycombs, while in the second formulation of numerical experiments, a volume of the solid body of the honeycombs is considered to be constant, resulting in variations in the thickness due to variations in the relative density. Mathematical modeling is performed within the framework of the theory of elasticity by the finite element method through three-dimensional modeling in Comsol Multiphysics system, as well as using the algorithms for analyzing the stress state of sandwich composites with tetrachiral honeycombs by solving the plane problem. The technological process of manufacturing the considered composites is proposed, as well as the results of laboratory experiments under three-point bending conditions are presented. It is shown that the boundary conditions effect the dispersion and regularity in the variation in the maximum stresses in honeycombs with different discretization. The results of modeling using Comsol Multiphysics and the proposed algorithms for solving the plane problem are in good agreement, and the results of additive manufacturing laboratory experiments for the case of the three-point bending are consistent with numerical calculations. [ABSTRACT FROM AUTHOR]