A New FE Modelling Approach to Simulate the Inter-Layer Adherence in Hybrid Sandwich Structures Achievable by Additive Manufacturing

Numerically predicting the mechanical behavior of additively manufactured sandwich structures, particularly those produced through filament extrusion, poses a significant challenge. Existing collapse mechanisms, including interlayer debonding, lack comprehensive numerical formulation. This paper presents an improved finite element (FE) modeling approach for filament-based additive processes. Utilizing the cohesive zone model (CZM), it incorporates a cohesive-type contact to simulate critical layer interactions, such as the core-face sheet interface. Validation against a literature-referenced composite sandwich structure with designed for additive manufacturing honeycomb core demonstrates good agreement between the proposed numerical approach and experimental test data in compression and bending.