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Modeling of a composite encapsulated foam core

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Hey everyone


I'm modeling a composite part with a foam core inside of it, but I'm not sure, what's the right way to do it. This is the part I'm talking about:


Including the core in the laminate means, that it will overlap on the inside of the part. I tried out several thicknesses to see, how the overlap affects the end result, but the deformation didn't change much at all. I went from 0.2 mm core thickness to 9 mm (the part is 10 mm thick) and the deformation only really decreased by a small amount after there was a large overlap.

I also modeled the core as a seperate component and applied a freeze contact between both parts. That resulted in an about 11% higher deformation. For this simulation I used the same outer geometry, which means, that the core is penetrating the laminate. This definetely looks wrong, but I'd still be interested in knowing, what impact this has on the simulation.

Here are pictures of the core included in the laminate and modeled as a seperate component:




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