DESIGN AND OPTIMIZATION OF FUNCTIONALLY GRADED HONEYCOMB STRUCTURES FOR OUT-OF-PLANE STIFFNESS AND ENERGY ABSORPTION

Honeycomb structures, inspired by nature, are widely valued for their remarkable strength-to-weight ratios, making them indispensable in aerospace, automotive, and other engineering applications. This study explores the mechanical performance of functionally graded honeycomb structures with various thickness gradation configurations. Seven designs, including uniform and staged thickness variations, were analyzed through finite element method (FEM) simulations and validated with experimental testing to assess their behavior under compressive loading. The results demonstrate that incorporating thickness gradation significantly enhances mechanical properties compared to uniform designs. Staged configurations improved compressive strength, energy absorption, and crushing force efficiency, with the number and placement of thickness variations playing a critical role. While increasing the number of gradation stages refined stability and crushing force efficiency, it also resulted in trade-offs, such as reduced load-bearing capacity and energy absorption. Designs with strategically placed thin regions outperformed others in terms of energy dissipation and stability, highlighting their suitability for applications requiring controlled deformation and impact resistance. This study provides valuable insights into the design and optimization of functionally graded honeycomb structures, offering a pathway for developing lightweight, high-performance materials tailored to specific engineering needs.