Project
Abstract  |
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Development & improvement of Lightweight structures is a
continuous challenge for engineering & production and in particular
for land & marine vehicles.
SANDWICH is going to enhance the features & capabilities
of steel sandwiches by filling them with different core materials:
metallic foams, PMI and PUR foams, light concrete & balsa.
The aim is to develop a set of panels for specific requirements
defined by three industry types involved (automotive, railroad,
shipbuilding).
SANDWICH panels improvements compared to conventional structures:
- up to 50% lighter
- 50% space saving
- 20% noise reduction
- enhanced vibration properties
- fire safety
- crash worthiness & corrosion resistance
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Erection time is expected to be reduced by 30 %.
12 partners from 8 European countries, joined forces each of
them an expert for one particular aspect & task. After a requirements
analysis, design & production of the test specimens &
prototypes follows.
A test phase delivers material behavioural data to be collected
in a design tool which in return supports designers to develop
tailor made SANDWICH products . A design guideline assures secure
type approval and thus marketing success.
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Objectives
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The SANDWICH project will develop products utilising sophisticated
lightweight steel sandwich panels for primary load carrying structures,
including solutions for the integration of sandwich panels into
land vehicles and ships and for the integration of multiple functions
into the sandwich panels.
The novel properties of the sandwich panels will include: - Up to 50 % weight reduction
- Up to 50 % less space consumption
- improved noise reduction and vibration properties
- enhanced fire safety
- significantly improved crash worthiness
- high potential of accurate pre-
manufacturing and
- 30 % decrease of erection time.
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The project will provide design guidelines and operational behaviour
data based on tests and calculations.
The participation of industrial end users and approving bodies
will ensure that the project results can be directly used by the
European industry.
Lightweight structures for land and marine vehicles contribute
significantly to both CO2 reduction and saving of resources.
The expected benefit for the partners involved will guarantee
a return on investment within two years.
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Description
of Work
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WP 1 Define and harmonise requirements for land and marine transport,
perform risk analysis to assure full coverage of all aspects for
future applications.
WP2 Develop design solutions for advanced sandwich panels, for
joints and attachments and for integrated functional units based
on available know how, in a second design phase make use of the
SANDWICH design tool and thus of the material behaviour knowledge
gained so far.
WP3 Produce test specimen and prototypes, and feedback requirements
towards „Design for Production„ into the design tool
database
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WP4 Test both qualitative and quantitative the design solutions
in small and large scale tests. Collect data on the operational
properties and derive design algorithms and feed the database
with all available material behavioural information
WP 5 Create design tools for optimised panel layout and integration,
considering the specific requirements of the different applications
and load cases, the design optimisation procedures and latest
available test results.
WP 6 Disseminate the results gained in prototype solutions of
the project to support fast and
efficient exploitation into all transport areas.
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Milestones and Expected
Results
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SANDWICH will deliver a new generation of lightweight products
for both land and marine vehicles based on cored sandwich panels
a tool utilising a sound material behaviour database filled through
intensive small and large scale testing design guidelines for
type approval of products after the project end.
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M1 (pm 6) requirements delivered
M2 (pm 9) first design
M3 (pm 12) first panels
M4 (pm 15) first version of design tool
M5 (pm 21) qualitative testing
M6 (pm 24) design updated
M7 (pm 27) design tool update
M8 (pm 33)quantitative testing finished
M9 (pm 36) project finished
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Co-operation with other Projects
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SANDWICH and FASDHTS agreed on exchanging parts of their project
results for the mutual benefit of both projects
SANDWICH and BONDSHIP agreed on exchanging parts of their project
results for the mutual benefit of both projects
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SANDWICH and CRASHCOASTER agreed on exchanging parts of their
project results for the mutual benefit of both projects
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