Abstract
This study proposes an arc-circular lightweight honeycomb structure. Three different configurations of honeycomb specimens, namely arched honeycombs (AHs), arc-circular honeycombs with a first-order hierarchical configuration (ACH-1), and arc-circular honeycombs with a second-order hierarchical configuration (ACH-2), are prepared using metal additive manufacturing technology, and quasi-static compression tests are conducted. The results show that all configurations exhibit significant multi-stage load responses, with the ACH-2 configuration, which incorporates smaller sub-cells, demonstrating higher compressive stress and energy absorption potential. The specific energy absorption (SEA) of ACH-2 is enhanced by 210% compared to the baseline AH. The effectiveness of the finite element analysis is validated against experimental results. Further parametric analysis of the wall thickness parameters, cell number, and macroscopic dimensions of ACH-2 reveals significant variations in how wall thickness at different local locations affects the mechanical properties. Additionally, although increasing the macroscopic dimension significantly enhances the energy absorption capacity, the effect of increasing the number of cells on the overall energy absorption performance at the same relative density is limited. Finally, a reverse design framework for ACH-2 with multi-stage plateau stress is established. The effectiveness of this performance design framework is validated through experiments, providing a feasible technical approach for the design of honeycomb structures with multi-stage plateau stress characteristics.