Composite sandwich structures are widely used in the fields of aviation, marine, and energy due to their high specific stiffness and design flexibility. Improving the mechanical properties of the cores is significant to the strength, modulus, and stability of composite sandwich structures. Two kinds of core machining configurations were designed by combining thin grooves, perforated holes, and thick contour cuts as well as non-machining plain cores. The cores and sandwich structures with these configurations were fabricated using a vacuum-assistant infusion process. Static tensile, compressive, shear, and peeling tests were conducted on the infused cores and sandwich structures. The results showed that the tensile, compressive, and shear moduli, and compressive strength of the infused cores can be greatly improved. The tensile strength changed negligibly due to stress concentration induced by irregular foam cell and the shear-lag phenomenon of the resin column/foam interface. The shear strength of the infused cores increased slightly. The thick contour cuts and perforated holes can greatly improve the face sheet/core peel capacity of the sandwich structures, whereas the thin grooves can moderately improve the peel capacity. Both infused cores with the designed machining configurations exhibited positive effects on the compressive, tensile, and shear moduli, and compressive strength, considering the material costs. The study provides a comprehensive and quantitative insight into the effects of core machining configurations on mechanical properties of infused cores and composite sandwich structures.
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