New to HyperSizer and trying to understand the various inputs with a simplified case before proceeding to more difficult geometry.

Component type: foam sandwich w/ 0.50" upper and lower panels. Thickness of foam core is set to be very small 0.0001". 2nd area moment is calculated by: (1/12 bh^3)*2 (b=2, h=.5"). Since the foam core is intentionally very small, the area moment reduces to 2/48 in^4 (or 0.042). [see attached calculation]

In the Free Body section, the panel is unconstrained with the total Mx load of 10,000 in-lbs. The panel dimensions (a=1", b=2") are entered, but do not appear to be related to the stress??

Calculating the average stress at the neutral axis of the top plate gives: 10,000 in-lb * 0.25" / (2/48 in^4)) = 60,000 psi.

Hypersizer is calculating a stress of ~30,000 psi.

My answer is 2x larger than Hypersizer. I thought that I should unitize the bending load, but this would only make the difference increase.

Help appreciated. Thanks.