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Textile composite reinforcement forming has been employed in many aeronautic industries as a traditional composite manufacturing process. The double-curved shape manufacturing may be difficult and can lead to defects when the composite parts have high curvatures and large deformations. Compared with the textile composites forming, surface 3D weavin...
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Citations
... Previous studies have reported on seamless 3D composite manufacturing technology, but only for manufacturing of fragmented specimen. Owing to the complexity of the manufacturing technology, reports on mass production technology are also lacking [46][47][48][49][50][51][52][53]. Textile reinforcement forming [46,47] held an advantage in terms of its process simplicity and speed. ...
... Owing to the complexity of the manufacturing technology, reports on mass production technology are also lacking [46][47][48][49][50][51][52][53]. Textile reinforcement forming [46,47] held an advantage in terms of its process simplicity and speed. However, it suffered from drawbacks such as wrinkling, [15]. ...
... buckling, and network sliding. Surface 3D weaving [46,47] excelled in producing intricate structures with fewer defects but faced limitations for fiber plies with specific orientations, and its weaving process was time-consuming. The mathematical determination of shapes of reed wires [54] demonstrated an advantage in creating seamless and specific shapes, but it was constrained in the variety of shapes it could produce and required numerous corrections, rendering it time-intensive. ...
A new weaving technology using a modified z-binder interlacement system was designed to demonstrate its potential for the effective, continuous, efficient, and rapid manufacturing of various three-dimensional (3D) woven structures. First, three representative 3D woven preforms were fabricated. Then, epoxy resin was transferred to a preform. The manufactured 3D woven textile-reinforced composites were investigated using micro-CT analysis, tensile tests, and bending tests to study the effect of the z-binder interlacing on the structure. Furthermore, a design rule was established that could seamlessly create complex 3D woven structures with non-uniform heights in the z-direction, such as boxes, bowls, and pyramids, demonstrating that the seamless 3D woven preform of the complex shape can be fabricated with structural integrity.
... Preforming defects can be experienced during the composites manufacturing. Wrinkling is one of the most common preforming defects at macroscale considering the effects on in-plane shearing and bending [23,24,40]. The methods such as finite element and experimental analysis were utilized to find out the correlation between the processing parameters like blank-holder pressure and wrinkle [6,23,24] and finally to optimise the preforming stage [25][26][27]. ...
... Although the deformability behaviours during the preforming have been widely recognized and investigated in many perspectives, the previous researches mainly focused on the woven or NCF (Non-crimp-Fabrics) fabrics with different punch shapes such as hemisphere [32][33][34], double-dome [27,35,36], eccentric cone [37], tetrahedral and square box [38][39][40][41][42]. On the contrary, even though Jacquot et al. [43] compared the deformability behaviours of woven and biaxial braided fabrics manufactured from the same comingled flax/PA12 yarns on the hemispherical punch, there are relatively few research works dealing with the braided reinforcements preforming. ...
At the first stage of the Resin Transfer Molding (RTM) process, the composite reinforcements preforming is a complicated physical stage including complex deformability behaviours. In this paper, the deformability of carbon triaxial braided fabrics, one of the advanced composite reinforcements, is originally investigated. The yarns sliding along both longitudinal and radial yarn directions is the primary preforming behaviour, which is quite distinct from the woven fabrics preforming. Moreover, the yarns sliding along two yarn directions present quite a difference between the axial and bias yarns. The manufacturing defects during the triaxial braided fabrics preforming such as fibre vacancies, buckling and gaps are also discussed. At last, the geometrical models to predict maximum sliding along longitudinal yarn direction are described based on basic preforming parameters. Besides, the criterion preventing fibre vacancies are also proposed.
... Such tensile stresses significantly influence fabric forming properties [3][4][5]. Passive and active systems were developed for the control of fabric forming [2,[6][7][8][9][10][11][12][13][14][15]. However, friction-based blank holders or other systems may reduce wrin- kling, but induce other defects in the fabric, such as fiber displace- ments or fiber pull-out [2]. ...
... The use of blank holders as a mechanism to regulate fabric forming processes has been widely studied [2,[8][9][10][11][12][13][14][15]. Blank holder-based material guide systems can reduce or eliminate wrin- kling, but in multilayer draping their influence towards a reduction of in-plane defects is small [2]. ...
For composite applications in automotive serial production, reinforcement textiles are brought into the desired shape by forming processes. The preform quality depends on the interacting factors of tool geometry, textile material, and forming process. The primary cause of defects in multilayer draping is relative movements of the plies, and the occurrence of wrinkles. Thus, the reduction of the interactions between plies is crucial to enhance preform quality. This was achieved with active metal sheets between the fabric layers. Those intermediate layers are additionally stimulated with piezo actors to reduce friction. Additional local and ply-specific clamping of layers was achieved with tension rods and segmented actuators. Defects and wrinkles in the preform could be eliminated or reduced significantly and fiber orientation could be controlled. Thus, a forming process providing high-quality preforms from multiple fabric layers was developed. Furthermore, automation complexity could be reduced significantly by utilizing rigid interlayers.
... Preforming set-up is illustrated in Figure 5 [6]. The main dimensions of forming tools are shown in the figure. ...
Woven and braided textile structures are largely used as the composite reinforcements. Forming of the continuous fibre reinforcements and thermoplastic resin commingled yarns can be performed at room temperature. The “cool” forming stage is well-controlled and more economical compared to thermoforming. Many studies have been addressed for carbon and glass fibres / thermoplastic commingled yarns reinforced composite forming for woven structure. On the contrary, few research works has deal with the natural fibre reinforced textile forming and none concerns the braided fabrics forming. In this present work, the Flax/Polyamide 12 commingled yarns are used to produce braided fabric and then to analyze their deformability behaviour.
... Many studies have been done not only on the carbon and glass fibres reinforced textile composite preforming on hemispherical shape [36][37][38] for woven fabric, noncrimp fabrics [39], 3D interlock [40] or weft-knitted fabric [36], but also on doubledome shape [41][42][43], eccentric cone [44], tetrahedral shape [45][46][47] and square box [48,49]. On the contrary, few research work has dealt with the natural fibre reinforced textile forming [33,35] and none concerns the braided fabrics forming. ...
Natural flax fibres have been extensively recognized by automotive industries to reduce
the weight of vehicles and obtain recyclable composite parts. Most of composite parts
are produced by using resin transfer moulding or thermoforming processes. As the first
step of these two composite manufacturing processes, the preforming is quite important.
Braided and woven fabrics are widely used as textile reinforcements to manufacture
the advanced composite parts. But few research works concern the preforming of the
reinforcements based on natural fibres and also there is no analysis of dry braided
fabrics forming. In the present work, the studies of formability behaviour of braided
and woven fabrics made of the same flax/polyamide 12 commingled yarns are performed.
Furthermore, an experimental comparison between the preforming behaviour
of braided and woven flax/polyamide fabrics is investigated under identical preforming
conditions. The different formability behaviour and the defects developed during preforming
stage are analysed. First results obtained on hemispherical shape show a higher
deformability for the braided reinforcements, which can generate some forming defects,
in particular buckles.
