Relating Weaving Parameters and 3D Woven Fabric Design with a Geometrical Modelling Approach

Abstract

Aeronautic composite parts made with 3D interlock woven reinforcements benefit from near net shape design capabilities and good damage tolerance. Mastering this complex automated process is critical in order to challenge the conventional construction of composite parts using laminated 2D fabrics. This study aims at understanding and predicting the relation between 3D weaving parameters and the real fabric geometry. A yarn-based geometric model has been developed to fulfill this critical need. Generally, non-mechanical 3D woven models require extensive experimental characterization of the fabric geometry. On the other side, mechanical modelling of 3D woven fabrics require large amount of computer resources. Therefore, those types of models are rather inefficient to rapidly generate an accurate 3D model according to weaving parameters. The developed approach is directly related to a specific manufacturing weaving software in order to generate a realistic 3D model automatically. Warp and weft tension ratio, multiples yarn types with constant elliptic cross-section shapes are some of the key features of the developed model. This tool aims at reducing manufacturing costs by relating the weaving parameters to achieve specific fabric requirements in a short time. The model precision and capability were validated with experimental observations and testing. 6 different interlock fabrics were modelled and subsequently woven. The fabric thickness was measured following the ASTM D1777 standard. The observations validated the selected modelling approach.