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Development of 2D/3D Braiding

Techniques for Multi-axial Preforming

Dhaval Jetavat, Khayale Jan, Sree S Roy, B S Sugun

Academic PI: Prof Prasad Potluri

School of MaterialsUniversity of Manchester

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Overview

Introduction

Textile preforming

Need for Multiaxial fibre preforming

2D Braiding 3D Braiding

Challenges

Development of Braiding/Winding

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Textile Composites Group

•

Research at University of Manchester is focused on developingmanufacturing concepts for ‘near-net’ preforms that requireminimum post-processing and at the same time incorporatingmulti functional materials.

Research Objectives Application of low cost automation and robotics in preform

manufacturing

To explore novel toughening concepts through hybrid preforms

To create novel multi-functional hybrids at tow-level and preformlevel

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Textile Composites Group

• Area of Expertise: – Textile technology – 3D Weaving, 3D/2D Braiding, Winding – Robotic Automation, Machine control – Composite manufacturing methods – Mechanical and Physical Testing

• Equipment Expertise – 3D Weaving, 2D Weaving, Braiding – Robotic machine (Tow placement, Winding machine, Tripod system for pick

and place) – Autoclave, RTM, Vacuum Bagging – Instron, ZwickRowell – C-scan, Thermography, DIC, SEM, CT scan

• Near net shape preforming – Preforming trials for creating ply contours – Combination of Braiding/Weaving/RTP processes – Fibre placement on double curvature surface with RTP – Tufting process to add through thickness reinforcement

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Fabric Form

2D Woven Stitched NCF Braided

3D Woven

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2D Braiding

Braiding is the process of diagonally interlacing three or more strands of yarn

in order to create continuous rope, tube or ribbon-like structures Variety of tows can be combined in the axial and braid directions in order tocreate hybrid materials Non-interlaced core materials such as fibre tows, foam materials, metalwires, fibre optics and smart actuating materials can be inserted into a braidedstructure Ability to form complex shapes is one of the key features of braiding

technology

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3D Braiding

3D braided textile preforms can be manufactured either byconventional horngear braiding or by modifying conventionalbraiding techniques

Other recognised methods are 2-step , 4-step row and column

Horngear Braiding machine

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Herzog Braiding Machine

3D braiding machine based on horngearmechanism with 32 carrier capacity hasbeen utilised

Required pattern or tow architecture- Sequencing of bobbin paths bydefining movement paths

- Reinforcing using axial tows

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Fibre path selection

Path Isolation Path Open

Depending on part geometryfibre path needs to be selected

This can be done with the trackarrangement

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Axial yarn arrangement

Maximum of 25 axial yarns can be inserted

Creel has been set-up under braiding bed to insert axial yarns

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Various profile structures

L braid : 24 carriers,17 stuffers Double solid braid : 32 carriers, 25 stuffers

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Solid braid : 16 carriers, 25 stuffers T braid : 20 carriers, 16 stuffers

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Machine design

An automated prototype machinecapable of producing variety ofwound architectures has beendeveloped.

Binding of multi-layer wound

structure during preforming

Winding, axial and binder yarns canbe introduced simultaneously

 “CoDeSys” provided by FESTO isused for configuration andoperation of the machine

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Braid-Winding

Consolidated structuredevelopment with

wrinkle minimization

Braid-winding for Quadriaxial Quasi-isotropic preforming(±45°/0°/90°)

Combines the benefits of interlaced and non-interlaced structure Complementary processes so possible in-line manufacturing

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3D weaving-3D Braiding- Tufting

NCF Skin Material

3D Woven “T” Section

3D Braided Noodle

5mm Tufting Pitch

10mm Tufting Pitch

Tufting of “T” section

to NCF material

at 45° near noodle region

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Conclusion

Multiaxial fibres can be introduced in 2D/3D braiding and

winding

Exploration of various profiles on 3D solid braider

3D braid profiles can be utilised to reinforce local areas incomplex shape preforms

Development of novel textile preforming machine to

produce multiaxial preforms with through thickness binder

Various technologies can be combined to produce near net

shape preform to meet design and structure requirements

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