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Woven Structure
direction = "warp" or "end" Perpendicular direction = "fill" or "weft" or "pick" or "woof Frequently the warp direction corresponds with the 0, or longitudinal direction And fill with the 90 or transverse direction
However - this is not necessarily the case
Woven Fabrics
Generally
characterized by two sets of perpendicular yarns systems One set is raised and lowered to make sheds (these are warp yarns) The other set is passed through these sheds, perpendicular to the warp yarns (these are fill, or pick or weft yarns)
Woven Fabrics
The
structure of the woven fabric is the pattern of interlacing between the warp and weft yarns Yarns can float, or not interlace for some distance within a woven fabric
Crimp in Weaves
The crimp is defined as one less than the ratio of the yarn's actual length to the length of fabric it traverses. Crimp levels influence fiber volume fraction, thickness of fabric, and mechanical performance of fabric. High crimp leads to
Reduced tensile and compressive properties Increased shear modulus in the dry fabric and
the resulting composite Fewer regions for localized delamination between individual yarns.
Crimp
Crimp
is defined as the ratio of excess length of yarn in a fabric to the length of the fabric
C = ly/ lf - 1
lf
ly
Crimp
Crimp
is determined by the texture of the weave and the yarn size Generally, in weaving, the warp yarns have most of the crimp, the fill very little
This is a direct result of the warp yarns lifting
during weaving and the filling yarn being inserted along a straight path
Crimp
Various
models of crimp exist, the most rigorous developed by Pierce in the 1930s.
1 D d2 1
p2
Crimp
pi=(ljD j)cos j + Dsin j hi=(liD i)sin i+D(1cos i) ci=(li/pj)1 h1+h2=d1+d2=D
Wherepi =Thread spacing; li =Modularlength;ci =Yarn
i,j=warpandweftdirections.
Crimp
Simplified
tf + tw pf
Crimp
2.0% 1.8% 1.6% 1.4% 1.2% 1.0% 0.8% 0.6% 0.4% 0.2% 0.0%
22T12K 5HS6K 22T3K 3K 12K22B 4HS12K 44T3K 6K 22T6K 4HS3K 8HS3K 12K
10
12
14
16
18
20
22
24
Endsperinch
Thickness
Thickness
is a difficult parameter to
measure. Thickness is dependent on applied transverse pressure to the fabric Predictions of thickness show variation throughout the unit cell
Thickness
Thickness
Areal Density
Areal
Areal
density is a more reliable experimental metric for fabrics than thickness Areal density can be correlated to volume fraction
Areal Density
Areal
i yarns per unit length, Li = linear density of the i yarn, w = width, l = length, and I=warp or weft.
Areal Density
Woven Structures
Twill 3D Woven
Plain weave
3D Weaves
Layer-to-layer
Through thickness
XYZ
If large yarns are used in the warp direction and small yarns are infrequently spaced in the weft direction, the resulting fabric resembles a unidirectional material. Weaves can be formed with gradients in a single or double axis by changing yarn size across the width or length Complex shapes can be achieved through floating and cutting yarns to reduce total number of yarns in some section of the part
weaver, and fill, and a change in fiber volume fraction in consequence to the change in thickness.
Some fiber volume fraction effects can be controlled by tooling. The tailoring occurs in a discrete manner, using individual yarns, whereas most tooling will be approximately continuous.
a tapered panel where gradation in thickness is achieved by changing yarn size/count across the width
count is constant, warps and wefts per dent are modified to taper Z yarn path changes to accommodate the weave.
Number
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1 3
11 13 15 17 19 21 23 25 27 29 31 Dent
This variation in yarn packing results in variations in Vf for the resulting Fib e r composite. V olum e
Fract n io
0.500
1.000
1.500
2.000
2.500
The weave angle will 55 also change throughout the width of the part due 50 to varying warp yarn count and part 45 thickness.
Weave Angle 40
35
30
Calculat ed Targe t
25 0.0
0.5
1.0
1.5
2.0
2.5
Yarn Distributions
The distribution of warp, 60% weft, and Z yarn will also 55% vary throughout the part.
50 % 45 % 40 % Yarn Distribution 35 % 30 % 25 % 20 % 15 % 0.0
%Z
% Wa rp
% Fill
0.5
2.0
2.5
Variations in Modulus
All
0.5
1.0
1.5
2.0
2.5
Volume Fraction
Volume
fraction is the percent of fiber contained within a given volume (usually the composite in question) Volume fraction can be calculated from areal density
Vf = A / t Where Vf = fiber volume fraction, A = areal
Errors
Sources
of error
feed-back from shedding and insertion mechanisms Visual scan of fabric surfaces Xray or neutron scan of fabric interior
Using tracer yarns
"standard" weaving technology Complexity of weave is limited by number of independent shedding devices Some limitations on maximum thickness of fabric due to shed size and beatup limitations
3-D Weaving
filling insertion
fabric movement
Longitudinal yarns
Surface weavers
Lie in warp-thickness plane Located at t=0, t=max
Filling yarns
Lie in fill-thickness plane Generally aligned with the fill direction
Surface Weaver
warp
= i / c = (1/hp) (1/hw) t = mi Ai li
Process Variables
Yarn
sizes (all independent) Reed size (limited by yarn size) Picks per inch (limited by yarn size) Weave angle Number of filled warp positions
Using fiber volume (Vf), thickness (t), ply percentages (wt%) as inputs:
Here is fiber density for each n fiber type and w is the preform areal density.
Yarn spacings needed for each ith system (warp, fill, weaver) can then be found using the tow linear density N:
Np / ppil
tan =
t ppil Np
Tows required to meet thickness can be estimated assuming a common aspect ratio (AR):
d a b
a =
A = 6
3.9 10 in = .00455 in 6
2
The preforms were procured from a weaver, then evaluated based on the design methodology.
Example Calculations
Example Calculations for Sample 2, using IM7-12k graphite tows for all inputs:
0:
oz
10 in
0 90 ttt Total
77 17 6 100
90:
6 2 oz 10 in lb yd = ypi = 12.63 2 24.4 ypi 25.0 lbs 16 oz 36 in yd 6 2 oz 10 in lb yd ypi = 4.46 2 cos i = 7.9 ypi 25.0 lbs 16 oz 36 in yd
z:
90
Required Reported
ttt
Required Reported
34.9 67 22.9
4.5 16 2.9
Sample 2
Parameter areal weight 2 (oz/yd ) yarns per inch Volume fraction 57.2 110.4 43.2 0
Required Reported
90
Required Reported
ttt
Required Reported
12.5 24 7.5
4.5 6 2.7
22.5
Evaluating Sample 2:
6 2 oz 10 in lb yd 6 ypi = wz 2 cos (22.5) 11.8 lbs 16 oz 36 in yd
36 in .100 in yd
16 oz = 71.26 oz 2 lb yd
Vf =53.7%
It was calculated that 74.3 oz/yd2 was needed to meet the 56% volume fraction specified
Example
6
ends per inch, 6 picks per inch, 4 picks thick 12K AS-4 yarns long. & fill, 6K weavers, no surface weavers Weaver yarn ratio - rise/run =tan( w) ar
Thickness
= 0.25 inch All warp slots filled aspect ratio = (np mp)/t
0.55 0.5
0.45 0.4
4 ppi 6 ppi
10
12
14
40
45
0.35
0.3
0.25
0.2
section as consisting of rectangular pieces Develop weave parameters for each piece Develop interconnection paths
Production of Very Complex Shaped Weaves part into rectangular and Decompose
shell sections Consider impact of cutting yarns Consider "folding" type operations
scan of image Mistake in keying of "dots and spots" Slipped card/chain at pick insertion failure