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Development of 3D Braiding Concept for Multi-Axial Textile Preforms

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Development of 3D Braiding Concept for Multi-Axial Textile Preforms Development of 3D Braiding Concept for Multi-Axial Textile Preforms A thesis submitted to The University of Manchester for the degree of PhD in the Faculty of Engineering and Physical Sciences 2015 KHAYALE JAN Textile Composite Group SCHOOL OF MATERIALS Table of Contents Development of 3D Braiding Concept for Multi-Axial Textile Preforms ................................... 1 List of Figures .............................................................................................................................. 5 Abstract ...................................................................................................................................... 11 Declaration................................................................................................................................. 12 Copyright Statement ................................................................................................................. 13 Dedication .................................................................................................................................. 14 Acknowledgement ..................................................................................................................... 15 1 CHAPTER 1 INTRODUCTION ................................................................................................ 16 1.1 Brief Account of Textile Preforms and Preforming Techniques ................................. 16 1.2 Research Aims ............................................................................................................. 18 1.3 Research Objectives .................................................................................................... 19 1.4 Thesis Outlines ............................................................................................................ 20 2 CHAPTER 2 LITERATURE REVIEW ........................................................................................ 22 2.1 Introduction ................................................................................................................ 22 2.2 Composites.................................................................................................................. 22 2.3 Textile Composites ...................................................................................................... 23 2.4 Scope and Applications ............................................................................................... 24 2.5 Brief Account of Textile Preforms for Composites ..................................................... 26 2.5.1 2D Textile Preforms ............................................................................................. 27 2.5.2 3D Woven Preforms ............................................................................................ 29 2.5.3 Multi-Axial Textile Preforms ............................................................................... 31 2.5.4 3D Knitted Preforms............................................................................................ 32 2.5.5 3D Stitched Preforms .......................................................................................... 33 2.5.6 3D Braided Preforms ........................................................................................... 34 2.5.7 Filament Wound Preforms .................................................................................. 35 2.6 Textile Preforming Techniques ................................................................................... 35 2.6.1 Weaving .............................................................................................................. 35 2.6.2 Tubular Preforming Techniques .......................................................................... 39 2.6.3 Filament Winding ................................................................................................ 39 2.6.4 Braiding ............................................................................................................... 43 2.6.4.1 Horngear Braiding ........................................................................................... 44 2.6.4.2 3D Solid ........................................................................................................... 49 2.6.4.3 Cartesian Braiding ........................................................................................... 55 2 2.6.4.3.1 Two-Step Cartesian Braiding ..................................................................... 55 2.6.4.3.2 Four-Step Cartesian Braiding .................................................................... 57 2.6.4.3.3 Circular Braiding Machine ......................................................................... 68 2.7 Critical Review & Conclusion ...................................................................................... 76 3 CHAPTER 3 CONCEPTUAL DESIGN OF 3D NOVEL MACHINE ............................................... 78 3.1 Preliminary Concepts .................................................................................................. 78 3.1.1 Concept-1: Cartesian Braiding with Continuous Supply of Yarn from a Creel .... 78 3.1.1.1 Cartesian Braiding Bed .................................................................................... 79 3.1.1.2 Braid Locking Set-Up ....................................................................................... 81 3.1.1.3 A Hand Operated Prototype ........................................................................... 81 3.1.1.4 Advantages ...................................................................................................... 82 3.1.1.5 Limitations ....................................................................................................... 83 3.1.2 Concept-2: Cartesian Braiding with a Mini-Braiding Bed .................................... 83 3.1.3 Concept-3: Cartesian Braiding Machine Inter-twining Braiding, Axial & Semi- Axial Yarns ........................................................................................................................... 86 3.1.3.1 Axial Yarns ....................................................................................................... 86 3.1.3.2 Braiding Yarns ................................................................................................. 86 3.1.3.3 Semi-Axial Yarns .............................................................................................. 86 3.2 Modifications in Concepts .......................................................................................... 87 3.2.1 First modification: Cartesian Circular Braiding Machine incorporating Braiding, Axial & Binder Yarns ............................................................................................................ 88 3.2.2 Second modification: Circular Braiding cum Winding Machine for Multi-Layer Multi-axial Textile Preforms Incorporating Braiding, Axial & Binder Yarns ........................ 91 3.2.2.1 Bobbin Transfer System .................................................................................. 93 3.2.3 Final Modification ............................................................................................... 98 3.3 Conclusion ................................................................................................................. 100 4 CHAPTER 4 DEVELOPMENT OF THE NOVEL 3D TEXTILE PREFORMING MACHINE .......... 102 4.1 Construction of the Machine .................................................................................... 104 4.1.1 Braiding Rings .................................................................................................... 104 4.1.2 Pneumatic Actuators ......................................................................................... 106 4.1.3 Pneumatic Internal Grippers ............................................................................. 107 4.1.4 Miniature Shuttle .............................................................................................. 108 4.1.5 Axial Yarn Supply ............................................................................................... 110 4.2 Bobbin Transfer Mechanism ..................................................................................... 111 4.3 Braiding Yarn Placement ........................................................................................... 119 3 4.4 Process Layout of the Machine Operations .............................................................. 121 4.5 Conclusion ................................................................................................................. 123 5 CHAPTER 5 DEVELOPMENT OF MULTI-AXIAL BRAIDED PREFORMS ................................ 124 5.1 Prospective Fibre Architectures ................................................................................ 124 5.2 Development of Multi-Axial Textile Preforms .......................................................... 127 5.2.1 Preparation ....................................................................................................... 127 5.2.2 Tensions Adjustment ........................................................................................ 129 5.3 Validation of the Weave Architecture ...................................................................... 130 5.4 Initial Trials to Develop Preforms.............................................................................. 131 5.5 Preform with Various Structure Compactness ........................................................
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