Textile composites 1
School of Mechanical, Materials &Manufacturing EngineeringUniversity of Nottingham,
University Park, Nottingham, UK
Modelling of textilesModelling of textilesand compositesand composites
Andrew Long
Textile composites 2
Prof Andrew Long (Head)Prof Chris RuddProf Nick WarriorDr Arthur JonesDr Richard BrooksDr Mike CliffordDr Mike JohnsonDr Steve PickeringDr Colin ScotchfordDr Gavin Walker
14 post-doctoral fellows~20 PhD students3 technical staff
>£1.5million p.a. funding
We are: We study:Manufacturing processesTextile compositesDesign/performance modellingBiomedical compositesRecycling/end-of-life
Textile composites 3
Airbus UK Aston Martin, ACG, BAESystems, Bentley Motors, Boeing,Bombardier, DeepSea Eng., DowtyPropellers, ESI Software, Ford, Gamesa,Hexcel, JD Wilkie, NaREC, Rolls Royce,Smiths Aerospace, St-Gobain, Tenax,Unilever, Vestas, VT Halmatic
Key partners:
Major awards:Platform Grant – Processing and Performance of Textile Composites (EPSRC, £445k, 05-09)
High Value Composite Materials from Recycled Carbon Fibre (DTI, £333k, 05-08)
Development of novel anti-slash technical textiles (DTI, £220k, 05-08)
Fatigue, Damping and Impact Properties of Textile Composites (EPSRC, £168k, 06-09)
Simulation of 3D woven fabrics for structural composites (DTI, £189k, 06-09)
Multi-scale integrated modelling for high performance technical textiles (DTI, £318k, 07-10)
Analysis and modelling of advanced preform processing (EPSRC, £495k, 07-10)
Warpage compensation in composite laminate manufacture (DTI, £242k, 07-10)
Carbon Fibre Recycling – Materials and Product Development (Boeing, $260k, 07-10)
Automated tape placement for wind energy rotor-blades (DTI, £302k, 07-10)
Textile composites 5
Structural analysisStructural analysisDamage during impact loadingDamage during impact loading
4mm 1:1 Twintex0/90° Post Failure
4mm 1:1 Twintex 0/90°Damage Simulation
Failure Point
Textile composites 6
Transmissiontunnel
Jet enginenose cone
Marinepropeller
Pilot’shelmet
Process modellingProcess modellingDraping simulationDraping simulation
Textile composites 7
Picture frame shear rig
Process modellingProcess modellingFormability characterisationFormability characterisation
P Harrison, M J Clifford, A C Long, C D Rudd.Composites Part A 37 (2004) 915-931.
0
5
10
15
20
25
0 10 20 30 40 50 60 70 80
Shear Angle (Deg)
Sh
ear
Fo
rce
(N)
50mm/min
300mm/min
500mm/min
1000mm/min
2x2 twill weave glass/polypropylene 190 oC
Model predictions
Textile composites 8
PAM-RTMESI Software
http://www.esi-group.com
RTM-Worxhttp://www.polyworx.com
LIMSUniversity of Delaware
http://www.ccm.udel.edu
Process modellingProcess modellingLiquid composite mouldingLiquid composite moulding
Textile composites 9
Flow simulation for liquid composite moulding – Darcy’s Law:
In-plane K Through-thickness K
PK=u ][1
Process modellingProcess modellingLiquid composite mouldingLiquid composite moulding
Textile composites 11
Key features:
• Interference detection/correction
• In-plane shear,statistical tow paths
• Export to severalgraphical/data formats
• Automatic specificationof material orientations
Interlacing pattern (splines) Superimposed tow sections
Textile compositesTextile compositesTexGenTexGen -- textile modellingtextile modelling
Textile composites 12
TexGen model & micro-CT reconstruction of Chomarat 800S4-F1 4 harness satinweave
TexGen model & micro-CT reconstruction of Chomarat 150TB plain weave
Textile compositesTextile compositesTexGenTexGen -- textile modellingtextile modelling
Textile composites 13
TexGenTexGenOpen sourceOpen source –– free code!free code!
http://http://texgen.sourceforge.nettexgen.sourceforge.net
Textile composites 14
1. Model created usingTexGen
2. Mesh generation(third party software)
3. Automatic materialproperty/ orientation
assignment
Textile compositesTextile compositesTexGenTexGen -- textile modellingtextile modelling
Dry fabric/prepreg compliance Resin flow/permeability Composite mechanical properties
Textile composites 15
Textile compositesTextile composites3D woven composites modelling3D woven composites modelling
-0.0005
0
0.0005
0.001
0.0015
0.002
0.0025
0 0.05 0.1 0.15 0.2 0.25 0.3
Displacement (mm)
Pre
ssu
re(M
Pa)
0
0.010.020.030.04
0.050.06
0.070.080.09
0.1
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
Applied Strain
Ave
.Str
ess
(GP
a)
Weft
WarpThrough thickness
Binder failure
Warp/weftfailure
Resin failure
0
0.010.020.030.04
0.050.06
0.070.080.09
0.1
0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
Applied Strain
Ave
.Str
ess
(GP
a)
Weft
WarpThrough thickness
Binder failure
Warp/weftfailure
Resin failure
Preform compaction on mould closure Composite mechanical performance
3D woven “thick” &complex shapedcarbon preforms
3Tex Inc
“TexGen” model oforthogonal weave
unit cell
Textile composites 16
K free= hm
2 /12
K porousm
mijmij KhH
K1
2
3
1
2
1
18
f
f
V
V
cr
k
Tow permeabilities – Gebart model:
2
2/5
22 1 rVV
ckf
0
yP
Fyx
PF
y
yP
Fxx
PF
x
yyyx
xyxx
Governing equation:
ab
abK
F where
Element permeability:
Textile compositesTextile compositesPermeability modellingPermeability modelling –– ““Grid AverageGrid Average””
Textile composites 17
Monte Carlo method:• yarn crossovers displaced “randomly” along global x and y axes
• movement follows a Normal distribution with user-specifiedstandard deviation
Plain weave
0
5
10
15
20
25
30
35
less 1.635 1.655 1.675 1.695 1.715 1.735
Kx (10-9 m2)
Freq
uenc
y
Tow displacements.d. = 8.7%
R2 = 0.93
Textile compositesTextile compositesPermeability modellingPermeability modelling –– ““Grid AverageGrid Average””
Textile composites 18
Plain weave nylon 6.6 airbag fabric
Textile compositesTextile compositesPermeability modellingPermeability modelling –– CFDCFD
Geometric model
Discretised model (CFX) Pressure field for through-thickness flow
Textile composites 19
Engineering & Physical Sciences Research CouncilDepartment of Trade & IndustryAdvanced Composites Group Airbus UK Aston Martin LagondaBAE Systems Bentley Motors Bombardier Aerospace UKCarr Reinforcements Deepsea Engineering Department for TransportDowty Propellers ESI Software Euro-ProjectsFEA Ltd Ford Motor Company Formax UK LtdGranta Design Hexcel Composites JR TechnologyKatholieke Universiteit Leuven Litec LTC LtdMIRA MSC Software PeraQinetiQ Ltd Quadrant Plastics Rolls-RoyceSaint-Gobain Vetrotex Sigmatex Southfield CoachworksToho Tenax University of Bristol University of CambridgeUniversity of Cranfield University of Delaware University of LoughboroughUniversity of Manchester University of Ottawa University of TwenteUniversity of Ulster Uvasol VT Halmatic
Textiles & CompositesTextiles & Composites -- Sponsors/collaborators:Sponsors/collaborators:
…… Thank YouThank [email protected]
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