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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
d2
D 1
p2
Crimp
○ pi = (lj – D j) cos j + D sin j
○ hi = (li – D i)sin i + D(1 - cos i)
○ ci = (li/pj) - 1
○ h1 + h2 = d1 + d2 = D
tf + t w
pf
Crimp
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
100%
98%
nylon 6
nylon 6,6
96%
Relative Thickness
polyester
PEN
94%
92%
90%
88%
86%
0 100 200 300 400 500 600
Testing Pressure (g/cm2)
Theoretical Predictions of Thickness
Double Cloth
Satin
Mechanical behavior:
The Effect of Yarn Crimp
Plain weave
XYZ
Doubly Stiffened Woven
Panel
Variations in Weave Design
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
Gradations through yarn size
Shape through floats
Issues with shaping woven
fabrics
Tailoring the cross-section of a woven
fabric will generally result in
a change in weave angle,
a change in the distribution of longitudinal,
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.
Example of single taper weave
Consider a tapered panel where
gradation in thickness is achieved by
changing yarn size/count across the
width
Design of tapered woven panel
Pick count is
constant, warps
18
and wefts per 17
Pick Columns per inch
Warp per dent
Picks per column
16
dent are modified 15
14
to taper 13
12
Z yarn path 11
10
changes to Number 9
8
accommodate 7
6
the weave. 5
4
3
2
1
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
Dent
Variation in Fiber Volume Fraction
60%
This variation in
58%
yarn packing
results in variations 56%
in Vf for the 54%
resulting
Fiber 52%
composite.
Volume
Fraction 50%
48%
Calculated
46% Target
44%
42%
40%
0.000 0.500 1.000 1.500 2.000 2.500
Distance from Thin Edge (in)
Variation in weave angle
35 °
30 ° Calculated
Target
25 °
0.0 0.5 1.0 1.5 2.0 2.5
Distance from Thin Edge (in)
Yarn Distributions
60%
The distribution of warp,
weft, and Z yarn will also 55%
vary throughout the part.
50%
45%
Yarn 40%
Distribution %Z % Warp % Fill
35%
30%
25%
20%
15%
0.0 0.5 1.0 1.5 2.0 2.5
Distance from Thin Edge (in)
Variations in Modulus
All mechanical properties will vary
throughout the part
14
12
10
E11 E22 E33
Tensile 8
Modulus
(Msi)
6
0
0.0 0.5 1.0 1.5 2.0 2.5
Distance from Thin Edge (in)
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 r / t
Where Vf = fiber volume fraction, A = areal
density, r = density of the fibers, and t =
composite thickness
Process Control and Variability
Processing Errors
Damaged yarns
Misplaced yarns
Sources of error
Machinery malfunction
Machinery variability
Bad control parameters
Post-manufacturing deviations
Distortions in Woven Fabrics
On-line Monitoring of
Manufacturing
Realtime feed-back from shedding and
insertion mechanisms
Visual scan of fabric surfaces
Xray or neutron scan of fabric interior
Using tracer yarns
Three Dimensional Weaving
Uses "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
Types of 3-D Woven Fabrics
XYZ
Layer-to-layer
Through-thickness
3-D Weaving
shed
weaver
warp
Fills
Longitudinals
Weaver
t
Surface
warp Weaver
Physical Relationships of 3-D
Woven Fabrics
Vf = ∑ W i / W c
Wc = (1/hp) (1/hw) t
Wi = mi Ai li
ll = (1/hp)
lw = (1/hp)/cos(w)
ls = (1/hp)/cos(s)
lp = (1/hw)
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
Preform Input Parameters
Using fiber volume (Vf), thickness (t), ply
percentages (wt%) as inputs:
Here r is fiber density for each n fiber type and w is the preform areal density.
t
a
Np / ppil
t ppil
tan a =
Np
Determining Preform Thickness
Requirements
Tows required to meet thickness can be estimated
assuming a common aspect ratio (AR):
AR= b
a2
A=pab=pa AR
d a b
a= A =d 1
pAR 4AR
-4 2
A = ´
3.9 10 in
a = = .00455 in
6p 6p
lb yd =
6 2
Fiber direction % tows directional areal oz 10 in
0°
: ypi = 57.23 2 110.4 ypi
density
yd 25.0 lbs 16 oz 36 in
(oz/yd2)
0° 77 57.23
oz 10 in lb yd =
6 2
90° 17 12.63 90°
: ypi = 12.63 2 24.4 ypi
yd 25.0 lbs 16 oz 36 in
ttt 6 4.46
Total 100 74.32 6
2
z:
oz
ypi = 4.46 2
10 in lb yd a
cos i = 7.9 ypi
yd 25.0 lbs 16 oz 36 in
Applying the Methodology
Sample 1
Parameter 0° 90° ttt
Required Reported Required Reported Required Reported
Sample 2
Parameter 0° 90° ttt
Required Reported Required Reported Required Reported
9°
Sample Measured angle Predicted angle
1 9.0° 14.4°
2 22.5° 22.7°
22.5 °
Examining Volume Fraction from
Input Parameters
Evaluating Sample 2:
oz 10 in lb yd
6 2
6 ypi = wz 2 cos (22.5)
yd 11.8 lbs 16 oz 36 in
lbs 36 in 2 16 oz
Vf .064 .100 in ÷ = 71.26 oz
yd
3 2
in 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
Effect of Weave yarn ratio on
Fiber Volume Fraction
0.75
0.7
0.65
4 epi
6 epi
Fiber Volume Fraction
0.6
0.55
0.5
0.45
0.4
0.35
0.3
0.25
0 2 4 6 8 10 12 14
Weave Angle Ratio
Effect of Weave Yarn Ratio on
Weave Angle
70
60
Weave Angle (deg)
50
4 ppi
6 ppi
40
30
20
10
0 2 4 6 8 10 12 14
Weave Angle Ratio
Effect of Weave Angle on Distribution
Based on varying weave yarn ratio only
0.8
Percent longitudinal
0.7
Percent weaver
Percent fill
0.6
Distribution Ratio
0.5
0.4
0.3
0.2
0.1
0
0 5 10 15 20 25 30 35 40 45
Weave Angle (deg)
Effect of picks per inch on
Fiber Volume Fraction
0.45
0.4
Fiber Volume Fraction
0.35
0.3
0.25
0.2
0.15
0 2 4 6 8 10 12 14 16
Picks per inch
Effect of picks per inch on
Weave angle
45
40
35
30
Weave Angle (deg)
25
20
15
10
0
0 2 4 6 8 10 12 14 16
Picks per inch
Effect of Weave Angle on Distribution
Based on varying ppi only
0.8
Percent longitudinal
0.7
Percent weaver
Percent fill
0.6
Distribution Ratio
0.5
0.4
0.3
0.2
0.1
0
0 5 10 15 20 25 30 35 40 45
Weave Angle (deg)
Production of Complex
Shaped Weaves
Complex shape - complex, but uniform
section
Very complex shape - complex,
nonuniform section
Production of Complex
Shaped Weaves
Consider section as consisting of
rectangular pieces
Develop weave parameters for each
piece
Develop interconnection paths
Production of Very Complex
Shaped Weaves
Decompose part into rectangular and
shell sections
Consider impact of cutting yarns
Consider "folding" type operations
Ideal vs. Actual Geometry
Bad Control Parameters
Bad Control Parameters
Bad scan of image
Mistake in keying of "dots and spots"
Slipped card/chain at pick insertion
failure
Compression Induced Errors
RTM & Handling Induced
Errors