3-D textile reinforcements in composite materials Edited by Professor Antonio Miravete University of Zaragoza,Spain CRC CRC Press Boca Raton Boston New York Washington,DC WOODHEAD PUBLISHING LIMITED Cambridge England
3-D textile reinforcements in composite materials Edited by Professor Antonio Miravete University of Zaragoza, Spain Cambridge England RICPR 7/10/99 7:08 PM Page iii
Published by Woodhead Publishing Limited,Abington Hall,Abington Cambridge CB1 6AH,England Published in North and South America by CRC Press LLC,2000 Corporate Blvd,NW.Boca Raton FL 33431,USA First published 1999,Woodhead Publishing Ltd and CRC Press LLC ©1999，Woodhead Publishing Ltd The authors have asserted their moral rights. This book contains information obtained from authentic and highly regarded sources.Reprinted material is quoted with permission,and sources are indicated. Reasonable efforts have been made to publish reliable data and information,but the authors and the publishers cannot assume responsibility for the validity of all materials.Neither the authors nor the publishers,nor anyone else associated with this publication,shall be liable for any loss,damage or liability directly or indirectly caused or alleged to be caused by this book. Neither this book nor any part may be reproduced or transmitted in any form or by any means,electronic or mechanical,including photocopying,microfilming and recording,or by any information storage or retrieval system.without permission in writing from the publishers. The consent of Woodhead Publishing and CRC Press does not extend to copying for general distribution,for promotion,for creating new works,or for resale.Specific permission must be obtained in writing from Woodhead Publishing or CRC Press for such copying. Trademark notice:Product or corporate names may be trademarks or registered trademarks,and are used only for identification and explanation,without intent to infringe. British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. Library of Congress Cataloging in Publication Data A catalog record for this book is available from the Library of Congress. Woodhead Publishing ISBN 1 85573 376 5 CRC Press ISBN 0-8493-1795-9 CRC Press order number:WP1795 Cover design by The ColourStudio Typeset by Best-set Typesetter Ltd.,Hong Kong Printed by TJ International,Cornwall,England
Published by Woodhead Publishing Limited, Abington Hall, Abington Cambridge CB1 6AH, England Published in North and South America by CRC Press LLC, 2000 Corporate Blvd, NW, Boca Raton FL 33431, USA First published 1999, Woodhead Publishing Ltd and CRC Press LLC © 1999, Woodhead Publishing Ltd The authors have asserted their moral rights. This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. Reasonable efforts have been made to publish reliable data and information, but the authors and the publishers cannot assume responsibility for the validity of all materials. Neither the authors nor the publishers, nor anyone else associated with this publication, shall be liable for any loss, damage or liability directly or indirectly caused or alleged to be caused by this book. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming and recording, or by any information storage or retrieval system, without permission in writing from the publishers. The consent of Woodhead Publishing and CRC Press does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specific permission must be obtained in writing from Woodhead Publishing or CRC Press for such copying. Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe. British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. Library of Congress Cataloging in Publication Data A catalog record for this book is available from the Library of Congress. Woodhead Publishing ISBN 1 85573 376 5 CRC Press ISBN 0-8493-1795-9 CRC Press order number: WP1795 Cover design by The ColourStudio Typeset by Best-set Typesetter Ltd., Hong Kong Printed by TJ International, Cornwall, England RICPR 7/10/99 7:08 PM Page iv
Contents Preface iⅸ List of contributors xi进 Introduction:Why are 3-D textile technologies applied to composite materials? 1 A.Miravete Manufacturing costs 1 The problem in the thickness direction 2 Examples of application 6 Conclusions 8 1 3-D textile reinforcements in composite materials 9 F.K.Ko 1.1 Introduction 9 1.2 Classification of textile preforms 11 1.3 Structural geometry of 3-D textiles 14 1.4 Tailoring fiber architecture for strong and tough composites 21 1.5 Modeling of 3-D textile composites 24 1.6 Application of the FGM 30 1.7 Conclusions and future directions 37 1.8 References 40 2 3-D textile reinforced composites for the transportation industry 43 K.Drechsler 2.1 Introduction 43 2.2 The mechanical performance of conventional and 3-D reinforced composites 44 2.3 Manufacturing textile structural composites 49
Contents Preface ix List of contributors xiii Introduction: Why are 3-D textile technologies applied to composite materials? 1 A. Miravete Manufacturing costs 1 The problem in the thickness direction 2 Examples of application 6 Conclusions 8 1 3-D textile reinforcements in composite materials 9 F.K. Ko 1.1 Introduction 9 1.2 Classification of textile preforms 11 1.3 Structural geometry of 3-D textiles 14 1.4 Tailoring fiber architecture for strong and tough composites 21 1.5 Modeling of 3-D textile composites 24 1.6 Application of the FGM 30 1.7 Conclusions and future directions 37 1.8 References 40 2 3-D textile reinforced composites for the transportation industry 43 K. Drechsler 2.1 Introduction 43 2.2 The mechanical performance of conventional and 3-D reinforced composites 44 2.3 Manufacturing textile structural composites 49 v RICPR 7/10/99 7:08 PM Page v
i Contents 2.4 3-D composites in aerospace structures 56 2.5 Textile structural composites in automotive structures 58 2.6 Conclusions 6 2.7 References 65 3 Mechanical modelling of solid woven fabric composites 67 P.Vandeurzen,J.Ivens and I.Verpoest 3.1 Introduction 67 3.2 Review on solid woven fabric composites 67 3.3 Elastic model:the complementary energy model 78 3.4 Strength model 88 3.5 Conclusions 95 3.6 Acknowledgements 97 3.7 References 97 4 Macromechanical analysis of 3-D textile reinforced composites 100 A.Miravete,R.Clemente and L.Castejon 4.1 Introduction 100 4.2 Determination of the stiffness and strength properties of 3-D textile reinforced composite materials 101 4.3 Determination of the stiffness and strength properties of braided composite materials 116 4.4 Determination of the stiffness and strength properties of knitted composite materials 124 4.5 Application of macromechanical analysis to the design of a warp knitted fabric sandwich structure for energy absorption applications 128 4.6 Application of macromechanical analysis to the design of an energy absorber type 3P bending 134 4.7 Conclusions 145 4.8 References 146 Manufacture and design of composite grids 151 S.W.Tsai,K.S.Liu and P.M.Manne 5.1 Introduction 151 5.2 Grid description 152 5.3 Manufacturing processes 155 5.4 Mechanical properties of grids 159 5.5 Failure envelopes of grids 164 5.6 Grids with skins 172
2.4 3-D composites in aerospace structures 56 2.5 Textile structural composites in automotive structures 58 2.6 Conclusions 63 2.7 References 65 3 Mechanical modelling of solid woven fabric composites 67 P. Vandeurzen, J. Ivens and I. Verpoest 3.1 Introduction 67 3.2 Review on solid woven fabric composites 67 3.3 Elastic model: the complementary energy model 78 3.4 Strength model 88 3.5 Conclusions 95 3.6 Acknowledgements 97 3.7 References 97 4 Macromechanical analysis of 3-D textile reinforced composites 100 A. Miravete, R. Clemente and L. Castejon 4.1 Introduction 100 4.2 Determination of the stiffness and strength properties of 3-D textile reinforced composite materials 101 4.3 Determination of the stiffness and strength properties of braided composite materials 116 4.4 Determination of the stiffness and strength properties of knitted composite materials 124 4.5 Application of macromechanical analysis to the design of a warp knitted fabric sandwich structure for energy absorption applications 128 4.6 Application of macromechanical analysis to the design of an energy absorber type 3P bending 134 4.7 Conclusions 145 4.8 References 146 5 Manufacture and design of composite grids 151 S.W. Tsai, K.S. Liu and P.M. Manne 5.1 Introduction 151 5.2 Grid description 152 5.3 Manufacturing processes 155 5.4 Mechanical properties of grids 159 5.5 Failure envelopes of grids 164 5.6 Grids with skins 172 vi Contents RICPR 7/10/99 7:08 PM Page vi
Contents Vii 5.7 Flexural rigidity of isogrids 175 5.8 Coefficients of thermal expansion 177 5.9 Conclusions 179 5.10 Acknowledgements 179 5.11 References 179 6 Knitted fabric composites 180 H.Hamada,S.Ramakrishna and Z.M.Huang 6.1 Introduction 180 6.2 Description of knitted fabric 184 6.3 Tensile behavior of knitted fabric composites 184 6.4 Analysis of 3-D elastic properties 188 6.5 Analysis of tensile strength properties 205 6.6 Conclusions 214 6.7 References 215 7 Braided structures 217 T.D.Kostar and T.W.Chou 7.1 Introduction 217 7.2 2-D braiding 219 7.3 3-D braiding 220 7.4 Summary 237 7.5 References 238 8 3-D forming of continuous fibre reinforcements for composites 241 O.K.Bergsma,F.van Keulen,A.Beukers,H.de Boer and A.A.Polynkine 8.1 Introduction 241 8.2 Forming of continuous fibre reinforced polymers 251 8.3 Simulation of the forming process 256 8.4 Finite element simulation 265 8.5 Optimization of CFRTP products 275 8.6 Conclusions 280 8.7 References 281 9 Resin impregnation and prediction of fabric properties 285 B.J.Hill and R.Mcllhagger 9.1 Introduction 285 9.2 Hand impregnation 288 9.3 Matched-die moulding 289
5.7 Flexural rigidity of isogrids 175 5.8 Coefficients of thermal expansion 177 5.9 Conclusions 179 5.10 Acknowledgements 179 5.11 References 179 6 Knitted fabric composites 180 H. Hamada, S. Ramakrishna and Z.M. Huang 6.1 Introduction 180 6.2 Description of knitted fabric 184 6.3 Tensile behavior of knitted fabric composites 184 6.4 Analysis of 3-D elastic properties 188 6.5 Analysis of tensile strength properties 205 6.6 Conclusions 214 6.7 References 215 7 Braided structures 217 T.D. Kostar and T.W. Chou 7.1 Introduction 217 7.2 2-D braiding 219 7.3 3-D braiding 220 7.4 Summary 237 7.5 References 238 8 3-D forming of continuous fibre reinforcements for composites 241 O.K. Bergsma, F. van Keulen, A. Beukers, H. de Boer and A.A. Polynkine 8.1 Introduction 241 8.2 Forming of continuous fibre reinforced polymers 251 8.3 Simulation of the forming process 256 8.4 Finite element simulation 265 8.5 Optimization of CFRTP products 275 8.6 Conclusions 280 8.7 References 281 9 Resin impregnation and prediction of fabric properties 285 B.J. Hill and R. McIlhagger 9.1 Introduction 285 9.2 Hand impregnation 288 9.3 Matched-die moulding 289 Contents vii RICPR 7/10/99 7:08 PM Page vii