Textile composites 1

School of Mechanical, Materials &Manufacturing EngineeringUniversity of Nottingham,

University Park, Nottingham, UK

Modelling of textilesModelling of textilesand compositesand composites

Andrew Long

Andrew.Long@nottingham.ac.ukwww.textiles.nottingham.ac.uk

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 4

Modelling andModelling andAnalysisAnalysis

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 10

Textile ModellingTextile Modelling

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 YouAndrew.Long@nottingham.ac.ukwww.textiles.nottingham.ac.uk