Guideline for the Development of 3D-woven Profiles Produced on Conventional Narrow Weaving Machines. Benedikt Wendland

Transcription

1 Chapter 0 Acknowledgments Guideline for the Development of 3D-woven Profiles Produced on Conventional Narrow Weaving Machines Benedikt Wendland

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3 Guideline for the Development of 3D-woven Profiles Produced on Conventional Narrow Weaving Machines Von der Fakultät für Maschinenwesen der Rheinisch-Westfälischen Technischen Hochschule Aachen zur Erlangung des akademischen Grades eines Doktors der Ingenieurwissenschaften genehmigte Dissertation vorgelegt von Benedikt Patrick Kai Wendland Berichter: Univ.-Prof. Professor H. c. (RU) Dr.-Ing. Dipl.-Wirt.Ing. Thomas Gries Professor Andrew Long, BSc, MSc, PhD Tag der mündlichen Prüfung:

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5 Textiltechnik/Textile Technology herausgegeben von Univ. Prof. Professor h.c. (RU) Dr.-Ing. Dipl.-Wirt. Ing. Thomas Gries Benedikt Wendland Guideline for the Development of 3D-woven Profiles Produced on Conventional Narrow Weaving Machines Shaker Verlag Aachen 2015

6 Bibliographic information published by the Deutsche Nationalbibliothek The Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data are available in the Internet at Zugl.: D 82 (Diss. RWTH Aachen University, 2014) Copyright Shaker Verlag 2015 All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the publishers. Printed in Germany. ISBN ISSN Shaker Verlag GmbH P.O. BOX D Aachen Phone: 0049/2407/ Telefax: 0049/2407/ Internet: info@shaker.de

7 Chapter 0 Acknowledgments Preamble and acknowledgments: This phd-thesis was created during my employment as a researcher at the Institut für Textiltechnik (ITA) of RWTH Aachen University from 2010 until Parts of this phd-thesis consist of student project theses which were supervised by me. A list can be found following the literature. First of all I would like to thank my doctoral supervisor Univ.-Prof. Prof. h.c. Dr.-Ing. Dipl.- Wirt. Ing. Thomas Gries for the supervision at my time at ITA and for the revision of my thesis. I especially appreciate the atmosphere of trust, autonomy and responsibility I could experience during my work. I also would like to thank my second examiner Prof. Andrew Long from the University of Nottingham for his kind and reliable support during the revision and the fruitful cooperation in general. I would like to thank also the supervisor of my phd-exam Prof. Dr. rer. nat. Peter Loosen. Furthermore I would like to thank our librarian Christiane Cremer and my colleague Christopher Lenz for the additional revision of my thesis and Alexandra Jünger for the help with organizing the exam. I want to thank my many students for the support in form of their work and project theses, especially Bennet Preuß, Elisabeth Ens, David Wittrock, Marleen Strathoff and Fabienne Spreen; Jost Engels and Sebastian Hertle, Lorenz Wruck and Julian Kunze, Marius Meyer; Christian Gubka, Esra Teper and Fabienne Overkemping; Kilian Schönstein, Anita Mann, Mesut Cetin and Meike Kollmannthaler. I also appreciate thankfully the big support by the companies J.H. vom Baur Sohn GmbH & Co. KG, Wuppertal, Pascha Velvet bvba (Belgium) and Johnson Controls inc, Burscheid. As this thesis consists of results from the public funded projects Woven Omega (ZIM KF MF1) and Multirapier (Innonet 16INE037) I would like to thank the German Federal Ministry of Economy and Technology (BMWi) and the corresponding agencies for their funding. Last but not least I want to thank my family, friends and good colleagues for your support and understanding especially during the last months of my thesis. Benedikt Wendland

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9 Chapter 0 Table of contents Table of contents Introduction Motivation 1 Aims 1 Focus 3 Approach 3 2 State of the art: Production of 3D-woven composite profiles Definition of 3D textiles Multilayer fabrics Profile weaving Motivation for the use of 3D textiles 10 Reinforcement profiles in the lightweight industry Alternative manufacturing techniques for composite reinforcements Prepregs Radial braiding Pultrusion Resin transfer moulding (RTM) D-woven composites process technologies Definition and description of the weaving process Multirapier weaving Shuttle weaving Narrow needle weaving D weaving on special-purpose machines Weaving of 3D profiled fabrics with commingled hybrid yarns Weaving of carbon fibres Investigations and challenges Lee et al.: Investigation of the damage of two carbon fibre types at different locations of the weaving machine Knein-Linz and Machatschke: Investigation of weaving machine components Knein-Linz: Influence of the warp tension on filament damage 30

10 Table of contents Chapter Investigation of the warp yarn tension Summary of results and research gaps Calculation of the mechanical properties of three-dimensional fabrics and composites thereof Calculating the mechanical properties of 3D fabrics New approaches for the simulation of 3D fabrics Stig and Hallström Kim and Swan Iterative mesh refinement Ruijter Local adjustment of the mesh refinement Mahadik Digital element method Biragoni - Domain Superposition Technique Examination of the mechanical properties of 3D-fabric composites Baucom Impact behaviour of multilayer orthogonal fabrics Rudov-Clark and Mouritz Dynamic tensile strength as function of binder yarn content Carvelli et al. Cyclic tensile strength depending on the direction of strain Jin et al. Cyclic bending strength Ding und Jin Comparison with unidirectional laminate Bending strength of 3D-woven T-profiles Summary of the mechanical studies Applications of 3D-woven composites 49 3 Approach for developing single-step reinforcement profiles Objectives and requirements Analysis of the existent methods and identification of deficits Methods of product development VDI guideline Method Handbuch Faserverbundkunststoffe Cooper s stage-gate model DeMaCo Methods of process improvement FMEA 55

11 Chapter 0 Table of contents step method according to Rosiepen Guiding questions according to Rosiepen Factorial design of experiment Methods of production planning VDI guideline Methods of RWTH Aachen University Product lifecycle and technology management according to Reinhard Integrative product and process development according to Gausemeier Integrated product development model (ipem) according to Albers Methods for economically and technically rating Utility value analysis Quality function deployment Summary of the presented methods Evaluation of the presented methods Development of a 3-aspects method-guideline Requirement definition Pre-selection of processes Design of the product concept Detailed product design Detailed process design Production planning Recommended methods for rating 77 4 Product design: New FEM-calculation method based on beamelements State of the art: Calculation of mechanical fabric and composite properties Motivation Geometry creation with TexGen Meshing and export function of TexGen Deficits of the FEM calculation with TexGen and Abaqus 83

12 Table of contents Chapter New FEM approach with beam elements and its mathematical foundations Meshing of the yarn centre line Modelling of the friction Benefits and deficits of the presented calculation method 92 5 Product design: Testing of 3D-woven components Calculation of the external load distribution, profile parallel forces and bending moments 98 Normal and bending stress 100 Shear stress 102 Normal stress in the flank Stress vectors of the different component sections Upper belt Flanks Lower belt Stiffness matrix of the laminate 106 Buckling Measurement of the local direction-dependent strain Test setup for optical strain measurement Exemplary measurement Strain in x-direction Strain in z'-direction Shear strain Summary and recommendation concerning a verification by means of an optical strain measurement Process design: Parametric weaving study Step 1: Test of parameter significance with a factorial design plan and guiding questions Which processes or components have to be improved? Which measurement category defines the improvement of the product? Which tribological measurement category is used? 123

13 Chapter 0 Table of contents Which variable parameters are analysed? Warp tension Weft yarn tension measurement Use of water Weaving speed Edge yarns Distinguishing warp and weft influence Which influencing factors are variable, which are fixed? Creel Back rest Heddle frames and reed Weft insertion Weft yarn tension compensation Weft yarn restraint How can the results be integrated into existent models? Machine setup Factorial design plan Evaluation of the factorial design plan Evaluation: Influence on filament damage Influence of the filament breaking rate on laminate properties Significance of warp tension Significance of weaving speed Significance of water usage Step 2: Detailed test of the relevant parameter(s) with more interim values in a field trial Determination of the warp tension course over the machine angle Detailed study on the influence of warp tension Recommendations and outlook Production planning Composition of the cost structure 159 Relevant economic parameters Calculation principles Machine hourly rate 162

14 Table of contents Chapter Productivity Depreciation and capital costs Machine energy costs Area costs Maintenance costs Manufacturing labour costs Structure of the software tool DirectPreform Tab Basic Data Eco-Preform : Determination of multi-step preform costs EcoPreformPlus : Foam core integration and impregnation Structure Benchmark: Omega profile reinforced pressure bulkhead Assumption of the benchmark example Cost calculation of the benchmark prepreg stringer with EcoPreformPlus Cost calculation of the entire bulkhead preform with EcoPreform Cost calculation of the example in EcoPreformPlus Cost calculation with 3D-fabric technology Calculation of fabric production costs Cost calculation of 3D-fabric preforming and impregnation Results and summary of the exemplary calculation Importance of technical and economical evaluation Transfer of 3D weaving technology into the market 184 Transfer of this thesis results into industry and their economical usage Summary and outlook Abbreviations Literature Attachments 212