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24th Month Meeting WP 3 presentation. Author Fazeli , Monireh (TUD). Agenda. Brief overview of WP3 Background Structure and progress update WP 3 highlights during M1-M24 Selected exploitation results WP 3 future planning. WP 3- Manufacturing process for 3D textile fabrics.

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agenda
Agenda
  • Brief overview of WP3
  • Background
  • Structure and progress update
  • WP 3 highlights during M1-M24
  • Selected exploitation results
  • WP 3 future planning
slide3

WP 3-Manufacturing process for 3D textile fabrics

Research partners

  • 06 University Gent (UGent)
  • 08 TechnischeUniversität Dresden (TUD)

Industrial partners

  • 10 Lindauer Dornier GmbH (Dornier)
  • 12 PD Glasseiden GmbH Oschatz (PD-Goschatz)
  • 13 NV Michel van de Wiele (VdW)

Work package objective

  • The research focus is on the production processes and the related manufacturing systems for the processing of 3D shaped as well as deep-drapeable woven fabrics made of hybrid yarns.
slide4

WP 3: Structure and progress update

Tasks:

  • Task 3.1: Manufacturing of hybrid yarnfinished
  • Task 3.2: Manufacturing of semi-finished preforms 20%

(a) weaving technology for multilayered fabrics

(b) weaving technology for 3D-shaped fabrics

(c) inline prefixation of semi-finished fabrics

Deliverables:

  • D3.8: adapted air-mingling machinecomplete
  • D3.9: two special adapted looms (deviation) in agreement with the coordinator, the new deadline is 31/01/2014
wp 3 highlights during m1 m24
WP 3 Highlights duringM1-M24

Milestone 6 Manufacturing of the hybrid yarn

Opening and mingling through

air jet!

Laboratory machine RMT-D

Commingled

hybrid yarn

Matrix filament

Reinforcement filament

slide6

WP 3 Highlights during M1-M24

Milestone 6 Manufacturing of the hybrid yarn

  • Trials of the hybrid yarn composition (preliminary trials with GF/PP) :
    • Testing different glass fibre yarn counts
    • Different fibre-matrix ratios
    • Different matrix materials (thermoplastics)
slide7

WP 3 Highlights during M1-M24

Milestone 6 Manufacturing of the hybrid yarn

Optimization of the hybrid yarn manufacturing:

  • Changing the machinery parameters
    • Yarn feeding speed
    • Process speed
    • Air pressure
    • Adjustment of the flyer (yarn tension)
  • Evaluation of an optimized hybrid yarn:
    • Optical: homogenous mixture,bulkiness, closure of the yarn (low bulkiness), fibredamages, Hairiness processability at weaving process
slide8

WP 3 Highlights during M1-M24

Milestone 6 Manufacturing of the hybrid yarn

Yarn architecture and yarn Count

Final specification of the hybrid yarn:

  • Mixture ratio of 70:30 % mass content (GF/PET)
  • Yarn count of 840 tex
wp 3 highlights during m1 m241
WP 3 Highlights during M1-M24

Milestone 8 provided multilayered fabrics

Providedmultilayeredfabricsby TUD

wp 3 highlights during m19 m24
WP 3 Highlights during M19-M24

Milestone 8 Multilayer, 3D-shaped weaving processes

Final fabric structure

  • Referring to the telcon on 12.10.2012
  • Multilayer fabric (NCFV)
  • Warp layers: 4
  • Weft layers: 5
  • Weft and warp yarn: GF/PET 840 tex
  • mixture ratio of 70:30 % mass content
  • Z-yarn: GF/PET 840 tex mixture ratio of 70:30 % mass content and PET 583 dtex
  • Weft density: 240 yarns /10cm
  • Warp density: 240 yarns /10cm
  • Z-yarns density: 24 yarns /10 cm (GF/PET) and 120 yarns/10 cm (PET)
  • Estimated thickness of composite: 2 mm
wp 3 highlights during m19 m241
WP 3 Highlights during M19-M24

Milestone 8 Multilayer, 3D-shaped weaving processes

Calculation of yarn amount after inquiry of partners

  • This information was sent to PD-Goschatz on 04.12.12 to start yarn production process.
  • TUD received the yarn material from PD-Goschatz on 07.02.13
wp 3 highlights during m19 m242
WP 3 Highlights during M19-M24

Milestone 8 Multilayer, 3D-shaped weaving processes

New Dornier loom specification

Type of the machine :Rapier weaving machine

Width of the fabric: 100 cm to Max150cm

Number of healdframes: max 20

Thickness of the fabric: Max 10mm

Speed : Max 405 rpm

4 Electronic warp let-offs

wp 3 highlights during m19 m243
WP 3 Highlights during M19-M24

Milestone 8 Multilayer, 3D-shaped weaving processes

Next steps to prepare production of multilayer fabric

  • Warping yarn material
  • Starting to weave on new Dornier loom
  • Estimated date of availability of fabric:
  • 31.04.2013
  • .
wp 3 highlights during m19 m24 vdw
WP 3 Highlights during M19-M24 (VDW)

Milestone 8 Multilayer, 3D-shaped weaving processes

  • Intense discussion with TU Dresden concerning the weave structure: VDW-NCFV-120:4-300:5
  • Weft and warp yarn : GF/PET 840 tex
  • Z-yarns: PET 583 dtex and GF/PET
  • For each plate: 5 weft and 4 warp layers
  • Density of the yarns :
    • For the plate section:
    • 300 weft/10cm/plate
    • 120 warp/10cm/plate
    • Thickness of the plate: approx. 2 mm
    • For the wall section:
    • 150 wefts/10cm/wall (foronewallwith 3 weftlayers)
    • 60 warps/10cm/wall(foronewall)
wp 3 highlights during m19 m24 vdw1
WP 3 Highlights during M19-M24 (VDW)

Milestone 8 Multilayer, 3D-shaped weaving processes

  • Project and background info transferred to involved engineers.
  • Choice of machine setup for chosen weave structure
    • = Choice of fabric and weave structure-related parts: weaving accessories
  • First choice of machine layout
  • Weaving procedure
  • Second choice of machine layout
wp 3 highlights during m19 m24 vdw2
WP 3 Highlights during M19-M24 (VDW)

Milestone 8 Multilayer, 3D-shaped weaving processes

  • 2. Choice of machine setup for the chosen weave structure
  • Choice of reed density: 300 dents/meter
  • Choice of yarns/beam
  • Width of fabric: 1500 mm
  • Tot. no. of yarns on GF/PET (840 tex) groundbeam: 1800 yarns
  • Tot . no. of yarns on GF/PET (840 tex) pilebeam: 1800 yarns
wp 3 highlights during m19 m24 vdw3
WP 3 Highlights during M19-M24 (VDW)

Milestone 8 Multilayer, 3D-shaped weaving processes

  • 3. First choice of machine layout
  • Choice of motion mechanism
  • controlled fabricmotion
  • B. Requiredtension on outer plate warp yarns
  • C. Yarn supply system for z and wall warp yarns
wp 3 highlights during m19 m24 vdw4
WP 3 Highlights during M19-M24 (VDW)

Milestone 8 Multilayer, 3D-shaped weaving processes

  • 4. Weaving procedure
  • Preparation for programming of PLC
  • Zone A : weaving of outer plates
  • Zone B : weaving of transition structure
  • Zone C and D: weaving of wall layers
  • Zone E: Weaving of transition structure
  • Zone A2 : weaving of outer plates
wp 3 highlights during m19 m24 vdw5
WP 3 Highlights during M19-M24 (VDW)

Milestone 8 Multilayer, 3D-shaped weaving processes

  • 5. Second choice of machine layout
  • Based on new weaving machine platform: increased functionality and immediately up to date.
  • Optimized lever system dimensioning and positioning
  • Drive system dimensioning and positioning
slide21

Exploitable Result : Manufacturing of hybrid yarn

  • As a result, hybrid yarn with glass fibre was developed and produced by PD-Goschatz with different fibre volume content and yarn count
  • GF/PET hybrid yarns with a mixture ratio of 70:30 mass content % (55:45 volume content %) and a yarn count of 840 tex was determined as the best yarn architecture
  • The results are important to achieve demonstrator requirements (WP1,WP 2 and WP 4)
  • TUD, VdW and Dornier will use the yarn to produce the 3D-shaped weaving and multilayer fabric
slide22

WP 3 Future planning

  • Weaving trials

a) Multilayered weaves and spacer fabric

b) Inline pre-fixation

  • Deliverable 3.9
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