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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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24th month meeting wp 3 presentation

www.3D-LightTrans.com

24th Month Meeting WP 3 presentation

Author

Fazeli, Monireh (TUD)


Agenda
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

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.


  • 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


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)


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


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



  • 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


  • Weaving trials

    a) Multilayered weaves and spacer fabric

    b) Inline pre-fixation

  • Deliverable 3.9


Thank you for your attention

Questions?

Thankyouforyourattention!


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