CE10 - Usine du futur : Homme, organisation, technologies

Prediction,reduction and study of damages impacting 3D weaving – PREDICTISS-3D

Prediction, reduction and study of damages impacting 3D weaving

Studying and reducing damaging yarn/yarn interactions during the high density weaving of sensitive materials

Producing 3D woven reinforcements faster, with higher quality

The main objective of this project consists in finding main product and process parameters and evaluating their influence on damages generation and therefore mechanical performances loss impacting woven preforms and corresponding composites.<br />Based on these analyses and for a given configuration, damages will be predicted and reduced thanks to weaving process parameters optimisation.<br />In addition to a better scientific comprehension of complexes yarn and fibre interactions, a major impact should be a transposition of these results at the industrial scale.

A multi-scale approach has to be followed because of the complexity of the woven materials (fibrous materials) and interaction phenomena. Experiments have been conducted at two different scales with: 1) a monitoring of the process (instrumented weaving machine) in parallel to: 2) an analysis of the friction generated in an isolated yarn/yarn or tow/tow system in order to determine tribological parameters.

Results after 18 months:
Measures gathered at the laboratory isolated yarn/yarn system scale, as well as in the loom monitoring system, have enable to point out the importance and the influence of the nature of yarn/yarn interactions (yarn configuration in the shed) and friction. Recent results highlight the impact of filaments permeation in a “two yarns in contact” system and the importance of yarn torsion on forces and damages at stake.

Short-term prospect:
The precise observation and understanding of interaction at the yarn and fibres scale is complex because of the fineness of that scale (few tens of micrometres) and the speed of yarn crossing. Our hypotheses about yarn interaction behaviour at yarn and fibre scales will be exposed to the results gathering by high speed monitoring of filaments during intercrossing.

Walther J, Bessette C, Decrette M, Toulonias M, Bueno M-A, Osselin J-F, Charleux F, Coupé D. Yarn Damage Conditions Due to the interactions During Interlock Weaving Process: In-situ and In-lab Experiments. ACMa, août 2021, 18 p.
Walther J, Bessette C, Decrette M, Toulonias M, Osselin J-F, Charleux F, Coupé D, Bueno M-A. Interactions between tows during interlock weaving process. 9th 3D fabrics conference, avril 2021.
Walther J, Tourlonias M, Decrette M, Krügl S, Bueno M-A. Experimental simulation of carbon and glass tows friction during weaving process. 20th AUTEX Conference, septembre 2021.

Composite materials are increasingly used in many industrial sectors and for complex and critical mechanisms (aircraft turbine blades). Textile structures and particularly multilayer 3D woven fabrics used as composite textile reinforcements have improved composites performances thanks to specific properties (possibility for yarns orientation in the structure, good resistance to inter-layer delamination, high properties/weight ratio). Nevertheless, the production of textile woven reinforcements induces damages to the material because of its sensitivity to friction and yarn density. The damages produced during the weaving process may cause productivity and mechanical properties losses compared to the initial yarn, which are still hardly predictable.
The aim of this project is to study in-situ interactions and the wear they cause according to the tribological and process scales, so that correlation between warp yarns involved, weave patterns, frictions, the damages they induce and final properties may be enlightened. These results will feed a software which will be able to produce upstream damages predictions and automatic weaving parameter adaptations. Industrial scale weaving trials will be realized in our partner R&D facilities for results validations.
In order to achieve these aims, the PREDICTISS-3D project is built around five major tasks:
- damages characterization thanks to specific measurement protocols and process monitoring with a set of measurement devices in order to discern the numerous events occurring during the process,
- processed yarns, preforms and composites characterisation for weaving pattern and mechanical properties correlation determination,
- fibres and yarns tribological behaviour experimental simulation for yarns movements and yarns frictions correlation determination,
- damages mechanisms modelling and mechanical performances prediction for critical cases discrimination and weaving parameters automatic adaptation before production,
- industrial scale validation of results.
Our combined textile process and textile tribology competences will bring an original approach for the optimization of the weaving process and composite reinforcements performances.
At scientific scale, results will tend to improve friction phenomena occurring during the 3D weaving process so that its productivity and preforms quality and performances may be improved. This project joins the “Factory of the Future” as it partakes in improving a promising production technology and employs data measurement and processing innovative technologies. The consequences should consolidate national industries rank in the high performances composites sector. Productivity and quality improvements should enlarge the use of such materials for both more critical applications and lower value-added application (such as automotive transports). Environmental and society issues will also be impacted as the project should also participate to pollutant and greenhouse gas emissions reductions.

Project coordination


The author of this summary is the project coordinator, who is responsible for the content of this summary. The ANR declines any responsibility as for its contents.


Safran Composites / Recherche et Développement

Help of the ANR 297,140 euros
Beginning and duration of the scientific project: - 48 Months

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