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

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.

The analysis of yarn/yarn friction by direct measurement on a laboratory bench and indirect measurement, via yarn tension, on a weaving loom, made it possible to highlight the predominance of interfilament interactions during movements controlled by the weaving machine according to their friction behavior (static, dynamic, yarn positioning configuration) on the health of the fabric produced. More precisely, the measurements on a laboratory bench generating unit yarn-to-yarn friction required the development of a unique bench in the world simulating the kinematics and tensions of weaving. These tests highlighted the impact of the interweaving of the filaments of two yarns in contact and the twisting of the yarns on the forces involved and on damage. At the process scale, the characterization of the weaving process was obtained: 1) By measuring the tension of study yarns via tensiometers located at various positions of the yarn or its control elements. 2) Monitoring the position of the yarn by high-speed camera. The new paradigm replacing the definition of a fabric weave in terms of yarn/yarn crossing type, coupled with spectral analysis of the tension (reflecting the degradation) and monitoring of the position of the yarns has made it possible to highlight that, for the same number of yarns in motion, the predominant parameter is the number of interactions between yarns during the crossing characterized by the number of yarns in motion and the type of movement.

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.; Tourlonias, M.; Decrette, M.; Bueno, M.-A. Influence of multifilament yarn twist on yarn-to-yarn friction behavior: Application to carbon fiber weaving. Compos Part A: App Sci and Manuf. 2023, 174, 245-262.

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. In Proceedings of the 9th 3D Fabrics Conference, April 2021.

Walther, J.; Tourlonias, M.; Decrette, M.; Krügl, S.; Bueno, M-A. Experimental simulation of carbon and glass tows friction during weaving process. In Proceedings of the 20th AUTEX Conference, September 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.