Draping Behavior of Carbon Non-Crimp Fabrics and Its Effects on Mechanical Performance of the Hemispherical Composites

In order to investigate the draping behavior of non-crimp fabrics（NCFs）, two types of carbon NCFs with tricot-chain stitches or chain stitches were formed on a hemispherical mould via a stretch forming process. The shear angle and forming defects of the fabrics were measured on the hemisphere, under different blank holder forces（BHFs）. The results showed that increasing BHF could enhance the shear angle slightly, reduce the asymmetry for the deformation of the fabrics, and change the main type of the process-induced defects. Besides, compression tests were performed on the corresponding composite components. By analyzing the change of fiber volume fraction and structural parameters of the textile reinforcements, the effects of draping behavior of NCFs on the mechanical performance of the composites were studied. The results reveal that draping process has distinguishable impacts on the mechanical properties of the final components, which is closely related to the stitching pattern of the NCFs.

Coating process of multi-material composite sand mold 3D printing

Sand mold 3 D printing technology is an advanced manufacturing technology which has great flexible manufacturing ability. A multi-material composite sand mold can control the temperature field of metallic parts during the pouring process, while the current sand mold 3 D printing technology can only fabricate a single material sand mold. The casting temperature field can not be adjusted by using single sand mold material with isotropous heat exchange ability during the pouring process. In this work, a kind of novel coating device was designed. Multi-material composite sand molds could be manufactured using the coating device according to the casting process demands of the final parts. The influences of curing agent content, coating velocity and scraper shape on compactness and surface roughness of the sand layer(silica sand and zircon sand) were studied. The shapes and sizes of transition intervals of two kinds of sand granules were also tested. The results show that, with the increase of the added volume of curing agent, the compactness of sand layer reduces and the surface roughness value rises. With the increase of the velocity of the coating device, the compactness of sand layer reduces and the surface roughness value rises similarly. In addition, the scraper with a dip angle of 72 degrees could increase the compactness value of the sand layer. The criteria of quality parmeters of the coating procedure are obtained. That is, the surface roughness(δ) of sand layer should be equal to or lesser than half of main size of the sand particles(Dm). The parameter H of the coating device which is the distance between the base of hopper and the surface of sand layer impacts the size of transition zone. The width of the transition zone is in direct proportion to the parameter H, qualitatively. Through the optimization of the coating device, high quality of multi-material sand layers can be obtained. This will provide a solution in manufacturing the multi-material composite sand mold.

Design of Composite Dies for Motor Punching

This paper aims to design punching die of the stator and rotor. By analyzing and comparing, we determine the better processing program. Not only to ensure the precision and dimensional requirements, but also to improve efficiency. Through detailed analysis of the process, this paper determines the structure of two composite molds. The dimensions of its convex and concave die edge size and other parts are calculated and checked. Finally this paper completes the design of two molds.

Experimental Characterization by Fluorescence of Capillary Flows in the Fiber Tows of Engineering Fabrics

Liquid Composite Molding (LCM) is an increasingly used class of processes to manufacture high performance composites. In LCM, the fibrous reinforcement is first laid in a mold cavity. After closure of the mold or covering of reinforcement with a plastic bag, a polymer resin is either injected or infused under vacuum through the fiber bed. The engineering fabrics commonly used in LCM possess generally dual scale architecture in terms of porosity: microscopic pores exist between the filaments in the fiber tows, while macroscopic pores appear between the tows as a result of the stitching/weaving fabrication process. On a microscopic scale, capillary flows in fiber tows play a major role on the quality of composites made by resin injection through fibrous reinforcements. In order to better understand the mechanisms that govern the impregnation of fibrous reinforcements in LCM, a study of wicking behavior is carried out in fiber tows. The experimental approach is based on capillary rise experiments, which are less expensive and time-consuming than other more standard characterization techniques often used in porous media. In addition, it allows gathering representative data on the wicking properties of fiber tows as a function of their morphological characteristics such as micro-porosity, total cross-section area, specific surface area, filament diameter and packing configuration. The morphological properties of the fiber tows will also be characterized by other standard experimental methods in order to compare with the results obtained by capillary rise experiments. These standard methods include gravimetry for the micro-porosity and fiber mass density, microscopic analysis to measure the filament diameter, cross-section area and packing configuration of the filaments and capillary flow porometry to evaluate the equivalent pore diameter. The capillary rise method has already been used not only in Soil Mechanics, but also to characterize engineering textiles used in high performance composites. Such experiments are not easy to perform, because of technical difficulties such as textile geometrical alteration during testing, changes in fluid properties due to solvent evaporation and inaccurate observation of the progression of the capillary front (fading). To circumvent these problems, a monitoring technique based on fluorescent dye penetration inspection (DPI) and CCD image acquisition is proposed in this investigation. Visual monitoring of the capillary front is coupled with real-time fluid mass acquisition using a high resolution balance. Experimental observations on the height of the capillary front and the fluid mass absorbed by the fiber tows can be analyzed by four imbibition models. These models consider the evolution of the capillary height with (model I) or without gravity (model II) and of the fluid mass absorbed by capillary effect with (model III) or without gravity (model IV). The models without gravity will be used on short imbibition distances to derive the microscopic properties of fiber tows from the experimentally observed evolutions of the capillary height and the fluid mass absorbed by capillarity. After describing the new capillary rise setup devised for the fiber tow experiments, a set of experiments is carried out to characterize the properties of the fiber tows and investigate the wicking phenomena along the warp and weft directions. The consistency of this approach is compared with more standard methods. At the same time, the impact of fiber sizing on the tow wicking behavior is investigated. Note that experimental evaluations of tow permeability can also be derived from this approach. The results compare well with permeability predictions based on Blake-Kozeny-Carman models. In the future, it will be possible to apply the same experimental approach to engineering fabrics. Indeed, a comprehensive wicking characterization of fibrous reinforcements is expected to provide useful information in order to evaluate the optimal processing conditions of high performance composites fabricated by Liquid Composite Molding.

A review of numerical analyses and experimental characterization methods for forming of textile reinforcements

The forming of textile reinforcements is an important stage in the manufacturing of textile composite parts with Liquid Composite Molding process.Fiber orientations and part geometry obtained from this stage have significant impact on the subsequent resin injection and final mechanical properties of composite part.Numerical simulation of textile reinforcement forming is in strong demand as it can greatly reduce the time and cost in the determination of the optimized processing parameters,which is the foundation of the low-cost application of composite materials.This review presents the state of the art of forming modeling methods for textile reinforcement and the corresponding experimental characterization methods developed in this field.The microscopic,mesoscopic and macroscopic models are discussed.Studies concerning the simulation of wrinkling are also presented since it is the most common defect occurred in the textile reinforcement forming.Finally,challenges and recommendations on the future research directions for textile reinforcement modeling and experimental characterization are provided.