Development of 2D/3D Braiding

Techniques for Multi-axial Preforming

Dhaval Jetavat, Khayale Jan, Sree S Roy, B S Sugun
Academic PI: Prof Prasad Potluri
School of Materials
University of Manchester

Overview

Introduction
Textile preforming
Need for Multiaxial fibre preforming
2D Braiding
3D Braiding
Challenges
Development of Braiding/Winding

Textile Composites Group

Research at University of Manchester is focused on developing

manufacturing concepts for near-net preforms that require
minimum post-processing and at the same time incorporating
multi functional materials.

Research Objectives
Application of low cost automation and robotics in preform
manufacturing
To explore novel toughening concepts through hybrid preforms

To create novel multi-functional hybrids at tow-level and preform

level

Textile Composites Group

Area of Expertise:
Textile technology
3D Weaving, 3D/2D Braiding, Winding
Robotic Automation, Machine control
Composite manufacturing methods
Mechanical and Physical Testing

Equipment Expertise
3D Weaving, 2D Weaving, Braiding
Robotic machine (Tow placement, Winding machine, Tripod system for pick
and place)
Autoclave, RTM, Vacuum Bagging
Instron, ZwickRowell
C-scan, Thermography, DIC, SEM, CT scan

Near net shape preforming

Preforming trials for creating ply contours
Combination of Braiding/Weaving/RTP processes
Fibre placement on double curvature surface with RTP
Tufting process to add through thickness reinforcement

Preforming work under CimComp

NCF

Tufting

Pick and Place

3D woven fabric

3D woven T

Fibre Placement

Tufted 3D woven with

Textile Preforming Classification

Fibre Orientation
There are three levels of orientation
Random (quasi-isotropic
properties)
Cross-ply (transversely isotropic)
Unidirectional (orthotropic)

Effects of fibre orientations

Aligning fibres in direction of load

(i.e. producing unidirectional
composite) produces the highest
in-plane properties
Poor transverse or interlaminar properties
Can be improved by placing
fibres in transverse direction

Fabric Form
2D Woven

Stitched NCF

3D Woven

Braided

Design Challenges

Define fibre orientation

Fibre volume fraction in different directions
Optimise process to reduce wastage
Process capability to produce required structure
To achieve required mechanical performance
Effect of multiaxial fibre orientation on each other
- Nesting, mechanical properties

2D Braiding
Braiding is the process of diagonally interlacing three or more strands of yarn
in order to create continuous rope, tube or ribbon-like structures
Variety of tows can be combined in the axial and braid directions in order to
create hybrid materials
Non-interlaced core materials such as fibre tows, foam materials, metal
wires, fibre optics and smart actuating materials can be inserted into a braided
structure
Ability to form complex shapes is one of the key features of braiding
technology

2D Braiding

Tubular preforming using 2D braiding

Complex geometrical shapes can be overwrapped
Controlled fibre orientation between 10 to 80 & 0
Interlaced structures : 2/2, 1/1, 2/1

Biaxial & triaxial preforming in a

single layer
Multi-layer fibre continuity can be
maintained using reverse-braiding
technique

3D Braiding
3D braided textile preforms can be manufactured either by
conventional horngear braiding or by modifying conventional
braiding techniques
Other recognised methods are 2-step , 4-step row and column

Horngear Braiding machine

3D Solid Braiding
The 3D rotary system of braiding is
capable of fabricating net shape braided
preforms with better adaptability for
various configurations of yarn
interlacements.

3D Cartesian Braiding

Cartesian braiding machines

can braid preforms with
compact size, which are
more economical and
architecturally flexible
Preforming of thick and
complex shapes, near-net
shapes and delamination
resistant structures are the
distinguishing features of
Cartesian braiding

Herzog Braiding Machine

3D braiding machine based on horngear

mechanism with 32 carrier capacity has
been utilised
Required pattern or tow architecture
- Sequencing of bobbin paths by
defining movement paths
- Reinforcing using axial tows

Fibre path selection

Depending on part geometry
fibre path needs to be selected
This can be done with the track
arrangement
Path Isolation

Path Open

Axial yarn arrangement

Maximum of 25 axial yarns can be inserted
Creel has been set-up under braiding bed to insert axial yarns

Various profile structures

L braid : 24 carriers,17 stuffers

Double solid braid : 32 carriers, 25 stuffers

Solid braid : 16 carriers, 25 stuffers

T braid : 20 carriers, 16 stuffers

Intertwined X braid: 16 carriers, No stuffers

Solid X braid : 32 carriers, 12 stuffers

 3D solid braiding has been a successful step towards near-net and

complex shape preforming
Different material can be integrated in form of interlacing and
axial yarns
Relatively very small profile structures can be produced
Various braiding angles can be achieved by varying horngear and
take-up speed

Challenges
Key challenge is to achieve optimum fibre orientation in different
direction based on structure requirement
One method is to use manual or automated lay-up process.
However it is tedious and time consuming process
There are certain processes which can do multiaxial preforming,
but it lacks near net shape capabilities

How do we achieve near net shape

preforming with
multi axial Fibre preforming

Purpose built
technology

Process Integration
2D /3D
Braiding

2D /3D
Weaving

Fibre
placement

2D /3D
Winding

TuftingStitching

3D braiding through winding and z binders

A circular winding/braiding machine capable of producing tubular
structures
The machine allows axial yarns and binder yarns to be introduced
in the structure simultaneously whilst winding/braiding
Development of multi-layered structures along with multi-axial
capabilities

Machine design
An automated prototype machine
capable of producing variety of
wound architectures has been
developed.
Binding of multi-layer wound
structure during preforming
Winding, axial and binder yarns can
be introduced simultaneously
CoDeSys provided by FESTO is
used for configuration and
operation of the machine

Manufacturing process

Characterisation
Braid structure with Binder yarns

CT-scan Images

Braided structure
with axial yarn

Braid-Winding

Braid-winding for Quadriaxial Quasi-isotropic preforming(45/0/90)

Combines the benefits of interlaced and non-interlaced structure
Complementary processes so possible in-line manufacturing

Consolidated structure
development with
wrinkle minimization

3D weaving-3D Braiding- Tufting

NCF Skin Material
3D Woven T Section

3D Braided Noodle

5mm Tufting Pitch

10mm Tufting Pitch

Tufting of T section
to NCF material
at 45 near noodle region

Conclusion
Multiaxial fibres can be introduced in 2D/3D braiding and
winding
Exploration of various profiles on 3D solid braider

3D braid profiles can be utilised to reinforce local areas in

complex shape preforms
Development of novel textile preforming machine to
produce multiaxial preforms with through thickness binder
Various technologies can be combined to produce near net

shape preform to meet design and structure requirements