Advanced Textile Techniques for Composite Material Manufacturing

如今，飞机结构使用的复合材料占其总重量的50%。复合材料的强度来源于沿宏观载荷路径排列的超强微或纳米纤维。这些纤维被嵌入在一种基质材料中，这种基质材料使它们固定在原位，并确保载荷转移。在为一家飞机制造商工作期间，我观察到制造高性能复合材料结构的主要方法是使用机器人单向纤维放置方法或逐层手工或机器人沉积薄织物。这些方法是首选的，因为在随后的制造操作中纤维的移动是有限的。缺乏关于纤维运动的精确知识是阻碍采用新材料的新制造方法的瓶颈。因此，当纤维增强材料受到复杂的制造操作及其对最终产品性能的影响时，有必要发展其行为的基本知识。我在这里提出了一个为期5年的研究计划，将首先表征不同材料和纤维混合物（无机，聚合物，生物源）的纤维纱线的机械性能。我们将开发特定的测试设备，以模拟纺织操作和先进制造技术中施加在纱线上的载荷。我将使用这些观察结果来使用多链数字元素方法来模拟这种行为。该模型将使我们能够预测纺织装配和制造过程中纱线和复杂织物结构的变形。我们将生产具有精确预测增强元素及其对力学性能影响的复合结构。该研究项目将加速将新型复合材料和制造技术整合到航空航天、交通运输和生物医学等高度监管的行业中。

Today, aircraft structures are built using composite materials that represent up to 50% of their total weight. Composite materials derive their strength from aligning ultra-strong micro- or nano-fibers along the macro-scale load paths. These fibres are embedded in a matrix material that holds them in position and insures load transfer. While working for an aircraft manufacturer, I observed that the main approaches for manufacturing high performance composite structures is the use of robotic unidirectional fibre placement methods or layer-by-layer manual or robotic deposition of thin fabrics. These methods are preferred because the movement of fibres in subsequent manufacturing operations is limited. The lack of precise knowledge about the movement of fibres is a bottleneck that prevents the introduction of new manufacturing methods using novel materials. Consequently, there is a need for developing fundamental knowledge of the behaviour of fibre reinforcements when they are subjected to complex manufacturing operations and their effect on the final product’s properties. I propose here a 5-year research program that will first characterize the mechanical behaviour of fibre yarns of different materials and fibrous mixtures (inorganic, polymers, biosourced). We will develop specific testing apparatus to mimic the loads applied to yarns during textile operations and advanced manufacturing techniques. I will use these observations to model this behaviour using the multi-chain digital element approach. The modelling will allow us to predict the deformation of yarns and complex fabric structures during textile assembly and manufacturing. We will produce composite structures with accurate prediction of the reinforcing elements and their impact on mechanical properties. This research program will accelerate the integration of new composite materials and manufacturing techniques into highly regulated industries such as the aerospace, transport, and bio-medical.