Advanced Textile Techniques for Composite Material Manufacturing

今天，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加载路径排列的超强微米或纳米纤维。这些纤维被嵌入到一种基质材料中，该材料将它们固定在适当的位置，并确保载荷传递。在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铺放方法或逐层手动或机器人沉积薄织物。这些方法是优选的，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一个瓶颈。因此，有必要发展纤维增强材料在复杂的制造操作中的行为及其对最终产品性能的影响的基本知识。我在这里提出了一个为期5年的研究计划，首先将表征不同材料和纤维混合物(无机、聚合物、生物来源)的纤维纱线的力学行为。我们将开发专门的测试设备，以模拟纺织操作和先进制造技术过程中施加在纱线上的负载。我将利用这些观察结果，使用多链数字元素方法对这种行为进行建模。该模型将使我们能够预测纱线和复杂的织物结构在纺织品组装和制造过程中的变形。我们将通过准确预测增强元件及其对力学性能的影响来生产复合材料结构。这项研究计划将加速将新型复合材料和制造技术整合到航空航天、交通运输和生物医疗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.