Skip to main content

Advertisement

SpringerLink
Log in

Investigation of the formability behaviour during stamping of tufted and un-tufted carbon preforms: towards localized reinforcement technologies

  • Original Research
  • Published:
International Journal of Material Forming Aims and scope Submit manuscript

Abstract

The originality of this work consists in the study of the stamping behaviour of tufted and un-tufted carbon preforms. Several preforms by varying the tufting thread orientations (0°, 90° and 0°/90°) and with different stratifications ([0°/90°,-45°/+45°] and [0°/90°,-45°/+45°]2) were manufactured in order to study their out-of-plane deformability. The stamping test was carried out using a hemispherical punch and conducted at two blank-holder pressures (0.05 and 0.2 MPa). The experimental data highlight the influence of tufting threads on the forming force, maximum material draw-in, shear angle mapping and wrinkling phenomenon during the forming process. Furthermore, the orientations of tufting thread, the number of layers and the pressure of the blank-holder significantly affected the forming behaviour: all tufted preforms present a higher forming force, lower maximum material draw-in and shear angles and notable structural defects than the un-tufted preform. The increase in the pressure of the blank-holder from 0.05 to 0.2 MPa increases all these characteristics and emphasizes the structural defects on the fibrous reinforcements. Similarly, the transition from two layers to four layers in lamination at the same blank-holder pressure is followed by an increase of the forming force required for stamping operation, reducing the material draw-in and the shear angles especially those measured at the transient zone, and causes more structural defects on all stamped tufted and un-tufted preforms. For all these reasons, two localized tufting configurations, Right Localized Tufted (RLT) and Inclined Localized Tufted (ILT), at the stamping transition area are proposed. The stamping results show that these two original configurations present a minimum punch force and a maximum material draw-in similar to those measured on the un-tufted structure. The shear angles are higher than those recorded on the conventionally tufted preforms (over the entire surface).

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14

Similar content being viewed by others

Data availability

The raw/processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.

References

  1. (2019) The Global Market for Carbon fibers to 2025, Report ID n° 4721797, edited by Research and Markets, January 2019, no. January, pp 4721797

  2. Falzon BG, Hawkins SC, Huynh CP, Radjef R, Brown C (2013) An investigation of mode I and mode II fracture toughness enhancement using aligned carbon nanotubes forests at the crack interface. Compos Struct 106:65–73. https://doi.org/10.1016/j.compstruct.2013.05.051

    Article  Google Scholar 

  3. Gnaba I, Legrand X, Wang P, Soulat D (2018) Through-the-thickness reinforcement for composite structures : a review, pp 1–26. https://doi.org/10.1177/1528083718772299

  4. Gnaba I, Wang P, Legrand X, Soulat D (2019) Manufacturing and characterization of tufted preform with complex shape. Adv Aircr Spacecr Sci Int J 6(2):105–116. https://doi.org/10.12989/aas.2019.6.2.105

  5. Mouritz AP, Bannister MK, Falzon PJ, Leong KH (1999) Review of applications for advanced three-dimensional fibre textile composites. Compos Part A Appl Sci Manuf. https://doi.org/10.1016/S1359-835X(99)00034-2

  6. Dell’Anno G, Treiber JWG, Partridge IK (2016) Manufacturing of composite parts reinforced through-thickness by tufting. Robot Comput Integr Manuf. https://doi.org/10.1016/j.rcim.2015.04.004

  7. Dell’Anno G et al (2012) Automated manufacture of 3d reinforced aerospace composite structures. Int J Struc Intg 3(1):22–40

  8. Clegg HM, Dell’Anno G, Scott M, Partridge IK (2019) Suppressing delamination in composite intersections with tufting and Z-pinning. Twenty-second International Conference on Composite Materials (ICCM22), Melbourne Australia

  9. Scott M, Anno GD, Clegg H (2018) Effect of process parameters on the geometry of composite parts reinforced by through-the-thickness tufting. Appl Compos Mater 25(4). https://doi.org/10.1007/s10443-018-9710-4

  10. Sozer EM, Simacek P, Advani SG (2012) 9 - Resin transfer molding (RTM) in polymer matrix composites. In: Advani SG, K.-T. B. T.-M. T. for P. M. C. (PMCs) Hsiao (eds) Woodhead publishing series in composites science and engineering. Woodhead Publishing, pp 245–309

  11. Boisse P, Colmars J, Hamila N, Naouar N, Steer Q (2018) Bending and wrinkling of composite fiber preforms and prepregs. A review and new developments in the draping simulations. Compos Part B Eng 141(November 2017):234–249. https://doi.org/10.1016/j.compositesb.2017.12.061

  12. Liu LS, Zhang T, Wang P, Legrand X, Soulat D (2015) Influence of the tufting yarns on formability of tufted 3-dimensional composite reinforcement. Compos Part A Appl Sci Manuf. https://doi.org/10.1016/j.compositesa.2015.07.014

  13. Shen H, Wang P, Legrand X, Liu L, Soulat D (2019) Influence of the tufting pattern on the formability of tufted multi-layered preforms. Compos Struct 228(August):111356. https://doi.org/10.1016/j.compstruct.2019.111356

  14. Blais M, Moulin N, Liotier P-J, Drapier S (2017) Resin infusion-based processes simulation : coupled stokes-Darcy flows in orthotropic preforms undergoing finite strain. Int J Mater Form 10(1):43–54. https://doi.org/10.1007/s12289-015-1259-2

  15. Park CH, Lebel A, Saouab A, Bréard J, Il Lee W (2011) Modeling and simulation of voids and saturation in liquid composite molding processes. Compos Part A Appl Sci Manuf 42(6):658–668. https://doi.org/10.1016/j.compositesa.2011.02.005

  16. Labanieh AR, Garnier C, Ouagne P, Dalverny O, Soulat D (2018) Intra-ply yarn sliding defect in hemisphere preforming of a woven preform. Compos Part A Appl Sci Manuf 107(October 2017):432–446. https://doi.org/10.1016/j.compositesa.2018.01.018

    Article  Google Scholar 

  17. Abtew MA, Boussu F, Bruniaux P, Loghin C, Cristian I, Chen Y, Wang L (2018) Forming characteristics and surface damages of stitched multi-layered para-aramid fabrics with various stitching parameters for soft body armour design. Compos Part A Appl Sci Manuf 109:517–537. https://doi.org/10.1016/j.compositesa.2018.02.037

  18. Allaoui S, Cellard C, Hivet G (2015) Effect of inter-ply sliding on the quality of multilayer interlock dry fabric preforms. Compos Part A Appl Sci Manuf 68:336–345. https://doi.org/10.1016/j.compositesa.2014.10.017

    Article  Google Scholar 

  19. Allaoui S, Hivet G, Soulat D, Wendling A, Ouagne P, Chatel S (2014) Experimental preforming of highly double curved shapes with a case corner using an interlock reinforcement. Int J Mater Form 7(2):155–165. https://doi.org/10.1007/s12289-012-1116-5

  20. Zhu B, Yu TX, Zhang H, Tao XM (2011) Experimental investigation of formability of commingled woven composite preform in stamping operation. Compos. Part B Eng. 42(2):289–295. https://doi.org/10.1016/j.compositesb.2010.05.006

    Article  Google Scholar 

  21. Boisse P, Hamila N, Vidal-Sallé E, Dumont F (2011) Simulation of wrinkling during textile composite reinforcement forming. Influence of tensile, in-plane shear and bending stiffnesses. Compos Sci Technol 71(5):683–692. https://doi.org/10.1016/j.compscitech.2011.01.011

  22. Boisse P, Aimène Y, Dogui A, Dridi S, Gatouillat S, Hamila N, Aurangzeb Khan M, Mabrouki T, Morestin F, Vidal-Sallé E (2010) Hypoelastic, hyperelastic, discrete and semi-discrete approaches for textile composite reinforcement forming. Int J Mater Form 3(SUPPL. 2):1229–1240. https://doi.org/10.1007/s12289-009-0664-9

  23. Ouagne P, Soulat D, Moothoo J, Capelle E, Gueret S (2013) Complex shape forming of a flax woven fabric; analysis of the tow buckling and misalignment defect. Compos. Part A Appl Sci Manuf 51:1–10. https://doi.org/10.1016/j.compositesa.2013.03.017

  24. Capelle E, Ouagne P, Soulat D, Duriatti D (2014) Complex shape forming of flax woven fabrics: design of specific blank-holder shapes to prevent defects. Compos Part B Eng 62:29–36. https://doi.org/10.1016/j.compositesb.2014.02.007

  25. Gatouillat S, Bareggi A, Vidal-Sallé E, Boisse P (2013) Meso modelling for composite preform shaping - simulation of the loss of cohesion of the woven fibre network. Compos Part A Appl Sci Manuf 54:135–144. https://doi.org/10.1016/j.compositesa.2013.07.010

  26. Liu LS, Wang P, Legrand X, Soulat D (2017) Investigation of mechanical properties of tufted composites: influence of tuft length through the thickness reinforcement. Compos Struct. https://doi.org/10.1016/j.compstruct.2017.03.099

  27. Liu L (2017) Development and optimization of the tufting process for textile composite reinforcement. Ph.D. Dissertation, University of Lille, France

  28. Ten Thije RHW, Akkerman R, Ubbink M, Van Der Meer L (2011) A lubrication approach to friction in thermoplastic composites forming processes. Compos Part A Appl Sci Manuf 42(8):950–960. https://doi.org/10.1016/j.compositesa.2011.03.023

    Article  Google Scholar 

  29. Aridhi A et al (2019) Textile composite structural analysis taking into account the forming process. Compos Part B Eng 166:773–784. https://doi.org/10.1016/j.compositesb.2019.02.047

    Article  Google Scholar 

  30. Turk MA, Vermes B, Thompson AJ, Belnoue JPH, Hallett SR, Ivanov DS (2020) Mitigating forming defects by local modification of dry preforms. Compos Part A Appl Sci Manuf 128(September 2019):105643. https://doi.org/10.1016/j.compositesa.2019.105643

    Article  Google Scholar 

  31. Matveev MY, Endruweit A, De Focatiis DSA, Long AC, Warrior NA (2019) A novel criterion for the prediction of meso-scale defects in textile preforming. Compos Struct 226(January):111263. https://doi.org/10.1016/j.compstruct.2019.111263

  32. Yao Y, Peng X, Gong Y (2019) Influence of tension–shear coupling on draping of plain weave fabrics. J Mater Sci 54(8):6310–6322. https://doi.org/10.1007/s10853-019-03334-w

  33. Bardl G et al (2018) Analysis of the 3D draping behavior of carbon fiber non-crimp fabrics with eddy current technique. Compos Part B Eng 132:49–60. https://doi.org/10.1016/j.compositesb.2017.08.007

  34. Selezneva M et al (2020) Identification and validation of a hyperelastic model for self-reinforced polypropylene draping. Int J Mater Form. https://doi.org/10.1007/s12289-020-01542-3

  35. Guzman-Maldonado E, Wang P, Hamila N, Boisse P (2019) Experimental and numerical analysis of wrinkling during forming of multi-layered textile composites. Compos Struct 208:213–223. https://doi.org/10.1016/j.compstruct.2018.10.018

    Article  Google Scholar 

  36. Peng X, Rehman ZU (2011) Textile composite double dome stamping simulation using a non-orthogonal constitutive model. Compos Sci Technol 71(8):1075–1081. https://doi.org/10.1016/j.compscitech.2011.03.010

  37. Vanclooster K, Lomov SV, Verpoest I (2010) Simulation of multi-layered composites forming. Int J Mater Form 3(SUPPL. 1):695–698. https://doi.org/10.1007/s12289-010-0865-2

  38. Chen Q, Boisse P, Park CH, Saouab A, Bréard J (2011) Intra/inter-ply shear behaviors of continuous fiber reinforced thermoplastic composites in thermoforming processes. Compos Struct 93(7):1692–1703. https://doi.org/10.1016/j.compstruct.2011.01.002

  39. Harrison P, Gomes R, Curado-Correia N (2013) Press forming a 0/90 cross-ply advanced thermoplastic composite using the double-dome benchmark geometry. Compos Part A Appl Sci Manuf 54:56–69. https://doi.org/10.1016/j.compositesa.2013.06.014

  40. ten Thije RHW, Akkerman R (2009) A multi-layer triangular membrane finite element for the forming simulation of laminated composites. Compos Part A Appl Sci Manuf 40(6–7):739–753. https://doi.org/10.1016/j.compositesa.2009.03.004

  41. Wang P, Hamila N, Boisse P (2013) Thermoforming simulation of multilayer composites with continuous fibres and thermoplastic matrix. Compos Part B Eng 52:127–136. https://doi.org/10.1016/j.compositesb.2013.03.045

    Article  Google Scholar 

  42. Bel S, Hamila N, Boisse P, Dumont F (2012) Finite element model for NCF composite reinforcement preforming: importance of inter-ply sliding. Compos Part A Appl Sci Manuf 43(12):2269–2277. https://doi.org/10.1016/j.compositesa.2012.08.005

    Article  Google Scholar 

  43. Schirmaier FJ, Weidenmann KA, Kärger L, Henning F (2016) Characterisation of the draping behaviour of unidirectional non-crimp fabrics (UD-NCF). Compos Part A Appl Sci Manuf 80:28–38. https://doi.org/10.1016/j.compositesa.2015.10.004

    Article  Google Scholar 

  44. Hui C, Wang P, Legrand X (2019) Improvement of tufting mechanism during the advanced 3-dimensional tufted composites manufacturing : to the optimisation of tufting threads degradation. Compos Struct. https://doi.org/10.1016/j.compstruct.2019.04.019

  45. Verma KK, Padmakara G, Gaddikeri KM, Ramesh S, Kumar S, Bose S (2019) The key role of thread and needle selection towards ‘through-thickness reinforcement’ in tufted carbon fiber-epoxy laminates. Compos Part B Eng 174:106970. https://doi.org/10.1016/j.compositesb.2019.106970

    Article  Google Scholar 

  46. Thurm T (2005) Applications of one-sided stitching techniques for resin infusion preforms and structures. 41

  47. Dell’Anno G, Cartié DD, Partridge IK, Rezai A (2007) Exploring mechanical property balance in tufted carbon fabric/epoxy composites. Compos Part A Appl Sci Manuf. https://doi.org/10.1016/j.compositesa.2007.06.004

  48. Chehura E et al On-line monitoring of multi-component strain development in a tufting needle using optical fibre Bragg grating sensors. https://doi.org/10.1088/0964-1726/23/7/075001

  49. Martins AT, Aboura Z, Harizi W, Laksimi A, Khellil K (2018) Structural health monitoring for GFRP composite by the piezoresistive response in the tufted reinforcements. Compos. Struct. https://doi.org/10.1016/j.compstruct.2018.10.091

  50. Martins AT, Aboura Z, Harizi W, Laksimi A, Hamdi K (2019) Structural health monitoring by the piezoresistive response of tufted reinforcements in sandwich composite panels. Compos Struct 210(November 2018):109–117. https://doi.org/10.1016/j.compstruct.2018.11.032

  51. Dufour C, Boussu F, Wang P, Soulat D (2018) Local strain measurements of yarns inside of 3D warp interlock fabric during forming process. Int J Mater Form 11(6):775–788. https://doi.org/10.1007/s12289-017-1385-0

  52. Martins AT, Aboura Z, Harizi W, Laksimi A, Khellil K (2018) Analysis of the impact and compression after impact behavior of tufted laminated composites. Compos Struct 184(September 2017):352–361. https://doi.org/10.1016/j.compstruct.2017.09.096

  53. Hartley JW, Kratz J, Ward C, Partridge IK (2017) Effect of tufting density and loop length on the crushing behaviour of tufted sandwich specimens. Compos Part B Eng. https://doi.org/10.1016/j.compositesb.2016.12.037

  54. Samir D, Hamid S (2014) Determination of the in-plane shear rigidity modulus of a carbon non-crimp fabric from bias-extension data test. J Compos Mater 48(22):2729–2736. https://doi.org/10.1177/0021998313502063

  55. Omrani F, Wang P, Soulat D, Ferreira M, Ouagne P (2017) Analysis of the deformability of flax-fibre nonwoven fabrics during manufacturing. Compos Part B Eng 116:471–485. https://doi.org/10.1016/j.compositesb.2016.11.003

Download references

Funding

The research presented in this paper was funded by the National Research Agency (ANR), France, in the scope of the project COMP3DRE “COMPosites 3D REnforcés”.

Author information

Authors and Affiliations

  1. ENSAIT, GEMTEX, University of Lille, F-59000, Roubaix, France

    I. Gnaba, D. Soulat & X. Legrand

  2. ENSISA, LPMT, University of Upper Alsace, F-68000, Mulhouse, France

    P. Wang

Authors
  1. I. Gnaba
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. D. Soulat
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. X. Legrand
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. P. Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to I. Gnaba.

Ethics declarations

Conflicts of interest/Competing interests

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Code availability

Not applicable.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Gnaba, I., Soulat, D., Legrand, X. et al. Investigation of the formability behaviour during stamping of tufted and un-tufted carbon preforms: towards localized reinforcement technologies. Int J Mater Form 14, 1337–1354 (2021). https://doi.org/10.1007/s12289-020-01606-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12289-020-01606-4

Keywords

Search

Navigation