3D Preform Weaving with Gradient Fiber Orientation
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Solution Overview
Problem
Current methods for weaving three-dimensional preforms are limited in creating structures with gradient orientations, as they primarily restrict fibers to two directions (0° and 90°) on the X-Y plane, unable to effectively accommodate parts with varying loading conditions and functional requirements.
Innovation Solution
A method involving the decomposition of performance requirements into different functional locations, selection of varying guide sleeves and fibers, and a computer-generated weaving sequence to achieve a smooth transition in fiber arrangement and density, enabling the creation of a three-dimensional preform with a gradient structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If machine knitting process or fine weave piercing process is used, then three-dimensional preform can be manufactured, but gradient structure cannot be achieved due to device limitations
Solution Approach 1:
The preform manufacturing process is segmented into multiple functional zones along the weaving direction, with each zone having different fiber arrangement parameters. The guide sleeve array is divided into multiple groups that can be independently controlled, allowing different sections of the preform to have different fiber orientations and densities, thus achieving gradient structure without requiring a completely new device
Solution Approach 2:
The guide sleeves are designed to be movable rather than fixed, allowing their positions and orientations to be dynamically adjusted during the weaving process. This dynamic control enables the system to create gradient structures by continuously varying fiber arrangement parameters along the weaving direction, while the underlying device structure remains relatively simple
2Length of stationary object
If carbon fiber plain fabric or satin fabric is used for piercing, then large-thickness fabric can be manufactured, but gradient structure on plane cannot be achieved
Solution Approach 1:
Different regions of the guide sleeve array are assigned different fiber arrangement configurations, allowing each local area to have optimized fiber orientations and densities according to specific structural requirements. This local quality variation enables gradient structures to be created within the preform plane while maintaining the ability to manufacture large-thickness fabrics through the same device
3Ease of operation
If multi-arm mechanism with two or more weft insertion needles is used, then multi-layer movable shed can be formed, but only two directions (0° and 90°) for fibers on X-Y plane can be achieved
Solution Approach 1:
The system adds a new dimension of control by introducing guide sleeves that can orient fibers in multiple directions beyond the traditional 0° and 90°. The guide sleeves provide an additional degree of freedom for fiber orientation, allowing fibers to be arranged in various angles on the X-Y plane while maintaining the multi-layer weaving capability provided by the multi-arm mechanism
Data Source
AI summary
A method for weaving a three-dimensional preform includes the following steps: decomposing and determining performance requirements of different functional locations of the parts; selecting guide sleeves and fibers of each of the functional locations and designing a parameter; selecting guide sleeves and fibers of a transition area and designing a parameter, thereby implementing smooth transition of the transition area; determining a weaving sequence according to layouts of the guide sleeves and winding manners of the fibers in the functional locations and the transition area to generate a fiber iterative instruction for layer-by-layer weaving; arranging guide sleeves according to design requirements of the functional locations and the transition area to generate a guide sleeve array; and driving a weaving mechanism to select different fibers for subarea weaving layer by layer to obtain the three-dimensional preform having a gradient structure.