Textile Strip Simulation for Composite Fan Casings
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Solution Overview
Problem
Existing methods fail to effectively simulate the shaping of textile strips for composite material fan casings, leading to registering faults that degrade mechanical strength by creating uneven fiber distribution and resin penetration issues during the winding process.
Innovation Solution
A method simulates the shaping of a textile strip by calculating and positioning crossing points between warp and weft yarns on a mold of revolution, generating a three-dimensional mesh using finite elements, and adjusting winding length increments based on yarn length ratios and tension variations to account for the geometry of the mold and the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the textile strip is wound on a mold in the form of a body of revolution, then the composite material part can be formed with complex geometry, but registering faults appear in the strip causing angle deviations between warp and weft yarns
Solution Approach 1:
The patent applies preliminary action by calculating and determining the positions of crossing points between warp and weft yarns before the actual winding process. The simulation method predicts the three-dimensional positions of all crossing points along the winding path, allowing registration faults to be identified and corrected in advance, thus ensuring precise yarn alignment when the textile strip is actually wound on the mold.
2Ease of manufacture
If existing simulation methods are used, then the shaping process can be modeled, but they fail to accurately predict registering faults and yarn orientation
Solution Approach 1:
The patent applies segmentation by dividing the continuous textile strip into discrete elemental segments, each defined by crossing points between warp and weft yarns. The simulation method calculates the three-dimensional coordinates of individual crossing points along the winding path, enabling precise tracking of yarn positions and orientations. This segmented approach allows accurate prediction of registration faults by analyzing the spatial relationships between discrete crossing point segments rather than treating the strip as a continuous homogeneous material.
3Productivity
If the textile strip is shaped by winding, then fiber preform can be formed for composite material, but uneven fiber distribution and resin penetration issues occur
Solution Approach 1:
The patent applies preliminary action by using the simulation method to predict the three-dimensional positions and orientations of warp and weft yarns before the winding process. This allows identification of zones where registration faults may cause uneven fiber distribution or poor resin penetration. The results can be used to adjust the winding parameters, tension control, or textile strip design in advance, ensuring uniform fiber distribution and proper resin penetration in the final composite material part.
Data Source
AI summary
A method of simulating shaping a textile strip by winding on a mold presenting a surface of revolution is described. The textile strip is made by three-dimensional weaving between a plurality of layers of warp yarns and a plurality of layers of weft yarns, the warp yarn layers being interlinked by the weft yarn layers. For each warp yarn layer, the method includes positioning crossing points between at least some of the warp yarns of the warp yarn layer and at least some of the weft yarns, the warp yarns of the at least some of the warp yarns including a reference warp yarn having a determined axial position on the mold.