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1 1
Textile Preforms for Composites
1. Introduction
2. Fibres and yarns
3. Textiles in general
4. Fabrics: NCF – Woven – Braided – Knitted – 3D – Spaced
5. Modelling of textile composites
Stepan V. Lomov
Department MTM – KU Leuven
S.V. Lomov - Textile Preforms for Composites - 5. Modelling
2
Contents
1. Introduction
2. Geometrical models of textile reinforcement internal architecture
3. Models of textile reinforcement deformability
4. Models of textile reinforcement permeability
5. Mechanical properties of textile composites, damage
6. Conclusion: Models integration
S.V. Lomov - Textile Preforms for Composites - 5. Modelling
2
3
1. Introduction
2. Geometrical models of textile reinforcement internal architecture
3. Models of textile reinforcement deformability
4. Models of textile reinforcement permeability
5. Mechanical properties of textile composites, damage
6. Conclusion: Models integration
S.V. Lomov - Textile Preforms for Composites - 5. Modelling
S.V. Lomov 27.07.2012
Textile composites: meso-scale as a bridge to Macro
x
z
p
h z(x)
Q
Q
d2
d1
Z
A
B
Internal architecture of the reinforcement
Deformation resistance and change of
geometry
Compr. Shear Tension Bending
Perme-
ability
M
R=1/
K
Drapeability and formability
Impregnation
Production
Mechanical properties
and damage
Performance
Structural analysis
4
4 S.V. Lomov - Textile Preforms for Composites - 5. Modelling 4
3
5
Мodels
Unit cell
Manufacturing
Pefomance
Internal architecture of the reinforcement
Deformation
resistance and
change of geometry
Permeability
Drapeability and
formability Impregnation
Mechanical
properties and
damage
Structural analysis
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 5
6
Software
Unit cell
Manufacturing
Performance
Internal architecture of the reinforcement
Deformation
resistance and
change of geometry
Permeability
Drapeability and
formability Impregnation
Mechanical
properties and
damage
Structural analysis
WiseTex
TexGen
FlowTex
CFD
WiseTex
Abaqus
TexComp
Abaqus
ANSYS
PAM-RTM
LCM
RTM-Works
PAM-FORM
QuikForm
CoData
Abaqus
Nastran РАМ-SYSPLY
Abaqus PAM-CRASH
ANSYS
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 6
4
7
WiseTex software package: Virtual textiles and textile composites
• commercialised by K.U.Leuven R&D
• integrated in SYSPLY package of ESI Group
6 industrial licenses
30+ university licenses
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 7
Textile structures in WiseTex
Woven
Braided NCF
Laminates
Knitted
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 8
5
Smart composites
AE
sensor
on-board
computer
super-
computer
structural
health analysis
decision on
maintenance
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 9
10
1. Introduction
2. Geometrical models of textile reinforcement internal architecture
• A model of internal geometry of (2D or 3D) woven fabric
• From geometrical model to finite elements
3. Models of textile reinforcement deformability
4. Models of textile reinforcement permeability
5. Mechanical properties of textile composites, damage
6. Conclusion: Models integration
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 10
6
Road map: Geometrical model of the (deformed) unit cell
Structure: weave / topology / interlacing
– contacts, relative positions
Geometry: Placement of the yarns inside
the (deformed) unit cell
– yarn paths / directions / twist
– yarn volumes / cross-sections
Deformations of the dry fabric:
compression, tension, shear, bending
FE mesh: Yarn volumes,
contacts
Textile mechanics
Textile mechanics
FE
“CAD”
Meshing
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 11
Road map: Geometrical model of the (deformed) unit cell
Structure: weave / topology / interlacing
– contacts, relative positions
Geometry: Placement of the yarns inside
the (deformed) unit cell
– yarn paths / directions / twist
– yarn volumes / cross-sections
Deformations of the dry fabric:
compression, tension, shear, bending
FE mesh: Yarn volumes,
contacts
Textile mechanics
Textile mechanics
FE
“CAD”
Meshing
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 12
7
Woven fabric: Detailed road map
Weave model
Elementary bent intervals
Crimp height and yarn thickness
Yarn properties
Ends/picks count
Weave coding
Yarn shapes
Full description of the geometry
Input
Distance between the layers
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 13
Weave model: matrix coding
warp zones NWa
yarns in a warp zone NWaZ[iWa]
weft rows NWe
weft layers L
4
1 2 3
1 2 3 4 layer 1
layer 2
level 0
level 1
level 2
1210
0121
1012
2101warp 1
warp 2
warp 3
warp 4
1 2-1
2-2
2-3
3
4-1
4-2
4-3
0 4
1 1
2 2
3 3
4 0
1 1
2 2
3 3
1
2
3
4
warp zones
Weave
model
Elementary
bent intervals
Crimp,
yarn
thickness
Yarn
prop.
Ends /
picks
Weave
coding
Yarn shapes
Full
description of
the geometry
Input
Distance
between
layers
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 14
8
Elementary bent intervals
base weft yarns
elementary bent interval: warp
iWa
iWa,
iWaInt
iWe1 iWe2
Elementary bent interval iWaInt of warp yarn iWa
1. Numbers of base weft yarns iWe1, iWe2
2. Position of the yarn vis-à-vis the base pos1, pos2
pos2 = BELOW
pos1 = OVER
Weave
model
Elementary
bent intervals
Crimp,
yarn
thickness
Yarn
prop.
Ends /
picks
Weave
coding
Yarn shapes
Full
description of
the geometry
Input
Distance
between
layers
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 15
Yarn shape in a bent interval – 1
element e
eeee
sPBA
eeee
sPBA
BAsPW
sPBAW
eee
eee
,|minmin
;,min
)(,
,,
Problem B:
find the positions of the
ends of the bent interval
(crimp heights)
Problem A:
find the shape P(s) for the
given end positions
Weave
model
Elementary
bent intervals
Crimp,
yarn
thickness
Yarn
prop.
Ends /
picks
Weave
coding
Yarn shapes
Full
description of
the geometry
Input
Distance
between
layers
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 16
9
Yarn shape in a bent interval – 2
h_We
d11_We
d21_We
d12_We
d22_We base contour
p
d11_Wa h_Wa
• distance between base
contours: picks count
• dimensions: compression
resistance
• crimp height: equilibrium of
bending forces
0)(;2/)(;0)0(;2/)0(:)( pzhpzzhzxz
p
dxz
zBW
0
2/52
2
min12
1
p
xxxxx
p
hAxx
h
z
,
2
11164
2
1 2223
z(x)
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 17
Characteristic functions of bent intervals
h_We
d11_We
d21_We
d12_We
d22_We
p
d11_Wa h_Wa
0 0.2 0.4 0.6 0.8 10
1
2
3
4
5
6
h/p
A
F
h/p
p
hF
p
Bdx
z
zBW
p
0
2/52
2
12
1
p
hF
ph
B
h
WQ
22
p
hF
pdx
z
z
p
p1
1
1
0
2/52
2
energy
transversal force
average curvature
z(x)
main parameter:
h/p
main property
B(k)
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 18
10
Distance between the layers
)
,,,,,,(max
22
212111
,1,1,
1,1,2,1,1211,
1
We
jlk
We
jl
We
klj
We
lj
Wa
kj
We
klj
We
klj
We
jlk
We
jlk
We
jl
We
jltightkj
ll
PhPh
dddddshapeshapezZZ
level 1 level 2
pWe
shift of the
layers
Weave
model
Elementary
bent intervals
Crimp,
yarn
thickness
Yarn
prop.
Ends /
picks
Weave
coding
Yarn shapes
Full
description of
the geometry
Input
Distance
between
layers
weft j,l+1; interval k2
weft j,l; interval k1
hjlWe
hjl+1We
warp i z
Zl
Zl+1
x
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 19
Compressibility of the yarns
d1
d2
Q
5.0...3.0
12
10
22
10
11
;)(
)(
d
Qd
d
Qd
Weave
model
Elementary
bent intervals
Crimp,
yarn
thickness
Yarn
prop.
Ends /
picks
Weave
coding
Yarn shapes
Full
description of
the geometry
Input
Distance
between
layers
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 20
11
Crimp heights: minimum energy – 1
element e
eeee
sPBA
eeee
sPBA
BAsPW
sPBAW
eee
eee
,|minmin
;,min
)(,
,,
Problem B:
find the positions of the
ends of the bent interval
(crimp heights)
Problem A:
find the shape P(s) for the
given end positions
Weave
model
Elementary
bent intervals
Crimp,
yarn
thickness
Yarn
prop.
Ends /
picks
Weave
coding
Yarn shapes
Full
description of
the geometry
Input
Distance
between
layers
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 21
Crimp heights: minimum energy – 2
x
z
p
h z(x)
Q
Q
d2
d1
Z
A
B
warp i
warp crimp interval k
weft j’,l’
weft j’’,l’’
weft crimp interval k’
weft crimp interval k’’
min
,,,
kljWe
jlk
We
jl
We
jlk
We
jlk
We
jlk
kiWa
ik
Wa
ik
Wa
ik
Wa
ik
Wa
ik
p
hF
p
B
p
hF
p
BW
minimum energy:
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 22
12
Full system of equations
warp i
warp crimp interval k
weft j’,l’
weft j’’,l’’
weft crimp interval k’
weft crimp interval k’’
warps NWa
weft layers L
weft rows NWe
Unknown
variables
Number Equations
Dimensions of
warp and weft
yarns
Vertical positions
of mid-planes of
weft layers Zl
L
Weft crimp heights L*NWe
L
l
NWe
j
jlKNWeNWa1 1
2
We
jlh
1 10 1
2
...ij lWa Wa Wa
ik i i Wa
ik
Qd d
d
We
kjl
We
jl
We
jl
We
kjl
We
jl
We
kjl
We
jl
We
jl
We
kjl
We
jl
Wa
ki
Wa
ki
Wa
ki
Wa
ki
Wa
i
Wa
ki
Wa
ki
Wa
ki
Wa
ki
Wa
i
ijl
p
hF
hp
B
p
hF
hp
B
p
hF
hp
B
p
hF
hp
BQ
11
1
1
11
2
1
2
1
)
,,,,,,(max
22
212111
,1,1,
1,1,2,1,1211,
1
We
jlk
We
jl
We
klj
We
lj
Wa
kj
We
klj
We
klj
We
jlk
We
jlk
We
jl
We
jltightkj
ll
PhPh
dddddshapeshapezZZ
min
,,,
kljWe
jlk
We
jl
We
jlk
We
jlk
We
jlk
kiWa
ik
Wa
ik
Wa
ik
Wa
ik
Wa
ik
p
hF
p
B
p
hF
p
BW
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 23
The flowchart of the solution
hWelj=0
calculate Q for all contacts warp/weft
calculate d for all contacts warp/weft
calculate Zl
solve energy equation (l,j) for hWelj, all other
hWe given
max|hWelj- holdWe
lj|<prec
no
yes
h,%
0 2 4 6
5
10
15
iterations
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 24
13
Description of internal geometry
O
r(s)
X Y
Z
t
a1
a2
O
d2 d1
Each segment:
• direction
• curvature
• two dimensions
• average Vf
Unit cell:
dimensions X,Y,Z
number of yarns
Each yarn:
set of segments
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 25
Examples of calculations of internal geometry of 3D fabrics/composites
Glass 3D woven: X-ray µCT and simulated
Carbon/epoxy 3D woven: simulated and real cross-sections
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 26
14
Visualisation
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 27
28
1. Introduction
2. Geometrical models of textile reinforcement internal architecture
• A model of internal geometry of (2D or 3D) woven fabric
• From geometrical model to finite elements
3. Models of textile reinforcement deformability
4. Models of textile reinforcement permeability
5. Mechanical properties of textile composites, damage
6. Conclusion: Models integration
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 28
15
Road map: Geometrical model of the (deformed) unit cell
Structure: weave / topology / interlacing
– contacts, relative positions
Geometry: Placement of the yarns inside
the (deformed) unit cell
– yarn paths / directions / twist
– yarn volumes / cross-sections
Deformations of the dry fabric:
compression, tension, shear, bending
FE mesh: Yarn volumes,
contacts
Textile mechanics
Textile mechanics
FE
“CAD”
Meshing
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 29
A gallery of finite element models
3-axial braid
knitted
plain weave
3D woven
stitched
NCF S.V. Lomov - Textile Preforms for Composites - 5. Modelling 30
16
meso-FE: Road map
Geometric modeller
Geometry corrector
Meshing
Assign material
properties
Boundary conditions
FE solver,
postprocessor
Homogenisation
Damage analysis
N+1 N
N+2
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 31
meso-FE: Road map
Geometric modeller
Geometry corrector
Meshing
Assign material
properties
Boundary conditions
FE solver,
postprocessor
Homogenisation
Damage analysis
N+1 N
N+2
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 32
17
Yarn volumes
O
r(s)
X Y
Z
t
a1
a2
O
d2 d1
P f
Vf Fibre structure of
the yarns
Solid model
N+1 N
N+2
Orthotropy of the
impregnated yarns
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 33
Orthotropy of the impregnated yarns
2
1 3
f
mf
m
mf
t
f
E
EV
EEE
EVEVE
22
3322
1111
11
1
f
mf
m
f
mf
m
G
GV
GG
G
GV
GGG
23
23
12
1312
11
11
12
1
23
2223
121312
G
E
VV mf
f
f
Chamis model
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 34
18
Interpenetration of the volumes
no interpenetration
(rare) “vertical”
interpenetration
complex
interpenetration
The correction of the geometry should preserve:
• overall fibre volume fraction in the composite (dimensions of the unit cell and
amount of fibres in all the yarns)
• average fibre volume fraction in the yarns in realistic bounds (< 70…75%)
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 35
Manual correction
1
2
3
p0
1
p11
p0
2 p1
2
s1
s2
p0
1 p11 s1 s2
1
p01=p11
P02=p1
2
s1
s2
p01=p11
6 2 3 4 5
7
1
1. First interpenetration type 2. Second interpenetration type
3. Third interpenetration type
6 2 3 4 5
7
1
[1]
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 36
19
Interpenetration of the volumes: correction via inermediary FEA
z
- z
Deformation
Splitting
Separation
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 37
Example of the volume correction: 3-axial braid
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 38
20
Contact surfaces
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 39
Mesh interpolation
x
z y
sx sx
x
z y
320(MPa) 60(MPa)
fine mesh Global and local mesh
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 40
21
Voxels
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 41
42
1. Introduction
2. Geometrical models of textile reinforcement internal architecture
3. Models of textile reinforcement deformability
4. Models of textile reinforcement permeability
5. Mechanical properties of textile composites, damage
6. Conclusion: Models integration
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 42
22
What is a forming simulation?
Given:
1. Preforms characterisation
2. Mould geometry
3. Mould temperature
4. Forming speed
Calculate:
1. Wrinkling
2. Waste
3. Local shear and other local parameters of the reinforcement
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 43
Optimise forming operation
1. Mould geometry (radii of curvature...)
2. Blank orientation
3. Configuration of a blank-holder and blank-holder tension
4. Forming temperature and evenness of the temperature distribution
5. Forming speed
main optimisation parameter: WRINKLING
[2]
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 44
23
Optimise impregnation
Permeability of textile depends on local volume fraction
and local shear
Local volume fraction and local shear depend on local
deformation
Local deformation depends on draping of the preform
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 45
Forming impregnation
The front is not round – the preform is
anisotropic
Distribution of shear angles local
permeability
shear angles
impregnation: PAM-RTM
images: ESI Group
Drape: PAM-QuikForm
front movement
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 46
24
Example
Constant permeability
Accounting for the preform deformation
images: ESI Group S.V. Lomov - Textile Preforms for Composites - 5. Modelling 47
Optimise performance
Stiffness of composite depends on local orientation of the fibres
Local orientation of the fibres depends on local deformation
Local deformation depends on draping of the preform
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 48
25
Forming structural analysis
WiseTex
Local deformation
parameters
(thickness, shear…)
Forming:
QUIKFORM
Internal
geometry
Local stiffness [Q]
FE analysis:
SYSPLY
Stress/strain fields
TexComp
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 49
Key result: Distribution of shear angle of the preform
locking
images: Kristof Vanclooster S.V. Lomov - Textile Preforms for Composites - 5. Modelling 50
26
Cloth draping
Well advanced simulations of garments
[3]
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 51
Principle of kinematic draping simulation
1. NO mechanical properties
2. DEPENDS on the initial choice of
principal directions [4]
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 52
27
Good predictions for symmetrical configurations...
warp parallel
to the
cylinder axis
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 53
… may be very bad for asymmetrical situations
warp at 45° to the cylinder
axis
assumed in kinematic draping
and real advancement of
draping
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 54
28
Finite element simulations of draping: Example – 1
[5]
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 55
Expicit FE solution
[5]
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 56
29
Stages of PAM-FORM analysis
[6]
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 57
Material model for textile fabrics – 1
shear diagram
viscous matrix
non-linear tension
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 58
30
Material model for textile fabrics – 2
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
0 10 20 30 40 50
Shear angle, °
Sh
ear
forc
e,
N/m
m
0
50
100
150
200
250
300
0 0.2 0.4 0.6 0.8 1
EpsX, %
Fx
pe
r y
arn
, N
effective viscosity is
different from the
viscosity of the matrix
shear
tension
viscosity
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 59
Problems of kinematic draping solved!
kinematic draping PAM-FORM
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 60
31
WiseTex models of deformations of textiles
Compression
Uni-
and Biaxial tension
Shear
(un)bending + compression of yarns
work of compressive force Q on change of thickness db
= change of bending energy of yarns dW
d2Wa
d2We
q
d1Wa
d1We
Qij
T T
Q
hWa
p
• Friction between the yarns
• Lateral compression of the yarns
• (Un) bending of the yarns
• Torsion of the yarns
• Vertical displacement of the yarns T
T Q
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 61
FE modelling of deformations of textiles
images: Ph. Boisse
shear tension
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 62
32
63
1. Introduction
2. Geometrical models of textile reinforcement internal architecture
3. Models of textile reinforcement deformability
4. Models of textile reinforcement permeability
5. Mechanical properties of textile composites, damage
6. Conclusion: Models integration
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 63
Simulation of impregnation
Input:
• mould geometry
• permeability of the textile
• resin viscosity
• positions of inlets and
vents
• pressure drop
Output:
• movement of the flow front
• dry spots
• impregnation time
pΚ
gradv
Darcy equation
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 64
33
Solution of Darcy equation
pΚ
gradv
Assumption:
front moves with velocity <v> =
ideal wetting
inlets
vents
front iso-chrones
Meyer et al 2004
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 65
Calculation of preform permeability
Geometry: Placement of the yarns inside the
(deformed) unit cell
– yarn paths / directions / twist
– yarn volumes / cross-sections
“Voxels” Meshing
Voxel-mesh FE mech
(Navier-)
Stokes
solver
Fabric permeability
Analytical
“Hydraulic”
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 66
34
Darcy permeability: homogenised (Navier-) Stokes solution
p = 0
<u>
<u>
p = p u(A) - u(A´) = const(A)
AA´= periodic translation
A
A´
0 0
0 0
0 0
x
y
z
K
K
K
K
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 67
Geometrical models and voxel mesh
Reinforcement
model
Voxel model
woven, monofilaments quasi-UD woven, carbon
non-woven, glass NCF, carbon
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 68
35
(Navier-) Stokes solution
Requirements:
• Automated
• Fast and accurate
• Accurate in narrow channels
• Periodic boundary conditions
• Sheared unit cell
Implementation:
• Navier-Stokes:
(adapted) NaSt3d
staggered grid
• Stokes
collocated grid
stabilisation term
PETSc package, GMRES(m)
Navier-Stokes:
staggered grid,
difficulty with
isolated cells
F
S
F
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 69
Boundary conditions: faces of the unit cell and internal boundaries
wall and internal boundary Г
velocity
pressure (Stokes equation)
=> Re = 0.05
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 70
36
FlowTex: Integration with WiseTex and GUI
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 71
Experimental validation: Overview
Ky
Kx
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 72
37
Coupled meso-macro simulation
WiseTex
Local reinforcement
deformation Process model
Local reinforcement
geometry
Local permeability
[K]
Filling simulation
Processing
parameters
FlowTex
stand-alone
application
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 73
Necessary performance of mass-simulations
10,000 finite elements
or…
90 values of shear angles (0°, 1°, 2°…) and 5 degrees of compression =
= about 450 calculation variants
3h calculation time 2 s per fabric configuration
5 s
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 74
38
75
1. Introduction
2. Geometrical models of textile reinforcement internal architecture
3. Models of textile reinforcement deformability
4. Models of textile reinforcement permeability
5. Mechanical properties of textile composites, damage
6. Conclusion: Models integration
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 75
Road map: Micromechanics of textile composites
Geometry: Placement of the yarns inside the (deformed) unit
cell
– yarn paths / directions / twist
– yarn volumes / cross-sections
“Voxels” Meching
Voxel - partitioning FE mesh
FE
Stiffness
Orientation
averaging
Inclusions
Stress-strain fields, damage
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 76
39
Stiffness: Simple model neglecting yarn crimp
9090
00
90
0
900
900
PT
PT
h
h
hhh
VFVFVF
woven laminate UD laminate
two plies
representing warp
and weft
90°
0° h_0°
h_90° linear density of
warp/weft and
ends/picks count
Assumption: iso-strain
900 CCCh
h
h
h 900
Stiffness matrix Approximation: Young’s modulus
9090
00 E
h
hE
h
hE
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 77
Orientation averaging
The textile structure is subdivided into
elements; each element is represented
by a UD composite
CSi
GCS
Vi
N
i
i
N
i
iii
meff VVVGCSCSVGCSGCS11
;1 CCC
effective
stiffness of the
composite matrix stiffness
stiffness of
elements
Assumption: iso-strain
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 78
40
S.V. Lomov - Textile Preforms for Composites - 5. Modelling
Example: 3D woven glass/epoxy composite
exp OA
E1, GPa 24.3±1.2 22.7
E2, GPa 25.1±2.34 22.8
E3, GPa n/a 10.1
G12, GPa n/a 3.38
ν12 0.141±0.071 0.109
ν13 n/a 0.377
ν23 n/a 0.380
E45º, GPa 12.9±0.5 10.7
G45º, GPa n/a 10.3
ν45º 0.502±0.21 0.581
Vf, % E1,GPa E2,E3,
GPa 12 , 13 23
G12, G13,
GPa G23, GPa
3D weave, warp 2275 tex 64.1 47.2 10.8 0.266 0.440 4.24 3.73
3D weave, warp 1100 tex 60.1 44.5 9.7 0.271 0.445 3.79 3.35
3D weave, Z 276 tex 78.0 56.8 16.7 0.252 0.414 6.73 5.9
3D weave, fill 1470 tex 59.1 43.7 9.44 0.272 0.447 3.69 3.26
W
F
Z W
Elastic properties of the impregnated yarns
Areal density, g/m2 3255
Thickness, mm 2.6
Ends, 1/cm 2.76
Picks. 1/cm 2.64
Z-yarns, 1/cm 2.76
VF, % 48.9
79
Method of Inclusions: Yarns as a collection of curved segments
[C]
The yarn segment is NOT circular,
but has two different diameters
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 80
41
81
Curved segment as an equivalent ellipsoidal inclusion
, 3.14b R
a a
R 2a
2b
1. Volume fraction of each equivalent
ellipsoid in the unit cell corresponds to
the volume fraction of the segment
which it represents.
2. The elongation of the equivalent
ellipsoid depends on the curvature of
the segment.
3. The stiffness of the ellipsoid inclusion
is equal to the homogenised local
stiffness in the segment.
4. For a non-circular yarn the ellipsoid
has all the three axis different
5. The equivalent ellipsoids are NOT a
physical substitution of the yarn
segments; they are merely
mathematical means to calculate the
stress-strain states in the segments,
using Eshelby tensors
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 81
Flowchart
Geometrical
preprocessor Textile data
Internal geometry of
textile and partitioning
into segments
Segment
processor
Matrix and
fibre data
Assembly of
equivalent ellipsoidal
inclusions
Mori – Tanaka
homogenisation
Homogenisation
on micro-level
Homogenised stiffness
of the composite
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 82
42
Software: WiseTex and TexComp (KULeuven)
Models of textile geometry
and deformability
Predictive
models of
composites
mechanics
Models of internal structure and
deformation of unit cell of textile
reinforcement:
• woven 2D and 3D
• braided bi- and triaxial
• knitted
Homogenisation of stiffness of textile
composite, based on the method of
inclusions:
any textile reinforcement described by
WiseTex, including deformed (sheared,
compressed, tensed)
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 83
Comparison
5.13 4.955.65
5.25 5.44
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
GE001_G GE002_G GE012_G
G
W iseTex/TexComp
Experim ent
glass/epoxy
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 84
43
Stiffness prediction: FE and inclusions
exp OA Inclusions FE @49.3
E1, GPa 24.3±1.2 22.7 24.2 23.6
E2, GPa 25.1±2.34 22.8 24.2 23.7
E3, GPa n/a 10.1 9.1 9.5
ν12 0.141±0.071 0.109 0.161 0.128
ν13 n/a 0.377 0.370 0.365
ν23 n/a 0.380 0.368 0.359
no real need in FE for the stiffness prediction
W
F
Z W
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 85
Road map: Micromechanics of textile composites
Geometry: Placement of the yarns inside the (deformed) unit
cell
– yarn paths / directions / twist
– yarn volumes / cross-sections
“Voxels” Meching
Voxel - partitioning FE mesh
FE
Stiffness
Orientation
averaging
Inclusions
Stress-strain fields, damage
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 86
44
87
meso-FE: Road map
Geometric modeller
Geometry corrector
Meshing
Assign material
properties
Boundary conditions
FE solver,
postprocessor
Homogenisation
Damage analysis
N+1 N
N+2
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 87
88
Solving meso-FE problem
| |
( )
|
( )
|
Homogenised stiffness :
0;
1
2
1 1
ijkl kpq l j
ipq ipq q ip p iq
pq
ij ijkl kpq l
kl
ijkl ijpq pkl q ij
UC UCUC UC
C U
U U
C U
C C U d dV V
s
s
C
2 1
0 ( )
,
Local stress-strain field
= pq
ij p q ijvs s x x
,
0
,
Homogenised stress-strain field
( )
ijkl k lj
i i
ij ijkl k l
C u f
u v
C u
s
u x x x
x
x x
FE
FE
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 88
45
89
Example: Finite element model of 3D woven composite
Mesh in the yarns
Full mesh
Clearance between yarns 0.005 mm
Resin layer on the surface 0.005 mm
VF 43.7% (WiseTex: 48.9%)
Total elements 20768
Penetrating nodes corrected 3000
Max aspect ratio 469
Max aspect ratio in yarns 60
WiseTex
MeshTex
Correct representation of measurable
parameters:
• areal density
• thickness
• overall fibre volume fraction
• ends/picks count
• yarn dimensions
Simplifications:
• elliptical shape of yarn cross-sections
• constant dimensions of Z-yarns
• VF inside yarns up to 90% (Z-yarns)
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 89
Strains on the surface of the composite
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 90
46
Stress-strain diagram
0
50
100
150
200
250
300
350
400
450
500
0 0.5 1 1.5 2 2.5 3
eps, %
sig
, M
Pa
exp
elastic solution
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 91
92
Damage model – 1
Damage initiation: Hoffmann
2
9
2
8
2
7654
23
22
21 )()()(
LTZLTZZTL
TLLZZT
CCCCCC
CCCF
sss
ssssss
2
9
2
8
2
7
654
3
2
1
1,
1,
1
11,
11,
11
111
2
1
111
2
1
111
2
1
sLT
sZL
sTZ
cZ
tZ
cT
tT
cL
tL
cZ
tZ
cT
tT
cL
tL
cT
tT
cL
tL
cZ
tZ
cL
tL
cZ
tZ
cT
tT
FC
FC
FC
FFC
FFC
FFC
FFFFFFC
FFFFFFC
FFFFFFC
Definition of the damage mode
L T
Z
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 92
47
93
Damage model – 2
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 93
94
Tensile diagrams, 3D composite
• correct modelling of degradation
of stiffness
• reasonable evaluation of damage
initiation threshold
• qualitative representation of
intensity of damage S.V. Lomov - Textile Preforms for Composites - 5. Modelling 94
48
95
Progressive damage, 3D composite
S.V. Lomov - Textile Preforms for Composites - 5. Modelling 95
References
1. Bedogni, E., D.S. Ivanov, S.V. Lomov, A. Pirondi, M. Vettori, and I. Verpoest, Creating finite element model of 3D woven fabrics and composites:
semi-authomated solution of interpenetration problem, in 15th European Conference on Composite Materials (ECCM-15). 2012: Venice. p.
electronic edition, s.p.
2. Lamers, E.A.D., S. Wijskamp, and R. Akkerman, Modelling shape distortions in composite products, in Proceedings ESAFORM-2004. 2004:
Trondheim. p. 365-368.
3. http://www.optitex.com/
4. Sozer, E.M., S. Bickerton, and S.G. Advani, On-line strategic control of liquid composite mould filling process. Composites Part A: Applied Science
and Manufacturing, 2000. 31(12): p. 1383-1394.
5. http://www.esi-group.com/
6. Duhovic, M., P. Mitschang, and D. Bhattacharyya, Modelling approach for the prediction of stitch influence during woven fabric draping.
Composites Part A, 2011. 42: p. 968–978.
96 S.V. Lomov - Textile Preforms for Composites - 5. Modelling