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Design and Manufacture of Textile Composites PDF

479 Pages·2005·6.603 MB·English
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Design and manufacture of textile composites i © Woodhead Publishing Limited, 2005 Related titles from Woodhead’s textile technology list: 3-D textile reinforcements in composite materials (1 85573 376 5) 3-D textile reinforced composite materials are obtained by applying highly productive textile technologies in the manufacture of fibre preforms. The damage tolerance and impact resistance are increased as the trend to delamination is drastically diminished due to the existence of reinforcements in the thickness direction. 3-D textile reinforcements in composite materials describes the manufacturing processes, highlights the advantages, identifies the main applications, analyses the methods for prediction of mechanical properties and examines the key technical aspects of 3-D textile reinforced composite materials. This will enable materials scientists and engineers to exploit the main features and overcome the disadvantages in relation to laminated composite materials. Green composites (1 85573 739 6) Life cycle assessment is becoming increasingly important at every stage of a product’s life from initial synthesis through to final disposal, and a sustainable society needs environmentally safe materials and processing methods. With an internationally recognised team of authors, Green composites examines polymer composite production and explains how environmental footprints can be diminished at every stage of the life cycle. This book is an essential guide for agricultural crop producers, governmental agricultural departments, automotive companies, composite producers and materials scientists all dedicated to the promotion and practice of eco-friendly materials and production methods. Bast and other plant fibres (1 85573 684 5) Environmental concerns have regenerated interest in the use of natural fibres for a much wider variety of products, including high-tech applications such as geotextiles, and in composite materials for automotive and light industry use. This new study covers the chemical and physical structure of these natural fibres; fibre, yarn and fabric production; dyeing; handle and wear characteristics; economics; and environmental and health and safety issues. Details of these books and a complete list of Woodhead’s textile technology titles can be obtained by: ∑ visiting our website at www.woodheadpublishing.com ∑ contacting Customer Services (e-mail: [email protected]; fax: +44 (0) 1223 893694; tel.: +44 (0) 1223 891358 ext.30; address: Woodhead Publishing Limited, Abington Hall, Abington, Cambridge CB1 6AH, England) ii © Woodhead Publishing Limited, 2005 Design and manufacture of textile composites Edited by A. C. Long CRC Press Boca Raton Boston New York Washington, DC W OODHEAD PUBLISHING LIMITED Cambridge England iii © Woodhead Publishing Limited, 2005 Published by Woodhead Publishing Limited in association with The Textile Institute Woodhead Publishing Limited Abington Hall, Abington Cambridge CB1 6AH England www.woodheadpublishing.com Published in North America by CRC Press LLC, 6000 Broken Sound Parkway, NW, Suite 300, Boca Raton FL 33487, USA First published 2005, Woodhead Publishing Limited and CRC Press LLC © Woodhead Publishing Limited, 2005 The authors have asserted their moral rights. This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. Reasonable efforts have been made to publish reliable data and information, but the authors and the publishers cannot assume responsibility for the validity of all materials. Neither the authors nor the publishers, nor anyone else associated with this publication, shall be liable for any loss, damage or liability directly or indirectly caused or alleged to be caused by this book. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming and recording, or by any information storage or retrieval system, without permission in writing from the publishers. The consent of Woodhead Publishing Limited and CRC Press LLC does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specific permission must be obtained in writing from Woodhead Publishing Limited and CRC Press LLC for such copying. Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe. British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library. Library of Congress Cataloging in Publication Data A catalog record for this book is available from the Library of Congress. Woodhead Publishing Limited ISBN-13: 978-1-85573-744-0 (book) Woodhead Publishing Limited ISBN: 10-1-85573-744-2 (book) Woodhead Publishing Limited ISBN-13: 978-1-84569-082-3 (e-book) Woodhead Publishing Limited ISBN-10: 1-84569-082-6 (e-book) CRC Press ISBN 0-8493-2593-5 CRC Press order number: WP2593 Thepublishers’ policy is tousepermanentpaper from mills that operate a sustainable forestry policy, and which has beenmanufacturedfrompulp which is processed usingacid-free andelementarychlorine-free practices. Furthermore, the publishers ensure that the text paper and cover board used havemet acceptable environmental accreditation standards. Project managed by Macfarlane Production Services, Markyate, Hertfordshire ([email protected]) Typeset by Replika Press Pvt Ltd, India Printed by T J International Limited, Padstow, Cornwall, England iv © Woodhead Publishing Limited, 2005 Contents Contributor contact details ix Introduction xiii A C LONG, University of Nottingham, UK 1 Manufacturing and internal geometry of textiles 1 S LOMOV, I VERPOEST, Katholieke Universiteit Leuven, Belgium and F ROBITAILLE, University of Ottawa, Canada 1.1 Hierarchy of textile materials 1 1.2 Textile yarns 2 1.3 Woven fabrics 10 1.4 Braided fabrics 27 1.5 Multiaxial multiply non-crimp fabrics 35 1.6 Modelling of internal geometry of textile preforms 47 1.7 References 60 2 Mechanical analysis of textiles 62 A C LONG, University of Nottingham, UK, P BOISSE, INSA Lyon, France and F ROBITAILLE, University of Ottawa, Canada 2.1 Introduction 62 2.2 In-plane shear 63 2.3 Biaxial in-plane tension 73 2.4 Compaction 88 2.5 References 107 3 Rheological behaviour of pre-impregnated textile composites 110 P HARRISON and M CLIFFORD, University of Nottingham, UK 3.1 Introduction 110 3.2 Deformation mechanisms 111 3.3 Review of constitutive modelling work 116 3.4 Characterisation methods 129 v © Woodhead Publishing Limited, 2005 vi Contents 3.5 Forming evaluation methods 137 3.6 Summary 142 3.7 Acknowledgements 142 3.8 References 143 4 Forming textile composites 149 W-R YU, Seoul National University, Korea and A C LONG, University of Nottingham, UK 4.1 Introduction 149 4.2 Mapping approaches 149 4.3 Constitutive modelling approach 155 4.4 Concluding remarks and future direction 175 4.5 Acknowledgements 178 4.6 References 178 5 Manufacturing with thermosets 181 J DOMINY, Carbon Concepts Limited, UK, C RUDD, University of Nottingham, UK 5.1 Introduction 181 5.2 Pre-impregnated composites 181 5.3 Liquid moulding of textile composites 187 5.4 References 196 6 Composites manufacturing – thermoplastics 197 M D WAKEMAN and J-A E. MÅNSON, École Polytechnique Fédérale de Lausanne (EPFL), Switzerland 6.1 Introduction 197 6.2 Consolidation of thermoplastic composites 198 6.3 Textile thermoplastic composite material forms 205 6.4 Processing routes 217 6.5 Novel thermoplastic composite manufacturing routes 233 6.6 Conclusions 236 6.7 Acknowledgements 236 6.8 References 237 7 Modeling, optimization and control of resin flow during manufacturing of textile composites with liquid molding 242 A GOKCE and S G ADVANI, University of Delaware, USA 7.1 Liquid composite molding processes 242 7.2 Flow through porous media 244 7.3 Liquid injection molding simulation 247 7.4 Gate location optimization 254 © Woodhead Publishing Limited, 2005 Contents vii 7.5 Disturbances in the mold filling process 259 7.6 Active control 268 7.7 Passive control 274 7.8 Conclusion 285 7.9 Outlook 286 7.10 Acknowledgements 288 7.11 References 288 8 Mechanical properties of textile composites 292 I A JONES, University of Nottingham, UK and A K PICKETT, Cranfield University, UK 8.1 Introduction 292 8.2 Elastic behaviour 292 8.3 Failure and impact behaviour 312 8.4 References 327 9 Flammability and fire resistance of composites 330 A R HORROCKS and B K KANDOLA, University of Bolton, UK 9.1 Introduction 330 9.2 Constituents – their physical, chemical, mechanical and flammability properties 332 9.3 Flammability of composite structures 346 9.4 Methods of imparting flame retardancy to composites 349 9.5 Conclusions 359 9.6 References 360 10 Cost analysis 364 M D WAKEMAN and J-A E MÅNSON, École Polytechnique Fédérale de Lausanne (EPFL), Switzerland 10.1 Introduction 364 10.2 Cost estimation methodologies 366 10.3 Cost build-up in textile composite applications 374 10.4 Case study 1: thermoplastic composite stamping 382 10.5 Case study 2: composites for the Airbus family 396 10.6 Conclusions 402 10.7 Acknowledgements 402 10.8 References 402 11 Aerospace applications 405 J LOWE, Tenex Fibres GmbH, Germany 11.1 Introduction 405 11.2 Developments in woven fabric applications using standard prepreg processing 406 © Woodhead Publishing Limited, 2005 viii Contents 11.3 Carbon fibre multiaxial fabric developments 408 11.4 Improvement in standard fabric technology for non-prepreg processing applications 416 11.5 Braided materials 417 11.6 Tailored fibre placement 418 11.7 Preforming 419 11.8 Repair of fabric components 423 12 Applications of textile composites in the construction industry 424 J CHILTON, University of Lincoln, UK and R VELASCO, University of Nottingham, UK 12.1 Introduction 424 12.2 Fibre reinforced polymers 424 12.3 Membrane structures 426 12.4 Case studies 429 12.5 Future developments 431 12.6 References 435 13 Textile reinforced composites in medicine 436 J G ELLIS, Ellis Developments Limited, UK 13.1 Splinting material 436 13.2 Walking support frame 438 13.3 Bone plates 439 13.4 General application 441 13.5 Living composites 442 14 Textile composites in sports products 444 K VAN DE VELDE, Ghent University, Belgium 14.1 Introduction 444 14.2 Materials 445 14.3 Design 447 14.4 Production technology 449 14.5 Applications 450 14.6 Conclusion 456 14.7 Acknowledgement 456 14.8 References 456 Glossary 458 © Woodhead Publishing Limited, 2005 Contributor contact details Introduction Chapter 2 Professor A.C. Long Professor P. Boisse School of Mechanical, Materials and Laboratoire de Méchanique des Manufacturing Engineering Contacts et des solides University of Nottingham LaMCoS, UMR CNRS 5514 University Park INSA de Lyon Nottingham NG7 2RD Bâtiment Jacquard UK 27 Avenue Jean Capelle 69621 Villeurbanne Cedex Email: [email protected] France Chapter 1 Email:[email protected] Professor S. Lomov and Professor I. Verpoest Professor A. C. Long Katholieke Universiteit Leuven School of Mechanical, Materials and Department of MTM Manufacturing Engineering Kasteelpark Arenberg 44 University of Nottingham B-3001, Heverlee University Park Belgium Nottingham NG7 2RD UK Email: [email protected] Email: [email protected] Email: [email protected] Dr F. Robitaille Faculty of Engineering Dr F. Robitaille 161 Louis Pasteur Faculty of Engineering Room A306 161 Louis Pasteur Ottawa, Ontario Room A306 Canada K1N 6N5 Ottawa, Ontario Canada K1N 6N5 Email: [email protected] Email: [email protected] ix © Woodhead Publishing Limited, 2005

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