Quasi-fiber scale modelling of 3D woven preforms
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摘要: 3D机织复合材料在航空航天领域有着广泛应用，作为复合材料的增强结构，纤维预制体的几何构造对复合材料的力学性能有着决定性影响。但预制体是一种柔性结构，在成型过程中容易发生显著的几何结构变异，包括纱线路径的变化和截面的挤压变形。实现预制体的精细化、高保真度建模是对复合材料进行性能预测和结构设计的重要前提。针对碳纤维3D机织预制体的复杂纤维结构，基于虚拟纤维的概念提出了准纤维尺度建模方法，模拟了织造过程中纱线的运动和变形，实现了预制体的精确重构。利用Micro-CT技术表征了预制体样件的内部单胞结构，验证了模型的可靠性。Abstract: 3D woven composites are widely used in the aerospace field. As a reinforcement structure, the geometry of fiber preform has a decisive influence on the mechanical properties of composites. However, a preform is a flexible structure that is prone to significant geometric variation during the molding process, including yarn path changes and compressive deformations of cross-sections. Achieving refined and high-fidelity modeling of preforms is an important prerequisite for performance prediction and structural design of composite materials. Aiming at modeling of the complex fiber structure for carbon fiber 3D woven preforms, a quasi-fiber scale modeling method based on the concept of virtual fiber was proposed. Movements and deformations of yarn in the weaving process were simulated, and high precision model of 3D woven preform was constructed. The Micro-CT technology was used to analyze the unit cell structure inside the preform sample, which verified the reliability of the model.
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Key words:
- 3D woven preform /
- virtual fiber /
- woven composites /
- Micro-CT technology /
- fiber structure /
- modelling
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图 1 3D机织预制体单胞结构示意图：((a), (b)) 经纬纱交织结构；((c)~(f)) 经纱路径
Figure 1. Schematic diagram of unit cell structure for 3D woven preform: ((a), (b)) Warp and weft woven structure; ((c)-(f)) Warp paths
图 2 (a) Micro-CT测试；(b) 预制体表面形貌
Figure 2. (a) Micro-CT test; (b) Surface morphology of the preform
图 3 3D机织预制体经纱模型：(a) 虚拟纤维模型；(b) 经纱路径示意图
Figure 3. Warp yarn model of 3D woven preform: (a) Virtual fiber model; (b) Schematic diagram of warp yarn
Lweft—Horizontal spacing between adjacent weft yarns; h—Interlayer spacing of weft yarns
图 4 3D机织预制体初始状态模型：(a) 纱线交织结构；(b) 经向截面；(c) 纬向截面
Figure 4. Numerical model of 3D woven preform in loose state: (a) Woven structure; (b) Cross-section along warp direction; (c) Cross section along weft direction
图 5 3D机织预制体张紧过程仿真结果：(a) 位移云图；(b) 应力云图
Figure 5. Simulation results of the tightening process for 3D woven preform: (a) Displacement contour; (b) Stress contour
U—Displacement value; S—Stress; S11—Stress experienced in the x-axis direction
图 6 3D机织预制体虚拟纤维模型和Micro-CT图像对比：((a)~(c)) 虚拟重构模型；((d)~(f)) Micro-CT图像
Figure 6. Comparison between virtual fiber model and Micro-CT images of 3D woven preform: ((a)-(c)) Virtual fiber model; ((d)-(f)) Micro-CT images
图 7 纱线几何信息提取：((a), (b)) Micro-CT图像；((c), (d)) 虚拟纤维模型
Figure 7. Geometric information extraction of the yarns from: ((a), (b)) Micro-CT images; ((c), (d)) Virtual fiber model
$A_{\rm{weft\_section}}^{\rm {CT}}$—Area of the weft cross-section in the CT image; $A_{{\rm{weft\_section}}}^{{\rm{model}}}$—Area of the weft cross-section in the virtual fiber model; $A_{{\rm{warp\_section}}}^{{\rm{CT}}} $—Area of the warp cross-section in the CT image; $A_{{\rm{warp\_section}}}^{{\rm{model}}}$—Area of the warp cross-section in the virtual fiber model
图 8 虚拟纤维模型与Micro-CT图像经纱路径对比：Warp-1 (a)、Warp-2 (b)、Warp-3 (c)、Warp-4 (d)
Figure 8. Comparison between warp paths extracted from virtual fiber model and the Micro-CT images: Warp-1 (a), Warp-2 (b), Warp-3 (c), Warp-4 (d)
图 9 虚拟纤维模型与Micro-CT图像纬纱路径对比：Weft-1 (a)、Weft-2 (b)、Weft-3 (c)、Weft-4 (d)
Figure 9. Comparison between weft paths extracted from virtual fiber model and the Micro-CT images: Weft-1 (a), Weft-2 (b), Weft-3 (c), Weft-4 (d)
图 10 虚拟纤维模型与Micro-CT图像纱线横截面面积对比：(a) 经纱横截面；(b) 纬纱横截面
Figure 10. Comparison between cross sectional area of virtual fiber model and the Micro-CT images: (a) Cross sectional area of warp yarn; (b) Cross sectional area of weft yarn
图 11 经纱张紧收缩量ΔU对预制体结构的影响：((a)~(c)) ΔU=0.25 mm；((d)~(f)) ΔU=0.63 mm；((g)~(i)) ΔU=0.75 mm
Figure 11. Effect of warp yarn shrinkage value ΔU on fiber structure of the preform: ((a)-(c)) ΔU=0.25 mm; ((d)-(f)) ΔU=0.63 mm; ((g)-(i)) ΔU=0.75 mm
图 12 不同张紧条件下虚拟纤维模型与Micro-CT图像纱线路径对比：(a) 经纱路径；(b) 纬纱路径
Figure 12. Comparison of virtual fiber models with Micro-CT images yarn paths under different tensioning conditions: (a) Warp path; (b) Weft path
表 1 3D机织预制体建模参数
Table 1. Modeling parameters of 3D woven prefabrications
Modeling parameter aweft bweft bwarp Lweft h Value/mm 2.450 0.550 0.600 1.188 0.064 Notes：aweft, bweft—Major and minor axes of the weft cross-section; bwarp—Minor axes of the warp cross-section. 
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