Advances in forming and numerical simulation research of tufted composite preforms

Three-dimensional composite materials have great application value in aerospace and other fields due to their excellent anti-delamination capability. In recent years, they have attracted extensive attention from domestical and abroad researchers. However, for the traditional three-dimensional (3D) composite materials, they require long manufacturing cycles, complex manufacturing technique and are hard to be formed. This has become one of the key challenges restricting the broad application of the 3D composite components. Tufting is a simple single-sided stitching technique characterized by non-interlocked structure. This feature probably allows three-dimensional preforms made by tufting to be shaped on curved surfaces without defects. Firstly, this paper outlines the development of tufting technology and the structural characteristics of tufted composite materials. Secondly, it reviews existing research on forming tufted preform with curved mold, focusing on three aspects: Formability analysis, definition of forming defects, and digital characterization methods. It points out the progress made in current research and the shortcomings that still exist. Furthermore, it summarizes the numerical simulation methods for the forming process of tufted preform, highlighting the specific forming model of the tufted preform. Finally, it explores the future direction of tufting technology in the field of forming for composite materials.