Numerical Modelling of the Weaving Process for Textile Composite
Authors: Vilfayeau Jerome , Crépin David , Boussu François , Soulat Damien , Boisse Philippe 
Published: June 2013

Due to advancements made in 3D weaving process [1] and, in order to develop 3D textile structure as reinforcement of composite material for aeronautic application, a good prediction of the geometry and the mechanical properties of the 3D woven unit cell is required. Due to the complexity of these textile architectures, realistic geometric representations [2] of fabrics are often difficult to obtain especially for 3D woven fabrics, but these descriptions are necessary to define meshes for finite element computation [3]. At present, existing tools which model and define, early at a mesoscopic scale [4], the architecture of 3D fabrics don’t take into account the influence of the manufacturing process on the shape modification of the textile structure. Some numerical model exists for the braiding process [5] and the knitting process [6], but not yet for the weaving process. During the manufacturing process, fibres are subjected to significant deformations due to loads from the component of the loom or from the friction with the others fibres. These significant deformations lead to mechanical strength losses of the fabric. A numerical model of the different steps of the weaving process could predict these significant deformations and their influence on the geometry of the textile architecture. Thus, the objective of the NUMTISS project is to develop a numerical model of the deformation of the yarn during the weaving process. For the numerical modelling of the weaving process developed in finite element method, we considered all loom elements like rigid solid, and we will make the assumption that yarns are transverse isotropic elastic materials. Simulations of the process for a plain weave, a twill 2-2 and a satin 8 fabric have already been performed, as well as the simulation of orthogonal warp interlock structures. Then, to understand the kinematic motions of weaving process, the tracking of some strategic elements on the industrial weaving loom (reed, heddles, rapier,..) have been carried out. The tracking obtained from the video of the high speed camera will help us to define the numerical model of the weaving kinematic closer to reality. Correlations between numerical results and specific structures in glass fibres produced on the loom will be presented. The influence of each step of the manufacturing process on the characteristics of the textile structure could be analyzed [1]X. Chen, L. W. Taylor, L. J.Tsai. ”An overview on fabrication of three-dimensional woven textile preforms for composites”. Textile Research Journal, 2011, 81(9) 932–944 [2] SV Lomov, G Perie, DS Ivanov, I Verpoest and D Marsal. “Modeling three-dimensional fabrics and three-dimensional reinforced composites: challenges and solutions”. Textile Research Journal, 2011, 81(1) 28–41 [3] E. De Luycker, F. Morestin, P. Boisse, D. Marsal. « Simulation of 3D interlock composite performing”. Composite Structures, Volume 88, Issue 4, May 2009, Pages 615-623. [4] M. Ansar, W. Xinwei, Z. Chouwei. “Modeling strategies of 3D woven composites: A review”. Composite Structures 93 (2011) 1947–1963. [5] A. K. Pickett, J. Sirtautas, et A. Erber. « Braiding simulation and prediction of mechanical properties”. Applied Composite Materials, 2009. [6] M. Duhovic, D. Bhattacharyya. “Simulating the deformation mechanisms of knitted fabric composites”. Composites Part A : Applied Science and Manufacturing, 2006.