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六角形编织工艺、结构和性能及编织结构复合材料整合设计
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摘要
沿织物成型方向取向的三根或多根纤维(或纱线)按不同的规律运动,从而使纤维(或纱线)倾斜交叉,并相互交织在一起,形成织物,称为编织。编织技术主要分两维编织技术与三维编织技术。两维编织是两个系列纱线相互缠绕形成的织物结构。三维编织技术是两维编织技术的延伸,三维编织结构是通过3根或3根以上纱线缠绕或交织以及位移改变而形成的整体结构,在厚度方向上一般包含三根或三根以上纱线。两维编织和三维编织产品在复合材料预制件、生物医用产品开发等方面有较广泛应用。两维编织机器结构较简单,主要有平带编织、圆形编织、径向编织等。三维编织主要有纵横编织、三维旋转编织等。为满足一些新型领域需求,开发一种能利用细丝进行微观编织的编织机器具有很大发展空间。新发明的六角形编织能满足此要求,并且具有生产多角形预制件的独特能力。因此,对三维六角形编织工艺、结构和性能进行研究具有一定意义。同时,为更好利用编织技术进行复合材料预制件设计,综合传统两维编织原理、三维编织原理以及新开发六角形编织原理开发一种编织结构预制件整体化设计软件包具有重要意义。
     本文主要研究工作有:(1)六角形编织机器原理、构建方法。根据六角形编织基本原理,从硬件和软件系统两个方面分别详细讲述新型六角形编织机器的实现。(2)六角形编织结构模拟仿真。采用Matlab编程语言,基于编织结构形成过程,编写模拟六角形编织结构软件包,对六角形编织预制件细观结构进行模拟仿真。(3)六角形编织的多角形结构分析。研究利用三维六角形编织法编织多角形预制件的方法,然后针对典型三角形预制件进行详细分析,并进一步探讨主要工艺参数对该结构复合材料性能的影响。(4)编织结构预制件整合化设计软件包编写与设计参数研究。依据两维编织技术、三维编织技术、六角形编织技术基本原理编写进行编织结构预制件整合设计的软件包。然后,基于一些编织结构预制件设计结果,分别对编织工艺以及编织预制件主要参数进行系统研究分析。为合理设计编织预制件提供理论依据。
     论文主要结论:
     (1)所建造的六角形编织机器采用高精度步进电机驱动,基于Labview软件开发平台自定义编写程序控制,具有很大灵活性、可扩展性。该六角形编织机同时具备利用微观细丝进行精细化编织能力;可实现最大数目纱线承载。
     (2)实践证明利用Matlab语言编写的模拟仿真软件包能够对六角形编织预制件微观结构进行有效模拟仿真,并且该程序具有开放性,可进一步扩展,为研究编织结构预制件内部结构提供了一个有效工具。
     (3)研究发现六角形编织具有编织多角形预制件的独特能力。通过新型六角形编织预制件(三角形)的细观结构分析发现,预制件包含内部单胞、面单胞和角单胞三类单胞模型。然后对复合材料弹性常数进行研究,发现六角形编织复合材料和四步法编织复合材料力学性能存在一定差异。
     (4)利用Matlab软件开发的编织结构复合材料整合设计软件包能够对两维编织、三维编织以及六角形编织预制件进行预先设计,通过一些预制件设计实例证实了该软件包的可靠性与实用性。可有效指导开发人员进行预制件设计。
     (5)基于所开发的编织结构复合材料整合设计软件包,对编织工艺与编织结构预制件进行参数化研究,发现以下规律:对两维编织而言,编织速度与编织角度存在很大关系;编织纱和轴纱线密度及其比率对纤维体积分数都具有重要影响。对三维编织而言,编织尺寸由编织纱数目和编织角确定;编织角度、编织纱线粗细对纤维体积分数有影响。在相同编织角下,带轴纱六角形编织结构具有比带轴纱笛卡尔式编织结构更高纤维体积分数;但在不含轴纱情况下,笛卡尔式编织纤维体积分数要高于六角形编织。
A braid is a complex structure or pattern formed by intertwining three or more yarns or fibers along fabric forming direction. The braiding technology mainly includes two dimensional (2D) and three dimensional (3D) braiding techniques.2D braiding technology is an skill in which a braid is formed by interwineing two sets of yarns.3D braiding technology is an extension of2D braiding technology. Several types of2D braiding machines exist such as flat braiding machine, circular braiding machine,radical braiding machine and so on.3D braiding can be classified as Catesian (track and column) braiding and rotary3-D (horngear) braiding. To meet the requirement of new fileds, development of a new braiding machine which can use micofilament to braid is promising. The novel hexagonal braiding machine can meet the need and is capability of fabricating polygonal cross-sectional preforms. Therefore, it is of benefit to investgate the process, structures, properties of hexagonal braiding. Meanwhile, it is of great value to develop a integrated design package to guide the design of braided preforms based on the principles of traditional2D braiding,3D braiding and novel3D hexagonal braiding.
     The main research in the thesis includes:(1) The principle and building of hexagonal braiding machine. According to principle of hexagonal braiding, achievement of hexagonal braiding was investigated from hardware and software system aspects.(2) Simulation of hexagonal braiding. A software package for simulating the hexagonal braided structures was developed based on hexagonal braiding process by Matlab programme.(3) Hexagonal braided structures with polygonal cross-sections were analysized. The method to fabricate polygonal structures using hexagonal braiding was introduced and a type of braids with triangular cross-section was studied in detail.(4) Software package for integrated design for manufacturing of braided preforms and parametric study. According to principles of2D braiding and3D braiding technology and hexagonal braiding, a software package for integrated design of braided preform was programmed. Based on design results of different preforms, some important parameters of braiding process and braided preforms were studied. It provides theoretical basis for designing braided preforms.
     Conclusion:
     (1) The hexagonal braiding machine built is very flexibility, ease to enlarge as it is controlled by high precision digital step motor and control software system is programmed through open Labview platform. The braider is able to precisely fabricate fabric using microfilaments. Maximum number of yarns can be loaded in limited area.
     (2) It is proved the software package developed by Matlab can effectively process simulation of hexagonal braided preforms. The program is open and could be further expanded. It could be an important tool to investigate interior structures of hexagonal braided performs.
     (3) It is found that hexagonal braiding has unique capability of fabricating preform with polygonal cross-section. Through microscopic analysis of braided structure with triangular cross-section, it can be seen the preform is consist of interior cells, facial cells and corner cells. The properties of hexagonal braided composites were studied. The results show some differences between hexagonal braided composite and4step braided composites.
     (4) The software package developed using can be used as a useful tool to process design of2D braiding,3D braiding and hexagonal braiding. Its reliability and practicality is shown by some samples.
     (5) Based on integrated design software package, some important parameters were studied. The results show braiding speed and braiding angle have a great matter and the linear density and their ratio have great effect on fiber volume fraction of preform for2D braiding. For3D braiding, the dimension of preform is determined by number of braiding yarn and braiding angle. Also, given parameters of a preform, the machine set-up can be derived; Braiding angle and linear density of braiding yarn have effects on fiber volume fraction of braided preform. Fiber volume fraction of hexagonal braided preform without axial yarn is lower than that of4-step braided preform without axial yarn. But it is converse with axial yarns.
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