Achieving Vertically-integrated Carbon-fibre Reinforcement Design and
Manufacture Demonstrators for Structural Manufacturing and
Construction 3-D Composites
Parminder Singh Kang1*, Yong Sun1, Chris Silva2 and Alistair Duffy1
1 Faculty
of Technology, De Montfort University, Leicester, UK
2 M Wright and Sons Limited, Quorn Mills, Quorn, Loughborough, UK
*De Montfort University, Faculty of Technology, The Gateway, Leicester, LE1 9BH, UK
E-mail: pkang@dmu.ac.uk
1. Introduction
6. Key Findings
Composites are widely used engineering applications. However a new range of composites called 3-D woven are not widely used
One of the key findings of this research is the significantly improved compression-after-impact strength over existing industrial
due to the lack of purposely designed analysis tools. The AVISC project developed designer equipment to evolve 3D woven
standards, which could enhance the life span and safety performance for products made out of advanced 3-D woven materials.
composites. These woven composites, have binder yarns used to stitch the layers of fabric together; essentially a three
The performances of 3-D woven materials are given in the graphs below:
1000
2. Aims and Objectives
Tensile Strength (MPa)
Tensile Stress (MPa)
which make each binder yarn. Two different sizes have been used; 3000 (3K) and 6000 (6K) respectively.
Panel 50
15 layer 3K
600
400
3 layer 3K
800
80
6K
700
70
600
60
500
50
40
400
200
E(3K)r
300
The main objective of this project is to achieve robust vertically-integrated design and manufacture for structural 3-D Carbon Fibre
0
30
E(6K)r
1
2
3
4
5
Tensile Strain
0
5
10
15
350
250
50
200
40
150
30
50
20
0
0
20
5
10
Maximum Stress (MPa)
20
3K
150
Panel 50
100
2
3
Number of Layers
Mean Compressive Strength and Modulus
4
5
6
Number of Layers
Mean Compressive-After-Impact
80
800
solid CAD models to weaving CAD enabling composites and reinforcement pre-forms to match user requirements.
15
6K
200
60
Mean Tensile Strength and Modulus
through the correlation of theoretical simulations and test results and the development of algorithms and software to relate 3-D
Panel 50
Panel 50
300
Number of Layers
composites to be used in the construction sector. Key innovations are the creation of mechanical-property knowledge (MPK)
250
70
6K
100
20
200
0
Tensile Strain (%)
Reinforced Composites (CFRCs) for the high-value manufacturing sector and woven 3-D reinforcements for concrete and
Maximum Stress (MPa)
Panel 50
800
CAI test:
Impact Energy: 34 J
3K
90
sCAI (MPa)
3K
900
Choid Modulus (GPa)
5 layer 6 K
300
80
Modulus (GPa)
dimensionally woven material with warp, weft and binder. In this research emphasis has been put on the number of filaments
400
5 layer 3K
Panel 50
600
60
400
40
Modulus (GPa)
1000
Panel 50
200
20
3K
6K
3. Research Method
0
0
0
5
10
15
20
Number of Layers
M Wright and Sons (MWS) have designed, commissioned and developed a unique CNC-controlled loom, with weaving CADCAM,
Mean Flexural Strength and Modulus
capable of weaving 3-D solid carbon fibre reinforcement pre-form (CFRP) sections, whilst several 3-D solid CAD and finite element
7. Potential Industrial Applications
packages are currently available. The MPK base is created as a result of the project’s iterative weaving, moulding, testing and
The improved performance of all 3-D weaving composites using AVISC means that they can be optimised for specific applications,
analysis stages. The application of data mining techniques, correlation analysis and neural networks are used to interrogate the
and can be better designed for specific crash test criteria standards as required. As such, they have tremendous scope in their
developed, practical MPK base, so that so that any 3-D structural composite CAD design that is in the realms of practical
application to high value manufacturing industries, for instance the wind energy, aerospace, automotive, construction and medical
manufacture can create a weaving pattern in the weaving CAD system through novel software, algorithms and communications
sectors, etc.
interfaces. The resultant CFRP pre-form should give a right-first-time prototype when moulded into a composite to give the desired
properties of the original CAD design.
Aerospace Industry; all future aircraft have strict economic efficiency criteria to adhere to, which means that many conventional
Undertake
Generate
3-D Solid CAD
model
Finite Element
Undertake
Finite
Element
Analysis
Analysis
(FEA)
(FEA)
Use Cosmos FEA
outputs to refine
CAD model
Use Scotcad
CAD/CAM software
to generate Loom
CNC program
materials will have to be replaced by composites. The Airbus the A350 XWB will be the first airbus to be over 50% composites
which is optimistic.
Wind Energy Sector; the use of AVISC to design and manufacture lighter and comparably cheaper components would mean that
competitive energy prices through wind energy would be possible. The price of wind energy depends upon the institutional
setting in which wind energy is delivered. This means that wind energy costs should be measured in terms of: production,
Test
RTM
Component and
Mould
Output results to
FEA
CFR
Component
Weave CFR
Preform using
CNC program
4. Manufacturing Technology
Currently composite parts are made by stacking multiple layers of fabrics to form the desired shapes and dimensions. However,
there are many significant issues with this manufacturing process:

it suffers from potential layer separation

it can involve sequential curing

it is labour intensive or involves complex automatic equipment

it can produce excess waste and may be difficult to obtain repeatability
operation and maintenance costs for running a wind farm, the price per kWh that wind energy can be sold at.
This approach has the advantage over conventional reliance upon oil and gas, in that the effective currency is the unit price of
energy itself.
Automotive Industry; there is a current lack of standardisation of sizing and surface treatment technologies associated with
carbon fibre technologies. In addition, the existing carbon fibre industry is not fully equipped to support large scale vehicle
manufacture. Because AVISC is based upon unique MPK data standardisation of sizing and surface treatment technologies need
not be an issue. Components would be designed and manufactured to fulfil a specific set of criteria, rather than adapting existing
CFRPs to fit those criteria.
Construction Industry; the opportunity to replace steel as reinforcement for concrete is worth £100billion in terms of global
demand. There are also a considerable number of existing reinforced structures which do not meet current design standards due
to inadequate design and/or construction or which need structural upgrading to meet new seismic design requirements. Given
The solution offered by the 3 D weaving composites is the capability to offer a preformed shape to the required dimensions. This
CFRPs’ inherent properties, such as high tensile strength, good fatigue and corrosion resistance and ease of use, AVICS is a
offers the possibility to reduce the manufacturing process from fabric to composites considerably since there is no need to layup.
particularly attractive solution for the construction industry.
Manufacturing tests conducted at MWS suggested a fabric preparation timing reduced by a factor of 6 when using a preform
against a normal layup.
Medicine; there are a large number of potential applications for AVISC. One of the most promising areas is in the surgical
application of Fracture Fixation Plates (FFPs) in the treatment of bone fractures. Accordingly, a bone fracture can be assisted by
The layup process requires trimming of the each individual layup to fit within the fabric stack. This operation is time consuming and
screwing a FFP across the junction of a bone fracture. However, this can interfere with normal bone physiology by stress sealing of
waste material. The infusion timing for 3D woven fabric is also quicker than a normal layup. This is due to the binder yarn running
the bone beneath the plates. Density of living bone is directly proportional to the stress applied. Therefore, AVISC allows for the
through the thickness. This allows for the resin to reach the middle of the fabric quicker. MWS in house testing revealed that for
design of an FFP with a similar elastic modulus to bone, which offers a significant advantage over metal FFPs.
the same fabric areal weight the timing required to infuse a 3D woven where half the one required to infuse a normal layup.
At the current state of art the 3D weaving capability developed at M Wright & Sons Ltd allows for “T,I,L,U” shaped carbon preform
to be produced .
Sports Goods; the shaft of golf clubs but also bicycle frames, forks, handlebars, seat posts and crank arms are increasingly made
from carbon fibre composites.
Also, there are many possible markets for CFRCs where stiffness and low weight is required, such as in musical instruments.
5. Results
In addition, due to the fire-resistance of polymers and thermo-set composites, carbon fibre composites are increasingly being
The new 3-D woven carbon composites were tested under various loading conditions, following the procedures in the appropriate
applied to situations where heat has been a problem in the past.
ISO standards. These tests include tensile test, compression test, flexural test, interlaminar shear strength test and compression-
The potential markets for AVISC are therefore only limited by the lack of MPK for a given application.
after-impact test. The results show that, as compared to the industrial standard carbon composite Panel 50, the 3-D woven
composites possess higher compressive strength, similar tensile and flexural strength and do not experience interlaminar shear
8. Acknowledgements
failure. Most importantly, the 3-D woven composites possess much higher compression-after-impact strength and thus are more
The authors would like to thank Technology Strategy Board (Project No: 101147 and TSB Reference: 13451-87159) and De
resistant to impact damage. It is also found that the mechanical properties of the 3-D composites are influenced by binder yarn
Montfort University for funding this research.
size.
For further details, please consult the AVISC Web Tool at: http://www.avisc.org