24th month meeting wp 3 presentation

24th Month Meeting WP 3 presentation

GZE Florence, 20.09.12 www.3D-LightTrans.com

AuthorFazeli, Monireh (TUD)

GZE Florence, 19.02.13 WP 3 | M.Fazeli

A Project co-funded by the EC in the 7th Framework Programme

Agenda

Brief overview of WP3 Background Structure and progress update WP 3 highlights during M1-M24 Selected exploitation results WP 3 future planning

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Research partners06 University Gent (UGent)08 Technische Universität Dresden (TUD)

Industrial partners10 Lindauer Dornier GmbH (Dornier)12 PD Glasseiden GmbH Oschatz (PD-Goschatz)13 NV Michel van de Wiele (VdW)

Work package objective The research focus is on the production processes and the related manufacturing

systems for the processing of 3D shaped as well as deep-drapeable woven fabrics made of hybrid yarns.

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WP 3-Manufacturing process for 3D textile fabrics



Tasks:Task 3.1: Manufacturing of hybrid yarn finishedTask 3.2: Manufacturing of semi-finished preforms 20% (a) weaving technology for multilayered fabrics (b) weaving technology for 3D-shaped fabrics (c) inline prefixation of semi-finished fabrics

Deliverables:D3.8: adapted air-mingling machine completeD3.9: two special adapted looms (deviation) in agreement with the coordinator, the new deadline is 31/01/2014

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WP 3: Structure and progress update

II/11 III/11 IV/11 I/12 II/12 III/12 IV/12 I/13 II/13 III/13 IV/13 I/14 II/14 III/14Task 3.1Task 3.2

D 3.8 / MS6 15D 3.9 / MS 8 24



WP 3 Highlights during M1-M24

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Milestone 6 Manufacturing of the hybrid yarn

Matrix filament

Reinforcement filament

Commingledhybrid yarn

Laboratory machine RMT-D

Opening and mingling throughair jet!



Trials of the hybrid yarn composition (preliminary trials with GF/PP) : Testing different glass fibre yarn counts Different fibre-matrix ratios Different matrix materials (thermoplastics)

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WP 3 Highlights during M1-M24Milestone 6 Manufacturing of the hybrid yarn



Optimization of the hybrid yarn manufacturing: Changing the machinery parameters

Yarn feeding speed Process speed Air pressure Adjustment of the flyer (yarn tension)

Evaluation of an optimized hybrid yarn: Optical: homogenous mixture, bulkiness, closure of the yarn (low bulkiness),

fibre damages, Hairiness processability at weaving process

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Yarn architecture and yarn Count Final specification of the hybrid yarn:

Mixture ratio of 70:30 % mass content (GF/PET)

Yarn count of 840 tex

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Milestone 8 provided multilayered fabrics

Provided multilayered fabrics by TUD




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Referring to the telcon on 12.10.2012

Multilayer fabric (NCFV) Warp layers: 4 Weft layers: 5

Weft and warp yarn: GF/PET 840 tex mixture ratio of 70:30 % mass content Z-yarn: GF/PET 840 tex mixture ratio of 70:30 % mass content and PET 583 dtex

Weft density: 240 yarns /10cm Warp density: 240 yarns /10cm Z-yarns density: 24 yarns /10 cm (GF/PET) and 120 yarns/10 cm (PET)

Estimated thickness of composite: 2 mm

Final fabric structure

Milestone 8 Multilayer, 3D-shaped weaving processes




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This information was sent to PD-Goschatz on 04.12.12 to start yarn production process.

TUD received the yarn material from PD-Goschatz on 07.02.13

Calculation of yarn amount after inquiry of partners



GF/PET 840 TexWeft yarns (m) 319800 Weft yarns (kg) 269Warp yarns (m) 246000 Warp yarns (kg) 207Z-yarns (m) 38400 Z-yarns (kg) 33Sum(m) 604200 Sum(kg) 509

PET 583 dtexZ-yarns (m) 384000 Z-yarns(kg) 23



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New Dornier loom specification

Type of the machine :Rapier weaving machine

Width of the fabric: 100 cm to Max150cm

Number of heald frames : max 20

Thickness of the fabric: Max 10mm

Speed : Max 405 rpm

4 Electronic warp let-offs




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Warping yarn materialStarting to weave on new Dornier loom

Estimated date of availability of fabric:31.04.2013

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Next steps to prepare production of multilayer fabric





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Intense discussion with TU Dresden concerning the weave structure: VDW-NCFV-120:4-300:5

Weft and warp yarn : GF/PET 840 tex

Z-yarns: PET 583 dtex and GF/PET

For each plate: 5 weft and 4 warp layers

Density of the yarns :

For the plate section: • 300 weft/10cm/plate • 120 warp/10cm/plate• Thickness of the plate: approx. 2 mm

For the wall section: • 150 wefts/10cm/wall (for one wall with 3 weft layers)• 60 warps/10cm/wall (for one wall)


WP 3 Highlights during M19-M24 (VDW)



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1. Project and background info transferred to involved engineers.

2. Choice of machine setup for chosen weave structure= Choice of fabric and weave structure-related parts: weaving accessories

3. First choice of machine layout

4. Weaving procedure

5. Second choice of machine layout





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2. Choice of machine setup for the chosen weave structure

Choice of reed density: 300 dents/meter

Choice of yarns/beam

• Width of fabric: 1500 mm

• Tot. no. of yarns on GF/PET (840 tex) groundbeam: 1800 yarns

• Tot . no. of yarns on GF/PET (840 tex) pilebeam: 1800 yarns





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3. First choice of machine layout A. Choice of motion mechanism

controlled fabric motion

B. Required tension on outer plate warp yarns

C. Yarn supply system for z and wall warp yarns





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4. Weaving procedure

Preparation for programming of PLC

Zone A : weaving of outer plates Zone B : weaving of transition structure Zone C and D: weaving of wall layers Zone E: Weaving of transition structure Zone A2 : weaving of outer plates





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5. Second choice of machine layoutBased on new weaving machine platform: increased functionality and immediately up to date.

Optimized lever system dimensioning and positioning

Drive system dimensioning and positioning





Selected WP 3 exploitable results

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N. Exploitable result

Exploitable result manager

Beneficiaries involved

Relevant WPs

Relevant deliverables

Progress %

Expected Date of achievement

Weaving equipment (1)

Van de Wiele TU-D WP1, WP3, WP6

D1.2, D2.7, D3.9, D6.16

20% June 2014

Weaving equipment (2)

Dornier TU-D WP1, WP3, WP6

D1.2, D2.7, D3.9, D6.16

30% June 2014

Adapted air mingling machine

PD-GOschatz

TU-D, UGent WP1, WP3, WP6

D1.2, D2.7, D6.16

100% June 2012



As a result, hybrid yarn with glass fibre was developed and produced

by PD-Goschatz with different fibre volume content and yarn count

GF/PET hybrid yarns with a mixture ratio of 70:30 mass content %

(55:45 volume content %) and a yarn count of 840 tex was

determined as the best yarn architecture

The results are important to achieve demonstrator requirements

(WP1,WP 2 and WP 4)

TUD, VdW and Dornier will use the yarn to produce the 3D-shaped

weaving and multilayer fabric

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Exploitable Result : Manufacturing of hybrid yarn



Weaving trials

a) Multilayered weaves and spacer fabric

b) Inline pre-fixation

Deliverable 3.9

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WP 3 Future planning



Thank you for your attention!

Questions?

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24th month meeting wp 3 presentation

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