The novel woven spacer fabrics consist of upper and lower layers which are connected through internal crosslinks. The aim is to weave spacer fabrics with woven crosslinks in a single production step as near net shape sandwich preforms. By this way reproducible and automated manufacturing of sandwich preforms for composites are realized. The paper deals at first with the conception of a new weaving and take-up technology of complete spacer fabrics without subsequent textile assembly processes. Afterwards, the special technology is described, and finally the paper deals with a simulation model for the prediction of dynamic warp thread forces in order to minimize fiber damage during weaving process.
Weaving of near-net-shape spacer structures is an efficient way to produce preforms for fiberreinforced composites. The preforms are woven using non-crimp fiber arrangement in warp and weft directions. For getting a better insight into the weaving process as well as to analyze warp thread forces, a simulation model has been developed. This enables calculations under variation of machine and process parameters to minimize warp thread forces. The aim in conjunction with this is downsizing the tensile stress of threads for reducing fiber damage. The high potential of the noncrimp fiber arrangement is demonstrated in consolidated 2D composite sheets and 3D spacer composites.
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