A novel digital image correlation (DIC) technique has been developed to track changes in textile yarn orientations during shear characterisation experiments, requiring only low‐cost digital imaging equipment. Fabric shear angles and effective yarn strains are calculated and visualised using this new DIC technique for bias extension testing of an aerospace grade, carbon‐fibre reinforcement material with a plain weave architecture. The DIC results are validated by direct measurement, and the use of a wide bias extension sample is evaluated against a more commonly used narrow sample. Wide samples exhibit a shear angle range 25% greater than narrow samples and peak loads which are 10 times higher. This is primarily due to excessive yarn slippage in the narrow samples; hence, the wide sample configuration is recommended for characterisation of shear properties which are required for accurate modelling of textile draping.
The increasing demand for large, complex and low-cost composite aerostructures has motivated advances in the simulation of liquid composite moulding techniques with textile reinforcement materials. This work outlines the development and validation of a multi-physics process model that better simulates infusion behaviour through a complex preform compared with traditional models used in industry that do not account for fabric deformation. By combining the results of a preform draping model with deformation-dependent permeability properties, the shape and local flow characteristics of a deformed textile reinforcement have been more realistically defined for infusion. Simulated shear deformation results were used to define the distributed permeability properties across the fabric domain of the infusion model. Full-scale vacuum infusion experiments were conducted for a complex double dome geometry using a plain weave carbon fibre material. The multi-physics process model showed significant improvement over basic models, since it is able to account for the change in flow behaviour that results from local fabric deformation.
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