INTRODUCTION TO 2D WEAVING
The 2D weaving woven fabrics are made by interlacing the two components of yarn called warp and weft. The conventional weaving process used to form a 2D woven fabrics consisting of interlacing two orthogonal sets of yarns, warp 0 degree and weft 90 degrees, although it is not possible to have yarns in other in-plane orientation on the conventional 2D weaving loom.
WHAT
IS 3D WEAVING
A 3D
weaving is the process which allows the production of fabrics up to 10 cm in
thickness. In 3D fabric fibres placed in the thickness direction are called
z-yarn, warp weaver, or binder yarn for 3D woven fabrics.
In
this process more than one layer of fabric is woven at the same time, and
z-yarn interlaces warp and weft yarns of different layers during the process.
The
3D weave fabrics have substantial thicknesses, many times greater than the
diameters of the yarns.
In case of 3D weaving the constituent yarns cross at various angles between different layers to form a 3D mesh or a network like structure.
HOW 3D WEAVING DIFFERS FROM REGULAR WEAVING
In
standard regular 2-dimensional weaving weft threads are woven through warp
threads.
In
the simplest possible pattern, the weft alternates between passing above and
below the warp creating a single layer of fabric.
In
3-dimensional weaving, the main aim is to create thickness via stacking
multiple layers.
In
conventional weaving machines, the layering is achieved by dividing the warp
into multiple, separate sets.
PROCESS
OF 3D WEAVING
The
3D solid woven fabrics are manufactured by incorporating and manipulating yarns
in the length, width and the through-the-thickness directions.
Example:
WARP
yarns are called X yarns, WEFT yarns are called Y yarns and through the
thickness yarns are called Z yarns which is also known as Binder Yarns.
The weaving is also called as a single fabric system or 3 Phases.
DEVICES BEING USED
Many
of the structures can be made on the conventional weaving machines with little
modification but there have been successful attempts in developing new weaving
devices, particularly for making 3D woven fabrics.
Conventional
Weaving Machines
There
are mainly 3 methods:
1. By
effective utilization of warp and weft in single layer.
2. By
use of multi-layer warp and weft or multi-layer ground warp, binder.
3. Conventional
2D process can also produce pile fabrics by utilizing three sets of yarn,
single-layer ground warp, pile yarns.
New
Weaving Devices
The
new technology arranges warp yarns in a 3D form and allow weft yarns to be
inserted at different levels in one or two directions.
Example : Non-Interlacing Weaving Device
STRUCTURES
FORMED BY 3D WEAVING
3D
Structure:
In
particular 3D weaving structure, there will be no interlacing or crimp between
the yarns, they are arranged perpendicular to each other in X, Y and Z directions
and also thickness can be increased as well as high fibre volume fraction.
Based
on type of 3D structure:
3D Hallow:
The
architectures refer to tunnels running in warp and weft or any diagonal
directions with the thickness of the 3D architecture.
Flat
surfaces and other with uneven surfaces are the two different types of 3D
hollow architectures.
3D Shell
Structure:
It
is a structure comprising integrated single wall sections in the directions of
fabric width and without any tunnel like opening in fabric length thickness
defining a cross sectional shape direction.
3D Nodal
Structure:
Refer
to woven tubes, which are joined together comprising either integrated, single
walled or multi walled sections in the directions of fabric width an thickness
defining a cross sectional shape with either one or more tunnel like opening in
fabric length direction.
Based
on type of mechanism
1.
3D woven
2.
3D knitted
3.
3D non-woven
4.
3D Jacquard Design
5. Braided Structure
Based
on type of weaving process:
1.
2D weaving 2D fabrics
2.
3D weaving 3D fabrics
3. Noobing
Orthogonal
Woven Architecture
Angle-Interlock
Woven Architecture
A
structure with a set of straight weft yarns and warp yarns that weave with the
weft in a diagonal direction in the thickness.
Multilayer
Woven Architecture
The
layers are connected together through weaving by either the existing yarns
(self-stitching) or external sets of yarns (central stitching)
Three-Dimensional
Hollow Woven Preforms:
Mainly rigid yarns are used to form the structure and the structure consists of three or more layers of fabrics.
TYPES
OF FIBRES USED
The
most common fibres are:
Glass
Fibres
Aramid
Fibres
Carbon
Fibres
Steel Fibres
1.
GLASS FIBRES
The fibre
is available at low cost and the production rate of fibre is high.
The major properties of glass fibres are: High Stiffness, Non-Flammable, Good Chemical Resistance, Good Electrical Insulation
2.
ARAMID FIBRES
Aramid
fibre is an aromatic polyamide, better known by trade names such as Kevlar
(DuPont) and Twaron (Teijin Twaron)
The major properties of aramid fibres are: Low Density, High Strength, Good Abrasion Resistance, Good Chemical Resistance, Low Thermal Degradation, Insensitive To Moisture
3.
CARBON FIBRES
Carbon
fibre is composed of carbon atoms bonded and together to form a long chain.
The fibres
are extremely stiff, strong, and light, and are used in many processes to
create excellent building materials.
The major properties of carbon fibres are: Self Lubricity, Heat Resistant, Specific Tensile Strength, High Elastic Modulus
4.
STEEL FIBRE
Steel
fibre is a metal reinforcement, for reinforcing concrete is defined as short,
discrete lengths of steel fibres with an aspect ratio (ratio of length to
diameter) from about 20 to 100, with different cross-sections, and that are
sufficiently small to be randomly dispersed in an unhardened concrete mixture
using the usual mixing procedures.
The
major properties of steel fibre:
It has high tensile strength
It has good heat resistant
Fibre has high compressibility factor
Fibre has high thermal stability
APPLICATIONS
OF 3D FABRICS
Recently
3D woven fabrics have been finding increased usage in textile composite for
commercial structural application.
3D woven
fabrics are being used in a number of applications such as composite
reinforcement for construction automotive ballistic and various industrial
uses: for Marine application like carbon fibre preforms for high performance powerboats.
In medical
technology like artificial veins, arteries orthopaedic tubes, scaffolds,
artificial joints and organs etc.
Lightweight
constructions like rainforest section in automotive engineering and
aeronautics.
Woven
composite are idle for security applications where a
high level of protection is expected from the lightest possible components.
In transport
application and vehicle construction composite have major advantages
because lower weight of composite result in higher payload and lower fuel
consumption where it is used as drive shafts, oil pans, suspension arms, and
wheels.
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