Fibre reinforced polymer matrix composites are used frequently in aerospace applications. Manufacturers of aerospace components favour composites over traditional metallic alloys due to their light weight, high modulus, corrosion resistance and fatigue resistance. Advantages of composites for non-structural interior components over metallic include: ease of manufacturing for single parts of complex geometry as opposed to assemblies, cheaper manufacturing of a limited series of parts and composites greatly reduced noise, vibration and harshness. However, manufacturing interior composite components requires critical attention to detail during the preforming stages and handling of dry fabric textiles. Since these components are handmade they often yield lower profits and therefore efficient preforming is critical. Designing draping strategies for industrial liquid composite moulding processes requires a significant amount of time and testing, in simulation and also working on physical moulds. Mould and part surfaces are often defined by a number of geometric features, labelled base surfaces in the context of this thesis, which can be used to quickly probe multiple draping strategies and identify the best one. Traditionally, trial and error work is performed over a full mould surface until a working or acceptable draping strategy is found, rarely identifying the best strategy. The work in this thesis presents the initial development stages for a draping predictive tool aimed at quickly probing multiple draping scenarios in simulation prior to receiving moulds and identifying the best draping strategy for industrial non-structural aerospace composites. A multi-parameter remodelling tool – the conical frustum – was developed for uniformly identifying base surfaces through 12 geometric parameters linked into a database of in-plane shear and yarn orientations results. The development of the database is discussed, detailing Taguchi methods of experimental design used for developing linear functions from the database results, which allow interpolation of results on base surfaces that do not directly exist within the database. This thesis also includes major developments for the core draping algorithm used for linking individual base surface results together when probing draping strategies. Further investigations were performed on unique elements of in-plane shear behaviour that are encountered during draping, so that these could ultimately be considered during the development of this version of the draping algorithm whilst others may be included in future developments.

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As part of the Composite Technology for Exploration (CTE) project at NASA, woven fabric composites are being investigated for their use in Space Launch System (SLS) hardware. Composites are more difficult to analyze than isotropic materials and require more complex methods for predicting failure. NASA is seeking a method for predicting the damage initiation and propagation of woven fabric composites in order to utilize these materials effectively in SLS hardware. This work focuses on notched woven fabric composites under tensile loading. An analytical model consisting of a macro-level failure criterion and damage propagation was developed and implemented in explicit finite element analysis to simulate woven composite materials. Several failure criteria and propagation models were investigated and compared. A response surface was used to better understand the effects of damage parameters on the failure load of a specimen. The model chosen to have best represented the physical specimen used the Tsai-Wu failure criterion. Additional physical tests are needed to further validate the model. / Master of Science / A composite material consists of two or more different materials that are joined together to form a new material with improved properties. Woven fabric composites weave strips of fibers and a bonding material into a pattern to increase the material’s ability to withstand loads in various directions. NASA is seeking a method to predict the conditions under which woven fabric composites will break. A greater understanding of the capabilities of woven fabric composites will help NASA improve the structures involved in space exploration. This work attempts to build an analytical model that can predict the loads under which a woven fabric composite will break in tension. Several different analytical theories were used to model a woven fabric composite and the results were compared with lab tests. One of the theories, the Tsai-Wu failure criterion, was selected as the best representation of the physical specimen. Further additional physical tests are necessary to further validate the analytical model.

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I have explored the combination of sound, textile and space. How can one create textiles to use as sound dampening material in an arts and craft practice? To enhance the architectural aspect of textile as one of the five building materials I have chosen to weave walls. Walls don´t have to be straight or go from floor to ceiling but they should somehow create room and divide the space. I felt the need of walls working within Konstfack because of the distraction of fellow students in the open space classroom. Torn walls tells a story, we see the left traces. These traces I wanted to convert into woven textile. Sounds of people and objects in public spaces bounces between hard surfaces often without dampening, this creates an environment that causes stress and distraction. In Virginia Wolf´s essay “A room of Ones Own” (1929) she points at how important it is to create a workspace for the professional you, to take place and be part of the public realm. A big part of this master project has been making the actual materials to build with and executing fibre. Does the material do the job of sound absorption? Wool and silk both have a fibrous cell, which is suitable for sound absorption they also have low flammability and is biodegradable; therefore I chose to work mainly with these fibres. I share my knowledge through the experience of the space I create. How to create o Room of one´s own in an open office.

Thesis (PhD)--Stellenbosch University, 2015. / ENGLISH ABSTRACT: Dunnage bags are an inflatable dunnage variant, positioned and inflated between goods in multi-modal containers to restrain and protect the goods while in transit. This project endeavours to develop a simple method of generating new numerical prototypes for dunnage bags suitable for simulating operational loading of the bags. Previous research has produced a model that simulates the inflation of a paper dunnage bag using a simple pressure load. A dunnage bag reinforced with plain-woven polypropylene was chosen as the test case. Woven polypropylene is a highly non-linear, non-continuous, non-homogeneous material that requires specialised material models to simulate. A key aspect of this project was to develop a simple method for characterising woven-polypropylene and replicating it's response with material models native to LS-DYNA. The mechanical response of the plain-woven polypropylene was tested using a bi-axial tensile test device. The material response from physical testing was then mapped to two material models using the numerical optimiser LS-OPT. The response of the calibrated material models was found to correlate well with the measured response of the woven material. Dunnage bags are subjected to cyclic loading in operation. In order to capture the effects of compressing the contained gas, a gas inflation model was added to the model that calculates the pressure in the bag based on the Ideal Gas Law. A full bag model making use of the calibrated material models and the inflation model was subjected to a cycled boundary condition simulating loading and unloading of an inflated dunnage bag. The two prototype models captured the pressure drop in the bag due to material plastic deformation and the restraining force produced by the bag to within 10 %. The prototype models were also found suitable for predicting burst pressure in voids of arbitrary size and shape. / AFRIKAANSE OPSOMMING: Stusakke is 'n opblaasbare soort stumateriaal wat tussen goedere in multimodale vraghouers geposisioneer en opgeblaas word om sodoende die goedere vas te druk en te beskerm tydens vervoer. Hierdie projek poog om 'n eenvoudige manier te ontwikkel om nuwe numeriese prototipes vir stusakke, geskik om operasionele lading van die sakke te simuleer, te ontwikkel. Vorige navorsing het 'n model ontwikkel wat die opblaas van 'n papier stusak met eenvoudige drukkrag simlueer. 'n Hoë-vlak stusak versterk met plein-geweefde polipropileen, is gekies om getoets te word. Geweefde polipropoleen is 'n hoogs nie-lineêre, onderbroke, nie-homogene materiaal wat gespesialiseerde materiaalmodelle nodig het vir simulasie. Een van die fokuspunte van hierdie projek is om 'n eenvoudige metode te ontwikkel om die karaktereienskappe van polipropoleen te identifiseer en die gedrag daarvan na te maak met die materiaalmodelle van LSDYNA. Die meganiese reaksie van die plein-geweefde polipropoleen is getoets met 'n biaksiale/tweeassige trektoets-toestel. Die materiaal se reaksie op die fisiese toets is ingevoer op 'n numeriese optimiseerder, LS-OPT, om op die materiaalmodelle te toets. Die reaksie van die gekalibreerde materiaalmodelle het goed gekorelleer met die gemete reaksie van die geweefde materiaal. Stusakke word tydens diens onderwerp aan sikliese lading. Om die effek van die saamgepersde gas vas te stel is 'n gas-opblaasbare model bygevoeg by die model wat die druk in die sak bereken, soos gebaseer op die Ideale Gas Wet. 'n Volskaalse sakmodel wat gebruik maak van die gekalibreerde materiaalmodelle en die opblaas-model is onderwerp aan sikliese grensvoorwaardes wat die lading en ontlading van 'n opblaasbare stusak simuleer. Die twee prototipe modelle het die drukverlies in die sak a.g.v. die materiaal-plastiek vervorming en die bedwingingskrag van die sak beperk tot 10 %. Die protoyipe modelle is ook geskik bevind om barsdruk in arbitrêre leemtes te voorspel.

Sculptural Textiles is a material investigation exploring sculptural possibilities for machine woven textiles. Two important factors are yarn combinations and textile construction, and how these two together can result in fabrics that can be manipulated by hand into shapes and thus adaptable to various settings. The essence of this project is in the meeting between contrasts such as shiny-dull, elastic-stiff, transparent-opaque, natural and synthetic and how these meetings can create sculptural qualities. The project is aiming to create a range of sculptural textiles as well as being an exploration in material. Construction and density are tools to bring forth the beauty and function of the materials. The result is a range of textiles showing that small changes in material and construction can lead to different sculptural characteristics.

The present research aims at engineering design of military helmet shells with continuous 3D woven fabric reinforcements for improved protection at a lighter weight and a reduced cost. The research was carried out using both the experimental and numerical methods. The results proved that the designed 3D woven wadded through-the-thickness angle interlock (TTAI) fabrics can be successfully moulded as continuous reinforcements for the doubly curved military helmet shells; therefore, costs in pattern cutting in the current composite helmet making process are eliminated. An improved ballistic performance was also demonstrated in the continuously reinforced composite structures. The wadding yarns added into the conventional TTAI fabrics enhanced the mechanical properties along the warp direction significantly. Improved composite in-plane isotropy was achieved by using the wadded TTAI fabrics as reinforcements. The locking angle method was modified based on the deformation behaviour of TTAI fabrics and was used to predict and evaluate the mouldability of both conventional and wadded TTAI structures. Mouldability factor, defined from the locking angle, assists the design and selection of continuous reinforcements that are of the appropriate mouldability. The mouldability limit of a PASGT (Personnel Armour System for Ground Troops) helmet shell was determined as 25.54. Thus, TTAI fabrics with mouldability factor no larger than this value are capable of continuously reinforcing the doubly curved shape. Ballistic tests and post-mortem examinations through ultrasonic C-scan and X-ray computed tomography (CT) demonstrated the advantages of the continuously reinforced composite in energy absorption. Up to 19.3% more of the kinetic energy was absorbed by the continuously reinforced panel through generating a delamination volume that was twice as large as that of the discontinuously reinforced one, and the delamination damages were distributed over a wider area. Under the same level of fabric mouldability and composite areal density, the panels reinforced with fewer plies of heavier fabrics performed better. The wadded TTAI reinforced composite panel demonstrated the optimal ballistic resistance by showing a 25.5% thickness increase and 55.3% penetration through the thickness. The 3D wadded fabric and 2D plain weave fabric continuously reinforced flat panels presented an equivalent ballistic performance. Meanwhile, further numerical analyses were conducted based on the digitally obtained geometry of a PASGT helmet. Although the ballistic limits varied from location to location, an equivalent ballistic limit of the helmet shell was noticed for the PASGT shell when compared to its flat counterparts. The military helmet shells reinforced by 3D wadded TTAI fabrics continuously offer improved ballistic performance. This is attributed to the preserved reinforcement continuity and the enhanced through-the-thickness properties. The research provides a novel reinforcing strategy for the construction of future composite military helmet shells.

published_or_final_version / abstract / toc / Electrical and Electronic Engineering / Master / Master of Philosophy

This study investigates the effects of Z-pinning on the delamination performance in opening and shear loading modes in woven fabric reinforced / epoxy composite materials, as well as the effects of friction between specimen crack faces and the Z-pin failure mechanisms involved in mode II delamination. Mode I and mode II delamination tests are carried out on Z-pinned unidirectional (UD) and woven laminates. Both UD and woven laminates exhibit enhanced delamination resistance and crack propagation stability through Z-pinning. The effects of various structural and Z-pin parameters on the mode I and mode II delamination behaviour are separately assessed. The 4ENF testing configuration is deemed as the appropriate mode II configuration for the testing of Z-pinned laminates. A new basic friction rig is used to measure the friction coefficient between crack faces in woven laminates. An additional friction effect attributed to fibre architecture is identified. A specially designed delamination specimen is used to overcome the difficulty of accurately measuring crack propagation in Z-pinned woven fabric materials and aid data reduction using the available analytical methods. The failure mechanisms involved in the mode II delamination of Z-pinned laminates have been investigated with the implementation of a new test. Z-pins fail under shear loading through a combination of resin crushing, laminate fibre breakage, pin shear, pin bending and pin pullout. The balance of the failure mechanisms is shown to be a function of the crack opening constraint, material type, stacking sequence, Z-pin angle and insertion depth to Z-pin diameter ratio. Z-pin and material parameters influencing Z-pinning quality are identified, categorised and quantified. The importance of controlling Z-pin insertion depth is underlined and updated manufacturing procedures are proposed. Partial pinning appears as an advantageous alternative. A reduction in in-plane stiffness and in-plane strength in UD and woven fabric composites is measured, whilst no significant change of in-plane shear stiffness of UD materials is observed. A reduction in the fibre volume fraction is the single most important parameter affecting the in-plane stiffness. The performance of a Z-pinned sub-structural component is investigated. Enhanced loading carrying capacity and damage tolerance is achieved through Z-pinning.