Department of Polymer Engineering Polymer Composites I.pt.bme.hu/~vas/Polymer...
Transcript of Department of Polymer Engineering Polymer Composites I.pt.bme.hu/~vas/Polymer...
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László M. Vas 1
Polymer Composites I.Fibrous Reinforcements
BMEGEPT9110, 2+0+0 lecture, 3 cr.
Lecturer: Prof. Dr. László M. Vas
Budapest University of Technology and EconomicsDepartment of Polymer Engineering
1. General Properties of Fibrous Structures
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Literature
Sources
1. Chou T.-W. and Ko F.K. (edited by): Textile Structural Composites. CompositeMaterials Series 3. Elsevier, New York, 1989.
2. Vas L.M.: Textiltermékek tervezése. Szerkezeti és makrotulajdonságok. BME PT Tanszék, Bp. 2000.
3. Stoyan D. und Mecke J. Stochastische Geometrie – eine Einführung. Akademie-Verlag, Berlin, 1983.
4. Zurek W.: The Structure of Yarn. Warsaw (Poland), Springfield (USA), 1975.
5. Hearle J.W.S, Thwaites J.J., and Amirbayat J. (editors): Mechanics of Flexible Fiber Assemblies. Sijthoff&Noordhoff, (NATO ASI Series) Alphen a.d. Rijn (Ned.), Germantown (USA), 1980.
Literature recommended
6. Vas L.M.: Idealized statistical fiber bundle cells and their application to modeling fibrous structures andcomposites (in Hungarian), (DSc), Budapest 2007. (http://pt.bme.hu/~vas/HAS_DSc_Thesis/)
7. Bolotin V.V.: Statisztikai módszerek a szerkezetek mechanikájában. Műszaki Könyvkiadó Bp. 1970.
8. Álló G., Főglein J., Hegedűs Gy.Cs., Szabó J.: Bevezetés a számítógépes képfeldolgozásba. Kézirat. BME MTKI. Bp. 1993.
9. Neckar B. and Ibrahim S.: Structural Theory of Fibrous Assemblies and Yarns. TU of Liberec, 2003.
10. Vetier A.: Szemléletes mérték- és valószínűségelmélet. Tankönyvkiadó Bp. 1991.
11. Gibson R.F.: Principles of Composite Material Mechanics. McGraw-Hill, New York, 1994.
12. Wulfhorst B.: Textile Fertigungsverfahren . Eine Einführung. Carl Hanser Verlag, München, 1998.
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Multiphase structures
Phase morphology of multiphase structures – in the case of
two components
Multiphase composed material structures:
• Polymer blends, alloys
• Filled polymers
• Composites: reinforced, fiber reinforced structures
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Reinforced composite
Composites*:
Multiphase (its parts are separated by phase boundaries), composed (is built up of
several types of material) structural material, the components of which are:
- reinforcement (fibrous structure of usually high strength and modulus ) and
- matrix (embedding material of smaller strength but high toughness ),
and it is characterized by the excellent connection (adhesion, high interfacial
strength) between fiber and that is maintained at high levels of deformation
and load.
*Czvikovszky T., Nagy P., Gaál J.: A polimertechnika alapjai. Műegyetemi Kiadó, Budapest, 2000. 368. old.
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Composites
Creating composite materials
• Metals (M)• Ceramics (C)• Polymers (organic) (P)• Composites created
M→M: steel fiber →Al (MMC – Al-foam composite);
C →C: glass fiber →cement (CMC – glass-concrete);
P →P: PET-fiber →PVC (PMC – roof-membrane)
M →C: steel →concrete (steel-concrete); P →C: cellulose fiber →clay (adobe)
C →M: ceramic →Al (ceramic foam comp.); M →P: steel →rubber (steel-radial tyre)
C →P: glass fiber →UP (UP resin comp.); P →M: ??? (carbon/PBO fiber+metallic
foam???)
László M. Vas
Composite:
X(fiber)→Y(matrix)
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Composite structures
Fiber Matrix
Glass fiber
Carbon fiber
Aramide (Kevlar™), PBO (ZylonTM) fiber
Boron fiber
Ceramic fiber
Natural fiber
Thermoplastics
Duromer
Elastomer
CeramicsMetals
*Czigány T.: Polimer kompozitok. Előadások. BME Polimertechnika Tanszék, Budapest, 2009.
Short fiber Filament fiber
ordered
disordered
ordered
disordered
Material combinations:
Fiber-orientation combination:
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Producing reinforcing structures,
reinforcements
Indirect reinforcing (regular or irregular textile
reinforcements):
Direct reinforcing (irregular reinforcing structure):
Composite
production
(Mixing)
Composite
production
(Embedding)
Textile
production
Composite
CompositeReinforcing
textiles
Fibers
Fibers
Matrix
Matrix
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Textile production and textiles
Textiles:
The primary output products of the textile industry, which are fibrous
materials made of fibers by textile technological operations such as
•spinning /forming of yarns/threads/rovings (opening /carding (to
flocks/fibers), ordering, uniting, drawing/drafting, twisting), and
•producing of fabrics/textile sheets (web-forming, weaving, knitting,
braiding).
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Human- and technical textiles
Human textiles• Clothing/garment textiles (work-, free-time-, and fashion-textiles);
• Home/Domestic-textiles (carpet, curtain, table-cloth, coverlet, bedcloths, etc.);
Technical textiles• Composite reinforcements;
• Traffic vehicles (covering, carpet), transportation;
• Indutech (industrial textiles: filter fabrics, lifting textiles, conveyor belts);
• Buildtech (construction textiles);
• Geotech (geotextiles);
• Agrotech (agro-textiles);
• Oeko/Ekotech (environmentally friendly textiles)
• Space research (spacesuits);
• Army/Military (camouflage, bulletproof vests)
• Protech (protective textile – personal/object e.g. against fire);
• Sporttech (sports textiles);
• Packtech (packaging textiles);
• Medtech (medical textiles)
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Structural
graph of
textiles
FiberYarnSheet
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Chapters for Fibrous Reinforcements
General properties of fibrous structures; classification, structure; properties of fibers; dimension, skeleton-space, density- and porosity-properties.
Fiber flows and fiber bundles, fiber flow types; fiber-diagrams, staple (hauteur) and beard (barbe) diagrams. SSTM fiber flow and the Martindale inequality.
Textile sheets of irregular structure; Poisson fiber mat model, linear vicinity, blindespot and pore size, properties of fibers intersecting a convex sample, area density; mechanical properties, deformation of fibers, energy based equations.
Bundle structure of textile samples, effect of gauge length, idealized statistical fiber bundles and expected tensile force processes. Estimation of tensile strength by Peirce.
Twisted structures, twist count, helix model, effect of twisting; Spun and filament yarns, thread, ropes; Probability of breakage, selecting yarn more suitable to given load.
Textile sheets of regular structure Binding cell, binding elements. Woven, knitted and braided structures. Description of regularity by plain patterns.
Structure and geometry of woven fabrics, basic weaves and their relation. Derived weaves and special technical fabrics.
Structure and geometry of knitted fabrics, special binding elements, knitted sheets of weft- and warp systems, reinforced structures. Properties of relaxed fabrics.
Strength properies of textile sheets and membranes. Evaluation of tensile test results. Linear orthotropic, monotropic and isotropic sheet models. Basics of designing technical textiles, layered- and cell-models. Special mechanical tests.
Nonlinear models of sheets. Kawabata’s models for woven and knitted fabrics. Bundle model of woven fabric sample. 3D reinforcing structures and applications.
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Fiber types applied to reinforcements
NATURAL FIBER:
Plant origin: (bast-, seed-, leaf-, fruit-, stalk-fibers)
Bast fibers: flax, hemp, jute
Animal origin: (wool or hair, worm/insect-silk, sea/shell-silk)
Gland secretions: natural silk (silkworm) (chord); <spider-silk>
Mineral origin:
Asbestos!!!
MAN-MADE FIBERS:
Natural based:
Plant origin: viscose (cord); <chitin, protein>
Mineral origin: basalt
Artificial based (synthetic):
Organic polymer: HPPE, polyester, polyamide, aramid (Kevlar),
PBO (Zylon)
Inorganic polymer: glass fiber, carbon fiber, ceramic fiber
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Basic properties and types fibers
Fibrous structures: 1D, 2D, 3D
Linear density: q=m(l)/l, 1 tex=1 g/km =1 mg/m
Slenderness ratio: λ=l/d Definition of textile fiber: 1D, λ=1000…5000…,
and they can be manufactured by textile technologies
Strength properties of fibers: specific strength [N/tex], breaking length [km]
Types of textile fibers:
• Filament – mono-
and multifilament
(length undefined)
• Staple/short-fiber
(length well defined)
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Geometrical properties of fibers 1.
Cross section of fibers• Convex shaped
• Concave shaped
• Hollow
Density properties of fibers• Volume and linear density
Properties of fiber length• Arc-length, chord-length, extent (projected length)
• Statistical properties (mean, standard deviation, beard-diagram, beard-length, short- and long fiber content,…)
Types of fiber shape• Straight, wavy, crimped, curly/kinky, hooked/looped/coiled – wavy shaped fibers, waviness/crimp
Properties of fiber surface• Even, uneven/rugged, grooved, slotted, pitted/broken, segmented
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Geometrical properties of fibers 2.
Cross section of fibers
Homogeneous fibers:
• Convex, concave, hollow
Inhomogeneous fibers:
• Bilateral (a), core/sheath (b),
fiber/matrix (c)
Natural fibers
Artificial/Man made fibers
Recently: application of
hollow glass fibers to self-
curing composites
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Geometrical properties of fibers 3.
Density properties of fibers:
Ultra-rough: > 10 dtex > 100 µm
Rough: 5…10 dtex 22…100 µm
Normal, medium 2…5 dtex 15…22 µm
Fine: 1…2 dtex 10…15 µm
Microfibers: 0,1…1 dtex 3…10 µm
Ultrafine: < 0,1 dtex 0,5…3 µm
Nanofibers < 0,01 dtex < 500 nm
Volume density, porosity
Linear density
Fiber Relativepore
volume%
Meanporesize
[nm]
CottonRamiWoolNatural silkViscoseAcetatePolyamide
2
7562
8…13,56556
Fiber fineness Lin. dens. Diameter
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Mechanical properties 1.Calculated strength properties of textile fibers
Specific tensile force (Q)
Specific breaking force (Qs)
Tensile stress (σσσσ)
Tensile- (σσσσB) and breaking strength (σσσσS)
Initial tensile stiffness (K)
Specific initial tensile stiffness (κκκκ)
K=AE[N]
Initial tensile modulus (E)
Formulae of Hooke’ law (tensile load andsmall deformation)
F =KεQ = κεσ = Eε
Breaking length (R)
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Breaking length of technical fibers
Weak LDPE foil Super-strong (high
performance)
HPPE: 400 km
Aramid (Kevlar):
235 km
Zylon (PBO): 450 km(E=270 GPa; σ
B=5,8 GPa
Tb=650oC; LOI=68)
Steel: 25-35 km(E=210 GPa,
σB=1,9 GPa; T
o=1425oC)
2016.10.27. www.dsm.com
Mechanical properties 2.
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Mechanical properties 3.
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Fiber paradoxes
Material Tensile strength, σσσσB[MPa]
Bulk form Fiber form Theoretical max.
Aluminum (Al)Iron, steel (Fe)
6001400
8004100
380011200
Polyethylene (HDPE)Polyethylene (HPPE)Polyamide (PA)Aramid (Kevlar)
303080-
10002000-3500
8503000
25000250002500025000
CarbonGraphite
(100)(100)
300020000
3500035000
GlassCeramics (Al2O3)
(100)200
40001600
1100026000
(1) Solid paradox: The tensile strength (σ
B) of fiber shaped materials is greater than that in bulk form, but less
than the theoretical one :
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Mechanical properties 4.
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Fiber paradoxes
(2) Fiber shape paradox:
While increasing the fiber diameter (d) the tensile
breaking force (FB) increases, but the tensile
strength (σB) decreases, that is if d1<d2 :
(3) Fiber length paradox:
While increasing the fiber gauge length (lo) the mean
tensile breaking force decreases, that is if lo1<lo2 :
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Mechanical properties 5.
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Fiber paradoxes
(4) Paradox of fiber blends :
Certain strength properties (X=S) of fiber
blends or hybrid fiber reinforced composites
may be better than those of the components.
Hence, if Si is the ith (i=1;2) component, S(α) is
the considered strength property of blend,
where α1=α and α2=1-α are the volume or
mass fraction of components, then for certain
blend ratios (0<α<1) it can stand that:
(Synergetic or hybrid effect)
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Mechanical properties 6.
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Fiber paradoxes
(5) Fiber bundle-paradox:
Because of the consecutiveness of the breakages taking place in a fiber bundle of n
fibers subjected to tensile load the measured bundle breaking force represented by the
maximum tensile force (Fn,max) normalized by the number of fibers (n) is smaller than
the mean tensile force of single fibers (FS). Hence the utilization factor of fiber
strength in the fiber bundle (ηn) can be defined :
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Fibers, fiber models 1.
Fiber shape properties
Straight (a), wavy (b), hooked (c) and
coiled (d) fiber shapes Arc length (lo) and chord length (l), chord
center (C) and extent (l1) of fibers of
different shapes
l1=l l1>l
Waviness/crimp #1:
Waviness/crimp #2:
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Fibers, fiber models 2.
Description of fiber curve/path, fiber surface
Center line of fiber and its
accompanying vector triple
Fiber as point set:
S = P(x,y,z)∈R3: r(s)=(x(s),y(s),z(s))∈Ck, s∈[so,so+lo]
Centerline vector-function:
r(s) = r(s;ω), ω∈Ω, so=so(ω), lo= lo(ω)
Vector of fiber surface point:
r(s,ϕ) = ro(s) + R(s,ϕ)[no(s)cosϕ + bo(s)sinϕ]
Chord length of fiber:
Fiber mass (q – linear density)
Possible stochastic variables (ω):
• starting point of fiber (so)
• fiber length (lo)
• fiber shape (r)
(tangent, normal, binormal)
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Fibers, fiber models 3.
Fiber orientation
Vector polygon approximating the
fiber curve
Orientation I: Defined by unit chord vectors of chain elements
Isotropic Uniaxial Biaxial
(planar)
Endpoints of fiber segment unit vectors
(ei) on the unit sphere:
Unit vector of ai is ei
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Bodor G.-Vas L.M. Polimer anyagszerkezettan
Műegyetemi K. Bp. 2000.
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Fibers, fiber models 3a.
Fiber orientation
Measurement and evaluation using gradient method
E.g. fibers of a glass fiber mat (machine direction: 90o)
Orientation I: Orientation angle distribution
of fiber-element-vectors detected in an
digital image of the fibrous structure
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Vas, L.M., Balogh, K.: Investigating Damage Processes of Glass Fiber
Reinforced Composites Using Image Processing, Journal of Macromolecular
Sciences Part B – Physics, Vol. B 41(4-6), 977-989 (2002)
(Laplace-Gauss)
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Fibers, fiber models 4.
Fiber orientation
Orientation II: Defined by the chord vector of the fiber
Joint probability density function of the
independent angle co-ordinates of the fiber chord
vector:
The small surface element, dA=sinv dudv, on the
surface (∂Go) of unit sphere Go=G(0,1) defines a
space-angle and the probability that a unit chord
vector falls in this infinitesimally small space-angle
is proportional to q(φ,θ)(u,v)dA. Hence the
distribution function of the fiber orientation is as
follows:
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Fibers, fiber models 5.
Fiber orientation – orientation tensor
Orientation II: Defined by fiber chord vector
Orientation vector of a fiber: p=(pi) unit vector:
A simpler parametric characterization of the fiber orientation is the expected value of
the orientation tensor (see: covariance matrix) than the joint distribution of the
orientation angles
• Orientation tensor, P, is the tensorial
or diadic self-product of orientation
vector, p.
• The expected value of P tensor
is given by the expected value of the
tensor-elements:
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(E(p)=0T
on the whole sphere)
[E(P)=D2(p) és E(pipj)=cov(pi,pj) on the whole sphere]
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Fibers, fiber models 6.
Fiber orientation – orientation tensor
Measuring orientation: on polished cross sections of an injection molded plate
Measuring by image processing software: • Sizes of the small (d=2b) and large (2a≥d ) axes
of intersection ellipse of fibers and the inclination
angle (α) of the large axis related to axis y. Calculated from these:
• Inclination angle (β) of fibers related to axis z :
•Supposing that a fiber takes up the orientation angles
β or -β with the same probability hence the measured
β∈ [0, π/2] angles can be extended by mirroring over
the domains [0, π] or [-π/2, π/2].
• The measured α angles falling into interval [0, π], can
be extended by translation over [0, 2π] corresponding
to π -period. α↔φ, β↔θ
2016.10.27.(x↔1, y↔2, z↔3)
Sample: 80x80x2 mm
Polished: 3 at edge, 3 in the middle
Image: 10 image/polished section
Polished-sections
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Fibers, fiber models 7. Fiber orientation – orientation tensor
Measuring orientation: by image analysis of polished cross sections (PCS)
Joint angle distribution (injection molded composite):
α↔φ, β↔θ
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PCS: 3rd position (in the middle (z); at the edge (x))
Frequency
θ [degree]ϕ [degree]
Length
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Fibers, fiber models 8. Fiber orientation – orientation tensor
Measuring orientation: by image analysis of polished cross sections (PCS)
Orientation tensor (x↔1, y↔2, z↔3):
Main diagonal elements along the thickness (y)
Edge-distributions:
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In the sheath: p33 is large, p11 is small, p22i is very small
In the core: p33 is small, p11 is large, p22 is very small
Position 3: in the middle, at the edge
Position 3: in the middle, at the edge
Place of measurement, y [µm]
ϕ [degree]
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Fiber sets, fiber flows 1.
Fiber set: fiber assembly of same properties
Fiber space: spatial structure created by fibers
Unoriented and oriented fiber sets or spaces
Isotropic (a) and uniaxially (b), as well as biaxially (c)
oriented anisotropic fiber sets or spaces
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Fiber sets, fiber flows 2.
Fiber flow - types
Types of uniaxial fiber flows (a): scheme of linear (b) and elementary
linear (c), simple linear (d), evenly continuous linear (e), elementary
contonuous linear (f), regular (g) and Zotyikov-type (h) fiber flows
Fiber flow: It is an oriented fiber space where the chord vectors of fibers create a
statistical stream-space that is they follow certain spatial stream-lines tangentially or
regarding their position and orientation they scatter about those trend-like lines.
Fiber: In general
it is modeled by
its chord vector.
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Fiber sets, fiber flows 3.
Fiber bundle: a set of fibers related to one another in some way
Definition of fiber bundle types:
Set of contacting fibers (a, b) and set of
fibers intersecting a given cross section (c, d)
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Fiber sets, fiber flows 4.
Twist-oriented fiber flows
Yarn (a) and solenoid (b)
as twist-oriented (circular) fiber space
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Properties of convex ranges 1.
Mean diameter
Diameter of convex range A
measured in direction of vector a
in the plane (k=2)
The mean diameter of convex range A∈ℜk is the average of diameters
mesured in every possible direction (like by caliper rule) (k=1,2,3) :
•paA = Projection of range A to
straight line of orientation vector a
• Go = unit sphere
• ∂Go = surface of unit sphere
• λk=k-dimensional volume (k=1,2,3)
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Properties of convex ranges 2.
Mean diameter
Application of LUCIA image analysator
software to marked fiber cross sections
PETP fiber cross section shapes
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Concave range mean diameter?Convexizing e.g.: by envelope ellipse, area-
equivalent circle/ellipse
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Properties of convex ranges 3.
Spherical vicinity (G)
Spherical vicinity of point (a) and convex range (b)
in one- and two-dimensional spaces
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ρ(P,Q)= distance of points P and Q (here: euklidean distance)
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Properties of convex ranges 4.
Linear/Fiber vicinity of point P (a)
and range A (b) in plane
Oriented, linear, or fiber-vicinity
Components of linear vicinity (B) of a 2D
range (A):
• Ao=fiber core (often empty)
• B\intAo=H(r,α,β,∂A)=edge-vicinity
(∂A is the edge of A)
Linear vicinity H(r,α,β,P)⊂Rk of orientation eo(α,β) and radius r for point P :
For a range A:
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Dimension of textiles 1.
Convex hull/envilope: the tightest convex set containing textile Γ
Convex hull (a), ε-body (b) of textiles and
representation in case of yarns (c)
Construction of εεεε-body: from convex hull, or given
formation 2016.10.27.
[0.01 mm]
Gray level density histogram
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Dimension of textiles 2.
Convex hull – measurement of ε-body
Diameter of
non-transparent
(e.g. carbon)
fiber or yarn
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εεεε-body :
coaxial cylinder
Diameter of
transparent
(e.g. glass)
fiber or yarn
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Dimension of textiles 3.
DimensionThe dimension of textile ΓΓΓΓ is 1≤k≤2 if the tightest real subspace W⊂R3, that is the
skeleton space of the textile is of k-dimensions, and for the convex hull of ΓW ,
denoted by WΓ, where ΓW is the projection of Γ into W (ΓW⊂WΓ⊂W), the following
conditions stand:
(1) Textile Γ can be laid on the skeleton space W without cutting up. This means that
textile Γ can be moved in a position without cutting up that W forms a kind of middle
surface (skeleton space) of Γ and there can be found such a (minimum) real number,
δ>0, for which the δ/2 radius spherical vicinity (G) of WΓ covers textile Γ:
Γ⊂G(δ/2, WΓ)
(2) Textile Γ is concentrated about skeleton space W meaning that δ is negligibly small to
the sizes of textile Γ in W, di(Γ) (i=1,...,k), (δ is less by at least 1-3 magnitudes) that is
for textile Γ of finite sizes it stands:
min d1(Γ), ... ,dk(Γ) >> δ
Textile Γ is of 3 dimensions, that is k=3, if there cannot be found such true W subspace
in R3. In this case W=R3.
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Dimension of textiles 4.
Density properties of textile structures
• Density of textiles (apparent density)
• Characteristic density
• ε-body density
λk = k-dimensional volume (k=1, 2, 3)
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KΓ = convex hull of Γ
WΓ = convex hull of ΓW
KΓε = ε-body of Γ
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Dimension of textiles 5.
Porosity properties of a textile structure
• Porosity of textiles (apparent porosity)
• ε-body-porosity
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ρo = volume density of the fiber material
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Dimension of textiles 6.
Definition of a sample
Convex sample cut out of a textile structure (real or model)
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Real sample:
Model sample (projection):
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Dimension of textiles 7.
1D Textiles
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Fiber
Sliver
Yarn
Thread
String
Rope
Strap, belt
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Dimension of textiles 8. 1D textiles
3.8-micron diameter carbon nanotube yarn that
functions as a torsional muscle when filled with an
ionically conducting liquid and electrochemically
charged
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Linear density spectrum of fibers and linear textiles
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FIBERS YARNS STRINGS/ROPES
Linear density
Dimension of textiles 9.
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Dimension of textiles 10.
2D textiles
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Web, fleece Woven fabric Braided sheet
Fiber mat Knitted sheet Knotted net
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Dimension of textiles 11.
2D textiles
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Dimension of textiles 12.
Area density ranges of 2D textiles
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Area density
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Dimension of textiles 13.
3D textile products
3D textile products made by tailoring (confectioned) (a)
and without tailoring (b)
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Dimension of textiles 14.
3D textiles and composite products
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Dimension of textiles 15.
Volume density ranges of 1-3D textiles
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Volume density
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Dimension
of textiles
16.
Geometrical
and mechanical
quantities in
case of
1D, 2D, and
3D structures
(Practical switch-number of
density and breaking
length: 103)
Properties Dimension of textiles
k = 1 k = 2 k = 3
Geometrical properties
Sizes of brick-shaped sample (lx)
l=length l=lengthb=width
l=lengthb=width
h=thickness
Cross section area (Ak) in skeleton space (SS) ⊥⊥⊥⊥to x
A1=0 A2=b A3=A=bh
Volume in SS (Vk) V1=l V2=bl V3=V=bhl
Characteristic density (ρρρρk) and measure unit
Strength properties
Characteristic specific force in direction x
Fx=F [N]
Specific force related density (Qx)
Hooke’s law for tensile load in x-direction Fx=K1εx fx=K2εx σx=K3εx
Characterizing tensile-stiffness (Kk)
K1= bhE =AE [N] K2=hE [N/m] K3=E [N/m2]
Specific tensile stiffness related to density (κκκκk)
Breaking length inx-direction (Rx)
2016.10.27.