Designing of 3D woven integrated T-joint tube

Abstract

T-joint tube composites have huge potential applications in structural engineering. The paper tries to find an easy way to design and manufacture woven integrated T-joint tube by the theory of ‘flattening-weaving-unfurling’. The difficulty in smoothly unfurling the flattened woven structure lies in the wrinkles formed at the crossing area of the two tubular members, which is analyzed in detail. The key to solve the problem is to increase the extensibility of the structure. A four-layer interlocked hollow woven structure with sandwiched weft wicks in a mini-hole was designed to give the fabric the ability of being extended after part of the wick yarns have dropped out. The parameters of the structure, such as base weave, weft density, number, and thickness of the wick yarns, are investigated to evaluate their effects on the extensibility of the structure. To achieve a higher extensibility, the final structure design should have the following features: coarse wick yarn, relatively higher weft density, 2/2 twill base, and number of wick yarns less than four. By using NedGraphics Jacquard CAD (Computer Aided Design) system, the contour of the crossing area of the T-joint tube was designed, the weaves in different sections of the fabric were assigned, and a JC5 format file was exported to control a normal electronic Jacquard loom to weave the structure. The final experiment indicates that the 3D T-joint tube can be unfurled smoothly and the method of the design is visually verified to be effective.