Geometric modeling of 3D woven preforms in composite T-joints

A common method to fabricate net-shaped three-dimensional (3D) woven preforms for composite T-joints is to weave flat 3D preforms via a standard weaving machine with variation in binder yarn path and then separate the preform in the form of a bifurcation. Folding introduces fiber architecture deformation at the 3D woven bifurcation area. In this paper, a geometric modeling approach is proposed to represent the realistic fiber architecture, as a preprocessor for finite element analyses to predict composite structural performance. Supported by X-ray micro-computed tomography (µCT), three important deformation mechanisms are observed including yarn stack shifting, cross-section bending, and cross-section flattening resulting from the folding process. Furthermore, a set of mathematical formulae for simulation of the deformations in the junction region are developed and satisfactory agreement is observed when compared with μCT scan results.