Shape-morphing structures based on pressure actuation promise efficiency gains and performance improvements in aviation but require complex three-dimensional geometries. The compliance of these morphing structures originates from areas of locally reduced wall thickness. However, the required high wall thickness ratios are challenging for integral fabrication from high-performance fiber-reinforced plastics, demanded to achieve high load-bearing capacity. This chapter presents a new approach for textile-based manufacturing of pressure-actuated cellular structures (PACS) using weaving technology. The chapter aims to identify manufacturing constraints from the textile process, incorporate them into the PACS cross-section design, and determine a suitable preform architecture for woven flexure hinges in PACS. Different woven flexure hinges made from a glass fiber-polyamide hybrid yarn are examined for application in PACS. The anisotropic flexure hinges are mechanically characterized under pure axial and pure bending loading in an adapted tensile and column bending test. The specimens are further assessed by leakage testing, optical microscopy, and thermogravimetric analysis. This work demonstrates that the bending stiffness of woven flexure hinges can be determined in simple mechanical tests, without the need for complex modeling of reinforcing fibers and manufacturing-induced anisotropy. The mechanical properties of a flexure hinge with a double-layer fiber arrangement are superior to those of a single-layer fiber arrangement, while integrating additively manufactured PA6 inlays into the woven preform offers an effective approach for achieving high wall thickness ratios. The combination of terry and spacer weaving is well suited for manufacturing preforms for three-dimensional cellular structures. However, consolidating the woven preform in compression molding remains challenging and requires technological improvements before fabricating a functional PACS prototype for experimental validation.

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Production-Induced Characteristics of Woven Flexure Hinges

  • Patrick Meyer

摘要

Shape-morphing structures based on pressure actuation promise efficiency gains and performance improvements in aviation but require complex three-dimensional geometries. The compliance of these morphing structures originates from areas of locally reduced wall thickness. However, the required high wall thickness ratios are challenging for integral fabrication from high-performance fiber-reinforced plastics, demanded to achieve high load-bearing capacity. This chapter presents a new approach for textile-based manufacturing of pressure-actuated cellular structures (PACS) using weaving technology. The chapter aims to identify manufacturing constraints from the textile process, incorporate them into the PACS cross-section design, and determine a suitable preform architecture for woven flexure hinges in PACS. Different woven flexure hinges made from a glass fiber-polyamide hybrid yarn are examined for application in PACS. The anisotropic flexure hinges are mechanically characterized under pure axial and pure bending loading in an adapted tensile and column bending test. The specimens are further assessed by leakage testing, optical microscopy, and thermogravimetric analysis. This work demonstrates that the bending stiffness of woven flexure hinges can be determined in simple mechanical tests, without the need for complex modeling of reinforcing fibers and manufacturing-induced anisotropy. The mechanical properties of a flexure hinge with a double-layer fiber arrangement are superior to those of a single-layer fiber arrangement, while integrating additively manufactured PA6 inlays into the woven preform offers an effective approach for achieving high wall thickness ratios. The combination of terry and spacer weaving is well suited for manufacturing preforms for three-dimensional cellular structures. However, consolidating the woven preform in compression molding remains challenging and requires technological improvements before fabricating a functional PACS prototype for experimental validation.