Modeling the Geometry of Satin Weave Fabric Composites

Abstract

The focus of this study is aimed at characterizing the weave architecture in orthogonally woven polymer and ceramic—matrix composites. Three-dimensional (3D) geometric models of the unit-cells of four harness (4HS), five harness (5HS), and eight harness (8HS) satin weave morphologies are developed. The fiber bundle and matrix architecture in the 4HS, 5HS, and 8HS morphologies is represented via mathematical shape functions within the domain of the repeating unit-cells of the woven fabrics. This work brings together the non-uniform layer methodology of Kuhn and Charalambides [1] and the sub-cell modeling approach developed by Hewitt et al. [2]. In addition, this article introduces the novel concept of a `middle matrix layer' in capturing the ingress of matrix material away from undulating bundle regions, as documented by Morscher [3]. The geometry models developed herein account for a porous polymer matrix deposited over the woven mat via either resin film infusion (RFI) or resin transfer molding (RTM). This modeling also incorporates micro-structural intricacies observed in woven CMCs fabricated using chemical vapor infiltration (CVI) techniques for the deposition of the ceramic—matrix phase. Finally, results on the overall volumetric composite characteristics are reported.