The key role of thread and needle selection towards ‘through-thickness reinforcement’ in tufted carbon fiber-epoxy laminates

Abstract

Tufting of dry preforms is one of the means of accomplishing through-thickness reinforcement (TTR) in a liquid composite molding process. Herein, once a preform is laid up, an automated robotic tufting setup is used to introduce the TTR. The selection of thread and needle for tufting process go hand-in-hand as tufting operation involves the act of penetrating preform by the needle as well as the trauma thread has to endure during this act. This paper explores the methodology of thread and needle selection through studies at different levels right from tufting of preforms to testing of tufted laminates. Glass, carbon and Kevlar threads in combination with a tufting needle and two different sewing needles are explored in this study. The effect of tufting speed on the quality of tuft is analyzed in terms of damage of fabric yarn, thread, and needle breakage. Layer-wise analysis of damage due to needle penetration in fabric yarns is carried out. Key mechanical properties of tufted composite samples are evaluated to determine the effect of tufting on the in-plane and out-of-plane properties.