Geometrical design and forming analysis of three-dimensional woven node structures

Structural frames have been established in many technical applications and typically consist of interconnected profiles. The profiles are commonly joined with node elements. For lightweight structures, the use of composite node elements is expedient. Due to the anisotropic mechanical properties of the fibers, high demands are placed on the orientation of the fibers in the textile reinforcement structure. A continuous fiber course around the circumference and at the junctions is necessary for an excellent force transmission. A special binding and forming process was developed based on the weaving technology. It allows the production of near-net-shaped node elements with branches in any spatial direction, which meet the requirements of load-adjusted fiber orientation. The principles by which these three-dimensional (3D) node elements are converted into a suitable geometry for weaving as a net shape multilayer fabric are reported. The intersections of the branches are described mathematically and flattened to a plane. This is the basis for the weave pattern development. Forming simulations on the macro- and meso-scales complement the analyses. A macro-scale model based on the finite element method (FEM) is used to verify the general formability and the accuracy of the flattenings. Since yarns are pulled through the textile structure in the novel forming process, the required tensile forces and the pulling lengths of the individual yarns are analyzed with a meso-scale FEM model. The flattening for two different node structures is realized successfully, and the simulation proves formability. Furthermore, the necessary forming forces are determined. Finally, the developed method for flattening the 3D geometry is suitable for the design of a variety of spatial node structures and the simulation supports the design of automated forming processes.