Development of Composite Materials using Braiding Technology

Braiding, both two-dimensional and three-dimensional, is popular in the manufacture of industrial ropes, fabrics and structures for composite application, says Pradeep Kulshrestha.

The technique is relatively simple and age-old, but the results are impressive.

Braiding is carried out in medium scale companies mostly on indigenous machines. The photograph below shows the machine from Susmatex Rope Braiding Machine at Hirpara Technical Textiles, Ahmedabad.

Creeling of yarn as per planned diameter of rope on braiding machine is done:

a) To insert individual ends in needles

b) To adjust settings

c) Complete the braiding

There is demand for industrial ropes for the marine industry, mountain climbing, yachting ropes, parachute lines, fishing nets, mooring lines, medical applications such as catheters and for dental floss. Research is on to develop high strength ropes.

These are needed for heat protection and thermal resistant applications also. These ropes are being developed by technical fibres like nylon glass, aramid and dyneema.

Fibre glass generally consists of extremely fine glass fibres used to manufacture fabric and structural objects for composite applications.

Carbon fabric is generally used in applications such as brake linings, aircraft interiors, windmill blades, tooling, primary and secondary structures. Carbon fibre provides maximum stiffness in aircrafts.

Braiding is a method of interlacing three or more threads in such a way that they cross one another in diagonal formation. Flat, tubular and solid products may be developed in this process.

Some braiding machine manufacturers are:

1. Braid Solutions, Faridabad, India

2. Taiwan Braiding Machine Manufacturers, Taiwan

3. Herzog Braiding Machine, Germany

4. Karl Mayer, Germany

5. Wuxi Longterm MachineryTechnologies Co., Ltd, China

6. United Textile Machinery Corporation, USA.

Of these, Wuxi has a range of different machines like braiding machine, lace braiding machine, rope braiding machine, and computerised lace braiding machine.

Radial braiding machine:

Radial braiding machine type RF 1/128-100

128 carriers
Bobbin 55 x 170 x 130 mm = 265 ccm
Motor power: 4 x 0,55 kw
Speed: 150 r. p. m.

Recommended for the production of 2 1/2 D carbon fibre and glass fibre products. Special bobbins are required for braiding clock-wise and anti-clock wise.

Types of carbon fibre:

Significance of different carbon fibres available:

K	Tex	Denier	No. of Filaments
1	70	630	1000
3	200	1800	3000
6	400	3600	6000
12	800	7200	12000
24	1600	14400	24000
50	3300	29700	50000

Test report of some carbon fibres:

Test Parameters	Units	Test Method	Test Result (3 K)	Test Result (12 K)	Test Result (50 K)
Single carbon fibre diameter	Micron (mm)	Projection Microscope	8.0	8.0	8.0
Single carbon fibre strength	cN	Fafegraph -M	7.98	12.0	8.05
Single carbon fibre elongation	%	Fafegraph -M	4.15	3.31	2.38

Selection of Aramid:

Company	DuPont Kevlar	DuPont Kevlar	DuPont Kevlar
Style	802F	745	258HPP
Product Specification	190 g/m2	450 g/m2	410 g/m2
Denier	1000	3000	3140

Properties of radical braiding machine:

Properties	Facilities
Improved mechanical and structural properties	2 1/2 D Radial Braiding Machine
Ability to form a variety of complex shapes	176 carriers
Manufacturing complex structural shapes	Bobbin: 76 X 80 X 280 mm
High torsional stability and structural integrity	Motor power: 4 X 0.55 kW
Braid high functional fibers: Aramid, Carbon, PP etc	Speed: 150 rpm

Braiding complex structures with carbon

Carbon braided lightweight bicycle

Among the various braided structures, biaxial and tri axial two dimensional (2D) braided structures have been applied in various technical sectors. Techniques to develop such structures are well developed compared to 2D braided structures while 3D braided structures contain multiple layers and are highly suitable for producing complex geometries. Cost effectiveness and capability of producing complex shapes makes braiding popular in composite applications.

The robotic radial braiding machine is the first of its kind in India developing automobile related composite materials.

Reference:

1. Advances in Braiding Technology by Yordan Kyosev

2. International Aerospace Abstracts - Volume 36 - Issue 4. 1996

3. ATIRA - Ahmedabad (Robotic Radial Braiding Machine)

4. Shanghai Henghui International Company Limited (Mainland), Shanghai

5. Exhibition at ITMA ASIA + CITME 2014, Shanghai

6. Technotex India Exhibition, Mumbai

7. Hirpara Technical Textiles Limited, Ahmedabad

About the author:

Pradeep Kulshrestha is an experienced professional in Textiles Operations Management. He has over 30 years of experience in administering world class manufacturing plants and project implementation.