Engineering topics
Publications and source records attributed to Farley, Gary L..
Composite-material (matrix/fiber) structural components manufactured at moderate to high rates in production-line-style processes, according to proposal. In method, production lines largely automated and takes advantage of fact matrix resins cured by electron beams in addition to heat. Net result reductions in production times and costs.
A machine for three-dimensional braiding of fibers is provided in which carrier members travel on a curved, segmented and movable braiding surface. The carrier members are capable of independent, self-propelled motion along the braiding surface. Carrier member position on the braiding surface is controlled and monitored by computer. Also disclosed is a yarn take-up device capable of maintaining tension in the braiding fiber.
Proposed novel looms used to make fabric preforms for complex structural elements, both stiffening elements and skin, from continuous fiber-reinforced composite material. Components of looms include custom reed and differential fabric takeup system. Structural parts made best explained by reference to curved "I" cross-section frame. Technology not limited to these fiber orientations or geometry; fiber angles, frame radius of curvature, frame height, and flange width changed along length of structure. Weaving technology equally applicable to structural skins, such as wing of fuselage skins.
Local characteristics of fabrics varied to suit special applications. Adjustable reed machinery proposed for use in weaving fabrics in various net shapes, widths, yarn spacings, and yarn angles. Locations of edges of fabric and configuration of warp and filling yarns varied along fabric to obtain specified properties. In machinery, reed wires mounted in groups on sliders, mounted on lengthwise rails in reed frame. Mechanisms incorporated to move sliders lengthwise, parallel to warp yarns, by sliding them along rails; move sliders crosswise by translating reed frame rails perpendicular to warp yarns; and crosswise by spreading reed rails within group. Profile of reed wires in group on each slider changed.
Fabrics used in curved composite-material structures prevented from skewing during composite layup by weaving them in modified process in which warp and fill yarns bonded together at their points of contact. (Bonding concept may prove similarly beneficial for braided and knitted fabrics.) In modified weaving process, adhesives prevent excessive shifting of warp and fill yarns with respect to each other.
A laminated composite material with improved interlaminar strength and damage tolerance having short rods distributed evenly throughout the composite material perpendicular to the laminae is introduced. Each rod is shorter than the thickness of the finished laminate, but several times as long as the thickness of each lamina. The laminate is made by inserting short rods in layers of prepreg material, and then stacking and curing prepreg material with rods inserted therethrough.
The invention is an apparatus and method for forming woven fabrics through the use of an adjustable reed. The adjustable reed has multiple groups of reed wires that guide the warp yarns. The groups of reed wires move on reed rails parallel to the warp direction. In addition, rail expanders permit the space between the reed wires to be modified and telescoping rods attached to the rail sliders can be turned to permit the reed wires to be skewed to alter the fill yarn angle. These adjustments to the reed permit simultaneous variation of fill yarn angles and fabric widths and allow these variations to be made during fabrication, without the need to halt production.
A nonlinear elastic finite element analysis is presented of the Iosipescu shear specimen tested in the modified Wyoming fixture for unidirectional graphite/epoxy composites. It is shown that the nonlinear effects due to specimen-to-fixture contact interactions and specimen geometry on the overall shear response are negligible. It is proposed that the tangential shear modulus should be used to characterize the shear resistance of composite materials with highly nonlinear shear response. The correction factors, which are needed to compensate for the nonuniformity of the shear stress or strain distribution in the specimen test section for shear modulus measurement, have to be defined carefully. Strain contours in the nonlinear response ranges are presented and the initiation of failure in the notch regions is investigated.
Flaws first located in infrared imagery, then probed ultrasonically to reveal details. Thermographic and ultrasonic techniques, applied sequentially, constitute basis of developmental method of nondestructive inspection of structures made of lightweight composite materials like carbon-fiber/epoxy-matrix laminates. Method enables rapid detection and evaluation of damage and other flaws in composite structures. Does not require access to both sides of structure to be inspected.
Short transverse rods incorporated into laminated composite panels to increase interlaminar strengths of panels, according to proposal. Rods help panels resist delamination caused by impacts from dropped tools or, in vehicles, by debris. Inserted into selected individual internal layers during preimpregnation.
An apparatus and method for integral fill yarn insertion and beatup are disclosed. A modified rapier contains a channel for holding fill yarn. The channel is covered with a flexible and inflatable boot, and an inflating apparatus for this boot is also attached. Fill yarn is inserted into the channel, and the rapier is extended into a shed formed by warp yarn. Next, the rapier is pushed into the fell of the fabric, and the flexible and inflatable cover inflated, which both pushes the yarn into the fell of the fabric and performs beatup. The rapier is withdrawn and the shed closed to complete one step of the weaving process.
Farley three-dimensional braider, undergoing development, is machine for automatic fabrication of three-dimensional braided structures. Incorporates yarns into structure at arbitrary braid angles to produce complicated shape. Braiding surface includes movable braiding segments containing pivot points, along which yarn carriers travel during braiding process. Yarn carrier travels along sequence of pivot points as braiding segments move. Combined motions position yarns for braiding onto preform. Intended for use in making fiber preforms for fiber/matrix composite parts, such as multiblade propellers. Machine also described in "Farley Three-Dimensional Braiding Machine" (LAR-13911).
The operating principles of two prototype braiding machines for the production of generalized braid patterns are described. Both processes afford previously unachievable control of the interlacing of fibers within a textile structure that make them especially amenable to the fabrication of textile preforms for composite materials. They enable independent control of the motion of the individual fibers being woven, thereby enabling the greatest possible freedom in controlling fiber orientation within a structure. This freedom enables the designer to prescribe local fiber orientation to better optimize material performance. The processes have been implemented on a very small scale but at a level that demonstrates their practicality and the soundness of the principles governing their operation.
A Stiffener Runout Test Specimen (SRTS) has been analyzed and tested to verify the failure scenario for a large composite wingbox beam subcomponent. The SRTS was taken from an undamaged region of the subcomponent that was similar to the failure region of the boxbeam. Extensive analyses were performed to determine the proper load introduction and constraint conditions required for the SRTS test to simulate the response of the subcomponent. The present paper describes the analyses that led to the design of test fixtures that ensured that the response of the SRTS duplicated the response of the box beam. The results of the SRTS test are described and compared with the analytical predictions.
A detailed description is given of the experimental procedure for testing composite Iosipescu specimens in the modified Wyoming fixture. Specimen preparation and strain gage instrumentation are addressed. Interpretation of the experimental results is discussed. With the proper experimental procedure and setup, consistent and repeatable shear properties are obtained.
U.S. Army helicopters are designed to dissipate prescribed levels of crash impact kinetic energy without compromising the integrity of the fuselage. Because of the complexity of the energy-absorption process it is imperative for designers of energy-absorbing structures to develop an in-depth understanding of how and why composite structures absorb energy. A description of the crushing modes and mechanisms of energy absorption for composite tubes and beams is presented. Three primary crushing modes of composite structures including transverse shearing, lamina bending, and local buckling are described. The experimental data presented show that fiber and matrix mechanical properties and laminate stiffness and strength mechanical properties cannot reliably predict the energy-absorption response of composite tubes.
An apparatus, system, and method for non-destructible evaluation (NDE) of a material use thermography to rapidly detect and/or generally locate a feature such as, for example, damage or a defect in the material. The apparatus, system, and method also use ultrasound to specifically locate the feature in the material for quantification and/or evaluation either by an operator or by an external device suited for such purpose. Accordingly, the apparatus, system and method are particularly useful for NDE in applications such as the analysis of the structure of an aircraft, for example, in which the scale of the material to be analyzed is large, thus requiring the rapid NDE afforded by thermography, and in which quantification and/or evaluation of a feature must be performed with precision, thus requiring the relatively high-resolution NDE afforded by ultrasound.
The development of prototype braiding machines for the production of generalized braid patterns is described. Mechanical operating principles and control strategies are presented for two prototype machines which have been fabricated and evaluated. Both machines represent advances over current fabrication techniques for composite materials by enabling nearly ideal control of fiber orientations within preform structures. They permit optimum design of parts that might be subjected to complex loads or that have complex forms. Further, they overcome both the lack of general control of produced fiber architectures and the complexity of other weaving processes that have been proposed for the same purpose. One prototype, the Farley braider, consists of an array of turntables that can be made to oscillate in 90 degree steps. Yarn ends are transported about the surface formed by the turntables by motorized tractors which are controlled through an optical link with the turntables and powered through electrical contact with the turntables. The necessary relative motions are produced by a series of linear tractor moves combined with a series of turntable rotations. As the tractors move about, they weave the yarn ends into the desired pattern. The second device, the shuttle plate braider, consists of a braiding surface formed by an array of stationary square sections, each separated from its neighbors by a gap. A plate beneath this surface is caused to reciprocate in two perpendicular directions, first in one direction and then in the other. This movement is made possibly by openings in the plate that clear short columns supporting the surface segments. Yarn ends are moved about the surface and interwoven by shuttles which engage the reciprocating plate as needed to yield the desired movements. Power and control signals are transmitted to the shuttles through electrical contact with the braiding surface. The shuttle plate is a passively driven prime mover that supplies the power to move all shuttles and the shuttles are simple devices that employ only a solenoid to engage the shuttle plate on command. Each shuttle is assigned a unique identity and is controlled independently. When compared to each other, the Farley braider is felt to have the advantage of speed and the shuttle plate braider, the advantage of simplicity.