Active tension control for one-sided double-needle single-thread stitching and its effect on the interlaminar properties of composites

IF 8.2 2区材料科学 Q1 ENGINEERING, MANUFACTURING

Composites Part A: Applied Science and Manufacturing Pub Date : 2026-03-01 Epub Date: 2025-11-24 DOI:10.1016/j.compositesa.2025.109461

Haoda Yang , Jun Wang , Jun Zhang , Xuehao Shan , Weihao Wang , Chenchen Tan , Zitong Guo , Zheng Sun

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引用次数: 0

Abstract

Stitching tension is a critical parameter in one-sided double-needle single-thread stitching, directly influencing preform quality and the performance of composite components. However, existing tension control methods are largely passive, and the influence of tension on Mode I fracture performance remains insufficiently explored. In this study, we introduce a tension-speed dual-loop control scheme, implemented via a novel mechanism capable of maintaining a mean absolute tension error below 0.05 N. Through Double Cantilever Beam tests, the effects of stitch diameter and tension on Mode I fracture toughness were systematically investigated. The results show that fracture toughness initially increases and subsequently decreases with rising tension, exhibiting a distinct peak value. This peak shifts toward higher tension levels as stitch diameter increases. The observed behavior is attributed to a dual-role mechanism: increased tension compresses the preform, enhancing interlaminar properties but simultaneously creating detrimental resin-rich zones. Appropriate tension regulation was found to increase Mode I fracture toughness by up to 22%. This work reveals this dual mechanism and provides a high-precision control method, offering a valuable reference for process parameter optimization and performance enhancement.

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单侧双针单线拼接主动张力控制及其对复合材料层间性能的影响

拼接张力是单面双针单线拼接的关键参数，直接影响到预制体的质量和复合材料的性能。然而，现有的张力控制方法大多是被动的，张力对I型裂缝性能的影响研究还不够充分。在这项研究中，我们引入了一种张力-速度双环控制方案，通过一种新的机制来实现，该机制能够将平均绝对张力误差保持在0.05 n以下。通过双悬臂梁试验，系统地研究了针径和张力对I型断裂韧性的影响。结果表明：随着拉伸强度的增大，断裂韧性先增大后减小，且有明显的峰值；随着针迹直径的增加，这个峰值向更高的张力水平移动。观察到的行为归因于双重作用机制：增加的张力压缩了预制体，增强了层间性能，但同时产生了有害的富树脂区。发现适当的张力调节可使I型断裂韧性提高22%。揭示了这一双重机理，提供了高精度的控制方法，为工艺参数优化和性能提升提供了有价值的参考。

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来源期刊

Composites Part A: Applied Science and Manufacturing 工程技术-材料科学：复合

CiteScore

15.20

自引率

5.70%

发文量

492

审稿时长

30 days

期刊介绍： Composites Part A: Applied Science and Manufacturing is a comprehensive journal that publishes original research papers, review articles, case studies, short communications, and letters covering various aspects of composite materials science and technology. This includes fibrous and particulate reinforcements in polymeric, metallic, and ceramic matrices, as well as 'natural' composites like wood and biological materials. The journal addresses topics such as properties, design, and manufacture of reinforcing fibers and particles, novel architectures and concepts, multifunctional composites, advancements in fabrication and processing, manufacturing science, process modeling, experimental mechanics, microstructural characterization, interfaces, prediction and measurement of mechanical, physical, and chemical behavior, and performance in service. Additionally, articles on economic and commercial aspects, design, and case studies are welcomed. All submissions undergo rigorous peer review to ensure they contribute significantly and innovatively, maintaining high standards for content and presentation. The editorial team aims to expedite the review process for prompt publication.