Integral weaving of orthogonal 3D ‘T’ stiffeners based on pleat weaving concept

This paper details about the manufacturability of integrally woven ‘T’ stiffeners using orthogonal weaving technology based on the pleat formation concept. The development was carried out on a customized automatic take-up-at-will rapier weaving machine equipped with multi-beam warp let-off and electronic dobby. Bridging the gap between the base portions of the flange sections and locking the web sections together by using equally spaced intermittent extra warp yarns were the added innovations in the work apart from integral weaving of the ‘T’ stiffener. These innovations were achieved by suitably modifying the weave design. The development comprised a 5-part weave design for the ‘T’ stiffener and was carried out using 6K carbon tows. Calculations for X, Y, Z contents and overall fibre content by volume, from first principles of cloth construction approaches, for the flange and web sections of the ‘T’ profile, have also been included.