纺织学报 ›› 2026, Vol. 47 ›› Issue (06): 223-232.doi: 10.13475/j.fzxb.20250706501

• 机械与设备 • 上一篇    下一篇

簇绒机针针尖形态特征对碳纤维复合材料缝合质量的影响

李翔宇1,2, 董九志1,2(), 陈晓霞1,2, 陈云军3, 李锐1,2   

  1. 1 天津工业大学 机械工程学院， 天津 300387
    2 天津工业大学 天津市现代机电装备技术重点实验室， 天津 300387
    3 天津工业大学 控制科学与工程学院， 天津 300387
  • 收稿日期:2025-07-29 修回日期:2025-12-30 出版日期:2026-06-15 发布日期:2026-08-19
  • 通讯作者: 董九志（1981—），男，副教授，博士。主要研究方向为复合材料预制件成型装备技术、新型纺织机械机电一体化。E-mail：dongjiuzhi@tiangong.edu.cn。
  • 作者简介:李翔宇（1998—），男，博士生。主要研究方向为碳纤维复合材料预制体成型装备技术。
  • 基金资助:
    国家自然科学基金项目(52405406)

Effect of tufting needle tip morphological characteristics on stitching quality of carbon fiber preforms

LI Xiangyu1,2, DONG Jiuzhi1,2(), CHEN Xiaoxia1,2, CHEN Yunjun3, LI Rui1,2   

  1. 1 School of Mechanical Engineering， Tiangong University， Tianjin 300387， China
    2 Tianjin Key Laboratory of Advanced Mechatronics Equipment Technology， Tiangong University， Tianjin 300387， China
    3 School of Control Science and Engineering， Tiangong University， Tianjin 300387， China
  • Received:2025-07-29 Revised:2025-12-30 Published:2026-06-15 Online:2026-08-19

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摘要：

为解决簇绒机针针尖形态与受力研究不足且其对碳纤维复合材料缝合成型质量影响规律不明的问题，建立了描述机针针尖形态的特征角度数学模型，揭示了特征角度与形态参数的映射关系，结合簇绒机针受力建立簇绒机针针尖峰值刺入力模型并完成其影响因素分析。利用万能拉伸试验机对不同针尖锥角的簇绒机针进行机针穿刺实验。结果表明：各锥度簇绒机针峰值刺入力预测结果与实测值的最大平均相对误差为6.34%（对应最大均方误差为0.15 N2），实验验证了簇绒机针峰值刺入力模型的有效性，簇绒机针针尖锥角与针尖刺入力、缝料损伤面积呈现出较高的正相关性；同时，减小机针的针尖锥角有助于提高针尖各角位置的特征角度，形成更锋利的切削刃形态以降低刺入阻力、抑制缝合过程中的纤维损伤，从而提升预制体簇绒缝合成型质量。

关键词: 簇绒缝合, 机针形态, 特征角度, 机针刺入力, 缝合质量

Abstract:

Objective The morphological characteristics of tufting needle tips and the mechanical response of penetration force during tufting are two key factors affecting stitching quality. However， systematic studies on morphological characterization and penetration-force modeling for tufting needles remain limited， and the influence of needle-tip morphology on the stitching quality of carbon-fiber preforms is still unclear. This study introduces a characteristic-angle-based modeling and evaluation method and combines needle-tip force analysis to comprehensively assess the effect of tufting needle-tip morphology on the stitching quality of carbon-fiber preforms.

Method Rake and inclination angles were introduced as characteristic angles to quantify tufting needle-tip morphology， and the corresponding expressions were established. By varying the cone angle， characteristic-angle distribution maps were generated to clarify the mapping between tip parameters and morphology. A peak penetration-force model was then developed based on needle-fabric interaction during penetration. Penetration tests， with ten repetitions for each needle type， were conducted on ten stacked layers of T300-3K plain-woven carbon fabric using four needles with different cone angles. Force-displacement curves， peak forces， and fabric damage morphology were obtained to validate the model and evaluate stitching quality.

Results The established characteristic-angle expressions revealed a clear mapping relationship between tufting needle-tip morphological parameters and the rake and inclination angles. As the needle-tip cone angle increased from 30° to 45°， the rake and inclination angles generally decreased at the angular positions along the needle-tip leading edge， indicating a negative correlation between the cone angle and the characteristic angles. Needles with smaller cone angles exhibited larger rake and inclination angles and a higher leading-edge proportion， which contributed to the formation of a sharper cutting-edge morphology. Based on the force interaction between the needle and fabric fibers， the peak penetration-force model showed that， when the needle diameter and fabric properties remained constant， the peak force was mainly governed by needle-tip morphology and increased with the cone angle. This trend was further supported by the penetration tests. The force-displacement curves exhibited a typical single-peak feature. During the initial penetration stage， the force increased continuously with displacement as the needle pushed and separated the fabric fibers. After the needle tip penetrated the fabric structure， the penetration resistance was gradually released and the curve entered a descending stage. The peak penetration forces differed clearly among the needles with different cone angles and increased sequentially with the cone angle. The measured peak forces agreed well with the model predictions， with a maximum mean absolute error of 0.38 N， a maximum mean squared error of 0.15 N2， and a maximum mean relative error of 6.34%， confirming the validity of the model. This mechanical response was further reflected in the damage morphology. Hole-like damage appeared in the fabric after needle penetration， and the average damage area increased from 3.12 to 3.78 mm2 from N1 to N4. Overall， a smaller cone angle increased the characteristic angles， improved the cutting-edge morphology， reduced penetration resistance， and suppressed fabric damage， thereby improving the tufting stitching quality of carbon-fiber preforms.

Conclusion The results demonstrate that tufting needle-tip morphology is a key factor affecting the stitching quality of carbon-fiber preforms. The characteristic-angle analysis shows a clear negative correlation between the needle-tip cone angle and the rake and inclin

Key words: tufting stitching, needle tip morphology, characteristic angle, needle penetration force, stitching quality

中图分类号: 

  • TS103

图1

簇绒机针几何模型"

图2

簇绒机针xoy面投影"

图3

各针尖锥角下的特征角度分布规律"

图4

簇绒机针针尖受力示意图"

图5

平纹碳布截面示意图"

图6

纱线移动示意图"

图7

纱线张力-径向压力力学模型"

表1

簇绒机针针尖几何参数"

机针编号 直径/mm 针尖长度/mm 针尖锥角/（°）
N1 2 4 30
N2 2 4 35
N3 2 4 40
N4 2 4 45

图8

实验用簇绒机针"

图9

实验装置图"

图10

实验用簇绒机针特征角度覆盖范围 λ—倾斜角；α—前倾角；δ—针尖锥角（δ=30°，35°，40°，45°对应实验机针N1，N2，N3，N4）；γ—针尖任意点处角位置。"

图11

簇绒机针刺入力-位移曲线 N1—针尖锥角30°测试机针；N2—针尖锥角35°测试机针；N3—针尖锥角40°测试机针；N4—针尖锥角45°测试机针；Fpeak—机针峰值刺入力。"

表2

峰值刺入力实验实测值与模型预测值对比"

机针
编号		 重复实验峰值刺入力实测结果/N 实测标
准差/N		 模型预
测值/N		 平均绝对
误差/N		 均方误
差/N2		 平均相对
误差/%
1 2 3 4 5 6 7 8 9 10
N1 4.39 4.45 4.59 4.52 4.32 4.31 4.41 4.62 4.55 4.49 0.11 4.73 0.26 0.08 5.60
N2 4.76 4.72 4.84 4.87 4.68 4.75 4.79 4.92 4.98 4.87 0.09 5.13 0.31 0.11 6.08
N3 5.15 5.19 5.22 5.29 5.07 4.99 5.10 5.38 5.31 5.16 0.12 5.53 0.34 0.13 6.22
N4 5.69 5.51 5.64 5.72 5.45 5.38 5.51 5.66 5.59 5.58 0.11 5.95 0.38 0.15 6.34

图12

铺层碳布孔洞损伤形貌照片 N1—针尖锥角30°测试机针；N2—针尖锥角35°测试机针；N3—针尖锥角40°测试机针；N4—针尖锥角45°测试机针；S—平均损伤面积。"

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