Study on the wear characteristics of carbon fiber yarns under the influence of multifactor coupling on braiding carriers

Abstract Reducing the wear of carbon fibers on braiding carriers is the key to manufacturing high‐performance carbon fiber composite prefabricated parts. In this study, a new analytical model is developed to describe the local friction behavior of yarns on braiding carriers. The degree of yarn wear is characterized by calculating the gray value of carbon fiber hairiness and observing the micro‐surface morphology of carbon fibers. The wear characteristics of carbon fiber yarns under the multi‐factor coupling influences of yarn tension, unwinding speed, and guiding element characteristics were considered. The results show that increases in unwinding angle and unwinding speed both increase the wear of carbon fiber yarns. Eliminating the effect of unwinding angle can reduce the yarn hairiness by more than 60%, alleviate the yarn tension fluctuation by more than 70%, and improve the yarn tension stability by more than 75%. Meanwhile, the relationship between the wrapping angle between the yarn and the yarn bobbin, the unwinding angle, and the yarn tension was established according to the Capstan Equation. A method is proposed to improve the characteristics and spatial position of the guiding elements to obtain more intact yarn and low‐damage yarn surfaces. Highlights A new analytical model for local friction of carbon fibers is developed. The friction‐wear‐fracture mechanism of carbon fiber yarns is constructed. Characterize the degree of yarn wear from a macro and micro perspective. Wear characteristics of carbon fiber yarns under multi‐factor coupling.