Method of fabricating a lug on a structural element of composite material, in particular a connecting rod

1. A method of fabricating a lug on a structural element of composite material, said structural element being made from a pattern presenting two opposite edges cut out from a fiber fabric made up of superposed primary plies bonded together in such a manner that the plies can slide relative to one another, said pattern having at least one extension for forming the lug, the method including rolling the pattern into a tube to form a body of the structural element in such a manner that the primary plies slide relative to one another to give a chamfer shape to the two edges, the chamfer-shaped edges being joined so that they overlap, the method further including separating the primary plies in the at least one extension, inserting intermediate plies between the primary plies, and piercing the at least one extension to produce a lug.

2. A method according to claim 1 , in which the pattern is cut from fabric comprising a base weave which is constituted:

firstly by at least twenty-eight weft fibers organized in at least eight columns each extending in the thickness direction of the fabric, and disposed in a staggered configuration with alternation between columns having at least three superposed weft fibers spaced apart at a predetermined pitch, and columns having at least four superposed weft fibers spaced apart by the same pitch, the weft fibers extending to define at least seven primary plies; and

secondly, by at least twelve warp fibers disposed in at least four parallel planes that are offset in the weft fiber direction, each plane containing three superposed parallel warp fibers arranged in each of these planes as follows:

a first warp fiber connects the topmost warp fiber of a four-weft fiber column to an upper intermediate weft fiber of a four-weft fiber column that is spaced apart from the preceding column by at least two pitch steps, the first warp fiber returning over a top end weft fiber of a four-weft fiber column that is spaced apart from the first column by at least four pitch steps;

a second warp fiber connecting a top intermediate weft fiber of a four-weft fiber column to a lower intermediate weft fiber of a four-weft fiber column that is spaced apart from the preceding column by at least two pitch steps, the second warp fiber returning over an upper intermediate weft fiber of a four-weft fiber column that is spaced apart from the first column by at least four pitch steps; and

a third warp fiber connecting a lower intermediate weft fiber of a four-weft fiber column to the bottommost weft fiber of a four-weft fiber column spaced apart from the preceding column by at least two pitch steps, the third warp fiber returning over a lower intermediate weft fiber of a four-weft fiber column that is spaced apart from the first column by at least four pitch steps;

the positions of the parallel warp fibers being offset longitudinally by one pitch step from one plane to another.

3. A method according to claim 1 , in which the pattern has an axis of symmetry and is cut out from said fabric in such a manner that the primary plies have weft fivers that extend along the axis of symmetry.

4. A method according to claim 1 , in which the pattern has at least two extensions that come to face each other when the pattern is rolled into a tube.

5. A method according to claim 1 , in which the intermediate plies are inserted to have fibers that are oriented obliquely relative to weft fibers forming the primary plies in the extension.

6. A method according to claim 1 , in which transverse fibers are inserted through the primary plies and the intermediate plies.

7. A method according to claim 1 , in which intermediate plies are inserted that are of lengths that increases with increasing distance on either side of a central plane of the extension.

8. A method according to claim 1 , in which the at least one extension is pierced after resin has been injected and polymerized to form a lug or lugs of coupling forks.

9. A method according to claim 2 , in which the holes pierced are fitted with pairs of rings.