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Carbon Fiber Filament Winding

Hal Peterson
Rob Haglin
Overview
Design and build a machine capable
of carbon fiber filament winding
Empirically test and optimize
mandrel
What is filament winding?
Process by which continuous reinforcing
fibers are accurately positioned in a
predetermined pattern to form a shape
(usually cylindrical).
Use machine to wrap composite around
mandrel
Mandrel is then removed, leaving hollow
composite part
Angles generally set at -45,0,+45
Why filament winding?
Composite shafts have high tensile
strength, low compressive strength.
To overcome the weakness in
compression.
Gives very high strength/weight ratio
Increases performance in machines
or automobiles when utilized,
because decrease in weight.
Applications of Filament Winding
Cars
Rockets
Aircraft
Propellers
Blades
Engine parts
Any place where weight is an issue, or there is a
desire to decrease weight to increase
performance.
Winding
Three types of winding
Helical
Circumferential
Polar
The machine
2 axis movement
Variable speed spindle to hold
mandrel
Computer controlled
Various diameters and lengths of
shafts
Wide range of wrapping angles
The Machine
Resin Delivery
2 main forms
Pre-preg (pre-coated with resin)
Resin bath impregnation
Resin bath
Advantages
Cheaper
Easy to store
Curable at room or elevated temp.
Disadvantages
Inconsistent
Messy
Pre-preg our choice
Advantages
Comes coated in resin
Most widely used
Can be used in hand lay-up if needed
Disadvantages
More expensive
Storage (low temperature)
Cured at elevated temp
Why we chose Pre-preg
Even disbursement of resin on fibers
Very precise fiber/resin ratio
Better control of fiber placement and
angle
Increases precision and repeatability
with parts
Curing
Room temp (can take long time)
Only for resin bath-impregnated
Oven (elevated temp)
Increased pressure
Machine Design issues
Design for versatility
Gearing
Wear of pre-preg on eyelet
Machine parts filling up with resin.
General Control Scheme

Computer Mandrel Motor

Amplifier M Mandrel
Encoder
DMC-1842 Controller

Slide Motor
Encoder
Limit Slide Motor
Switch
M
Amplifier
User Interface
Needed Information
Fiber Angle
Tube diameter
Tube length
Desired speed - optional
What happens
Instruction set generated from
parameters
What happens

Get Information Generate


From User Instruction Set

Write
User Presses
Instructions to
Start
Controller
Instruction Set
Object Oriented Approach
Visual Basic .NET
Decreases programming time
Use supporting programs from Galil
Developers kit
Advanced servo tuning
ActiveX controllers - $695
Questions
References
http://www.fibercote.com/pabo6.html
Manufacturing processes for
Engineering Materials, 5th Ed.
Material Science and Engineering
6th Ed
http://www.pslc.ws/macrog/mpm/co
mposit/fiber/process/prepreg.htm
Galil user documentation

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