Composite materials filament winding

J. P. Nunes, J. F. Silva, N. Crainic, A. T. Marques (2001) Technological developments to produce low-cost thermoplastic reinforced composites by filament winding, Proc. 7 European Conf. Advanced Materials and Processes-EUROMAT 2001, Rimini, Italy. 

Applications. Epoxy resias constitute over 90% of the matrix resia material used ia advanced composites. In addition, epoxy resias are used ia all the various fabrication processes that convert resias and reinforcements iato composite articles. Liquid resias ia combiaation, mainly, with amines and anhydride are used for filament winding, resia transfer mol ding, and pultmsion. Parts for aircraft, rocket cases, pipes, rods, tennis rackets, ski poles, golf club shafts, and fishing poles are made by one of these processes with an epoxy resia system. 

Process models allow composite case manufacturers to determine the affects of process variable settings on final cylinder quality. Because the cost of a composite cylinder can be as great as 500,000, the ability to simulate filament winding can significantly reduce cost and improve quality. Several computer models of the filament-winding process for both thermoset and thermoplastic matrix materials have been developed. These models are based on engineering principles such as conservation of mass and energy. As such, numerous resin systems and fiber materials can be modeled. 

The fiber motion submodel yields the fiber position during processing. In filament winding, the fiber position is affected by flow of the resin matrix material, expansion of the mandrel, and expansion of the composite. In the fiber motion submodel, only changes in fiber position caused by flow of the matrix are considered. Changes caused by thermal expansion of the mandrel and composite are included in the stress-strain submodel. 

Consolidation and development of interlaminar bond strength for thermoplastic matrix composites have been modeled by two mechanisms intimate contact and autohesion. Intimate contact describes the process by which two irregular ply surfaces become smooth (Fig. 13.10). In areas in which the ply surfaces are in contact, autohesion occurs, and the long thermoplastic polymer chains diffuse across the ply boundaries. Filament winding with thermoplastic matrix materials is considered an on-line consolidation process in that local... 

For typical filament winding applications, the fiber reinforcement provides the stiffness and strength required to maintain structural integrity. Thus, material characterization for filament wound structures focuses on characterizing the fiber dominated stiffness and strength properties of the composite. The stiffness of fiber reinforced plastics (FRPs), in the fiber direction, is dominated by the fiber stiffness characteristics. The strength will be influenced by a number of factors, however, and not all of them are related to the fiber, including ... 

Hummler, J., Steiner, K.V. Experimental Study of Robotic Thermoplastic Filament Winding of Complex Geometries (1990) Center for Composite Materials, University of Delaware, Newark, Delaware... 

Peters, S.T., Humphery, W.D., Foral, R.F. Filament Winding Composite Structure Fabrication (1991) Society for the Advancement of Materials and Process Engineering, Corina, California... 

Resin-based composites are usually defined as either conventional or advanced. Conventional composites usually contain glass or mineral fiber reinforcement, and sometimes carbon fiber, either alone or in combination with others. Conventional composites are usually produced in stock shapes such as sheet, rod, and tube. There are many methods of processing composite materials. These include filament winding, layup, cut fiber spraying, resin transfer molding, and pultrusion. 

Filament winding machines in which the motions for positioning, wrapping, and winding fibres are coordinated and programmed in three or more axes, specially designed to fabricate composite structures or laminates from fibrous and filamentary materials and capable of winding cylindrical rotors. 

Filament wound flat strip composites of PE fibie-rrinforced ethylene-butane copolymer have been used for diff oit biomedical applications. Composites of three difierent matrix compositions and two winding angles were reported. The matrix composition varied with the copolymer ratio raidering the composite material softening and it is more compliant and suitable for different biomedical application [75]. 

Manufacturing methods for composites vary from manual to fully automated processes, whereby the latter have better quality control than the former. Wet layup, pultrusion, and filament winding are all discussed in some detail, while other techniques such as pull-winding, resin transfer moulding, vacuum bag moulding, and injection moulding are left to specialized composite materials texts. 

Phenolics are now growing into the FRP composite areas of hand lay up, open and closed mould techniques, pultrusion and filament winding. The driving force behind this recent growth is the concern over flammability and smoke generation of materials used in transportation and in certain types of construction. Use of phenolics is limited to those fabrication processes and sizes of structure which allow high temperature curing. 

Mayer C, Reinforcements for harsh and demanding environments, cutting-edge thermoplastic composite material solutions for oU and gas conduits, 2nd International Convention for Filament Winding Technology, Brussels, Oct 17 19 2001. 

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