Integrated Design of D.D.I., Filament Winding and Curing Processes for Manufacturing the High Pressure Vessel(Type Ⅱ)

As energy crisis and environment pollution all around the world threaten the widespread use of fossil fuels,compressed natural gas(CNG)vehicles are explored as an alternative to the conventional gasoline powered vehicles.Because of the limited space available for the car,the composite pressure vessel(TypeⅡ)has been applied to the CNG vehicles to reach large capacity and weight lightening vehicles.High pressure vessel(TypeⅡ)is composed of a composite layer and a metal liner.The metal liner is formed by the deep drawing and ironing(D.D.I.)process,which is a complex process of deep drawing and ironing.The cylinder part is reinforced by composite layer wrapped through the filament winding process and is bonded to the liner by the curing process.In this study,an integrated design method was presented by establishing the techniques for FE analysis of entire processes(D.D.I.,filament winding and curing processes)to manufacture the CNG composite pressure vessel(TypeⅡ).Dimensions of the dies and the punches of the 1 st(cup drawing),2 nd(redrawing-ironing 1-ironing 2)and 3 rd(redrawing-ironing)stages were calculated theoretically,and shape of tractrix die to be satisfied with the minimum forming load was suggested for life improvement and manufacturing costs in the D.D.I.process.Thickness of the composite material was determined in the filament winding process,finally,conditions of the curing process(number of heating stage,curing temperature,heating rate and time)were proposed to reinforce adhesive strength between the composite layers.

The Analysis of the Line Pattern of Nonlinear Winding Filament on FRP Composite Air Vessel Resisting High Pressure

The FW process is a prefect method of manufacturing FRP composite air vessel resisting high pressure and aerial press vessel.In this paper FW pattern of FRP composite air vessel resisting high pressure was analyzed in a nutshell.The stability of FW patterns on end head is very sensitive to changing of pattern parameter.Consequently,its FW pattern was based on geodesic track.The FW angles and on equators depend on the dimension of end part and the condition of geodesic FW.Generally speaking, the polar holes of rocket engine shell are disproportional.Therefore,the FW angles of the shell column are changeable.The feasi- bility of nongeodesic FW of the shell column was discussed in this paper.Furthermore,it expounded the indispensable condition be- tween the length of shell column and the FW friction coefficient.At the same time,the general mathematic models of the movement control of nongeodesic FW were deduced.

On the Mechanical Analysis and Control for the Tension System of the Cylindrical Filament Winding

The constant winding tension can make the filament arranged in order. The stress distribution between the filament balance fully gives play to the enhancement of filament, and increases the intensive workload of the composite winding material. This paper conducts the mechanical analysis for the unwinding roller and tension measuring roller of the cylindrical winding machine so that gets the mechanical model, gives error compensation formula caused by the radius change of the yarn group in the unwinding side, designs the closed-loop control system and utilizes the dynamical- integral PID control strategy to achieve the tension control during the process of the cylindrical winding.

Design and Analysis of a Novel Tension Control Method for Winding Machine

Filament winding has emerged as the main process for carbon fiber reinforced plastic(CFRP) fabrication, and tension control plays a key role in enhancing the quality of the winding products. With the continuous improvement of prod?uct quality and e ciency, the precision of the tension control system is constantly improving. In this paper, a novel tension control method is proposed, which can regulate the fiber tension and transport speed of the winding process by governing the outputs of three di erent driven rollers(the torque of the unwind roll, the torque of the magnetic powder brake roller, and the speed of the master speed roller) in three levels. The mechanical structures and dynamic models of the driven rollers and idle rollers are established by considering the time?varying features of the roller radius and inertia. Moreover, the influence of parameters and speed variation on fiber tension is investigated using the increment model. Subsequently, the control method is proposed by applying fiber tension in three levels accord?ing to the features of the three driven rollers. An adaptive fuzzy controller is designed for tuning the PID parameters online to control the speed of the master speed roller. Simulation is conducted for verifying the performance and sta?bility of the proposed tension control method by comparing with those of the conventional PID control method. The result reveals that the proposed method outperforms the conventional method. Finally, an experimental platform is constructed, and the proposed system is applied to a winding machine. The performance and stability of the tension control system are demonstrated via a series of experiments using carbon fiber under di erent reference speeds and tensions. This paper proposes a novel tension control method to regulate the fiber tension and transport speed.

Abnormal Shape Mould Winding

A theory of composite material patch winding is proposed to determine the winding trajectory with a meshed data model. Two different conditions are considered in this study. One is Bridge condition on the concave surface and the other is Slip line condition in the process of patch winding. This paper presents the judgment principles and corresponding solutions by applying differential geometry theory and space geometry theory. To verify the feasibility of the patch winding method, the winding control code is programmed. Furthermore, the winding experiments on an airplane inlet and a vane are performed. From the experiments, it shows that the patch winding theory has the advantages of flexibility, easy design and application.

Analysis for the residual prestress of composite barrel for railgun with tension winding

Based on the elastic theory of cylindrical shells and the theory of composite laminates,a prediction model for the residual prestress of the simplified round composite barrel for railgun is established.Only the fibre pretension is considered in this model.A three dimensional numerical simulation for the residual prestress in the railgun barrel is carried out,by combining the temperature differential method with the element birth and death technology.The results obtained by the two methods are compared.It reveals that the distribution trends of residual prestress are consistent.And the difference for residual prestress in the filament wound composite housing of barrel is relatively small.The same finite element method is used to analysis the residual prestress in the non-simplified composite barrels for railgun,which are under different control modes of winding tension.The results mean that the residual prestress in barrel will increase while the taper coefficient for winding is decreasing.Therefore,the sealing performance in bore is improved,but the strength of the filament wound composite housing drops.In addition,the axial and circumferential residual prestress in the filament wound composite housing with constant torque winding are close to the ones in iso-stress design for barrel.

Research on Combination Winding of Revolving Bodies

A methematical model based upon the theory of differential geometry isestablished for the combination winding of revolving bodies and programs are developedfor the filament winding operations as well.Trial winding on a filament winding machineproved this model is right and useful.

A Mathematical Model for the Geodesic Winding of Surfaces of Rotation

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Research on PCC Control Method for Ribbon-free Random Winding

Based on analyzing the overlap appearance of random winding, basic principles of ribbon-free random winding and parametric selections for anti-overlap are discussed. The ribbon-free random winding control system and its related hardware construction as well as its software design are introduced by applying PCC technology to high speed spinning machine of synthetic filament.

Development of Computer Simulation System for the Winding of Toroidal Pressure Vessels

The pattern for filament wound toroidal vessels derived from differential geometry is presented. The pattern design and optimization procedure was put forward according to imposed design requirements. The mathematical model and movement equations of winding torns are obtained by analytic geometry. A computer simulation system of filament winding process based on optimal pattern design was developed to verify the correctness and practicability of the winding pattern. The optimum pattern and winding simulation were performed by this system. The simulation results show that the pattern satisfies both winding principles and structural optimization. The recommended design-oriented method can be applied to the preliminary design of filament wound toroidal vessels.

Strain-Rate Dependency of a Unidirectional Filament Wound Composite under Compression

This article presents the results of experimental studies concerning the dynamic deformation and failure of a unidirectional carbon fiber reinforced plastic(T700/LY113)under compression.The test samples were manufactured through the filament winding of flat plates.To establish the strain rate dependencies of the strength and elastic modulus of the material,dynamic tests were carried out using a drop tower,the Split Hopkinson Pressure Bar method,and standard static tests.The samples were loaded both along and perpendicular to the direction of the reinforcing fiber.The applicability of the obtained samples for static and dynamic tests was confirmed through finite elementmodeling and the high-speed imaging of the deformation and failure of samples during testing.As a result of the conducted experimental studies,static and dynamic stress-strain curves,time dependencies of deformation and the stress and strain rates of the samples during compression were obtained.Based on these results,the strain rate dependencies of the strength and elasticity modulus in the strain rate range of 0.001-6001/s are constructed.It is shown that the strain rate significantly affects the strength and deformation characteristics of the unidirectional carbon fiber composites under compression.An increase in the strain rate by 5 orders of magnitude increased the strength and elastic modulus along the fiber direction by 42%and 50%,respectively.Perpendicular loading resulted in a strength and elastic modulus increase by 58%and 50%,respectively.The average strength along the fibers at the largest studied strain rate was about 1000MPa.The obtained results can be used to design structural elements made of polymer composite materials operating under dynamic shock loads,as well as to build models of mechanical behavior and failure criteria of such materials,taking into account the strain rate effects.

纤维缠绕建造技术的研究与展望

纤维缠绕建造技术是一种以无芯纤维缠绕技术为基础,采用自主建造机器人来实现大尺寸纤维缠绕结构及其构件的快速、准确和自动化建造的新型技术。本文针对纤维缠绕技术具有扩展到大尺寸建筑及其构件建造的潜力,首先重点介绍了纤维缠绕技术的基本原理、材料系统、机械设备和关键技术,其次梳理和归纳了这一新型建造技术在建筑施工领域中的应用,最后进一步探索和展望纤维缠绕建造技术的未来发展方向。

考虑张力制度影响的碳纤维缠绕容器爆破性能预测与仿真插件开发

针对缠绕张力对碳纤维缠绕容器承载性能影响规律尚不明确的问题,基于ABAQUSTM软件开发了一套用户友好、自主选择性好且高效的插件工具,能够自动化完成模型建立和相关设置工作,实现了考虑多种缠绕工艺参数的容器结构精细化建模。基于该插件工具,对碳纤维缠绕容器在不同缠绕张力制度下的爆破性能进行了参数化分析,通过爆破试验验证了数值模型的有效性。对于直径为Ф155 mm和Ф474 mm的容器,90 N-80 N-60 N和200 N-180 N-160 N逐层减小的缠绕张力制度将提高容器的爆破性能;对于20 N和30 N递减张力制度,直径Ф474 mm容器的爆破压强随着内层张力的减小逐渐降低,当张力递减幅度增加时,容器的爆破压强趋于稳定,其下降幅度由16.79%减小到3.05%。此外,容器封头段与筒身段过渡区域的应变水平最高,为碳纤维缠绕容器的薄弱位置。

用CADWIND仿真锥形壳体的纤维缠绕

在CADWIND软件的帮助下,进行不等开口锥形壳体的数控缠绕编程工作。通过六维数控缠绕机缠绕出锥形壳体,获得比较满意的缠绕线型。本文主要介绍CADWIND软件的组成及功能并用该软件实现锥形壳体的缠绕编程。

基于柱形容器缠绕特性的控制稳定性分析

针对玻璃纤维缠绕机在工作中由于张力不稳定导致的线型变化,以及在高速缠绕模式下的张力调节不稳定的问题,设计了自适应模糊PID控制策略以及适用于高速缠绕工况的滑模控制策略。首先,针对缠绕工况建立缠绕动力学模型、张力控制模型;其次,引入模糊PID控制策略和滑模控制策略分别对不同工况下的缠绕特性进行MATLAB-Simulink仿真,寻找最优控制策略;最后,基于被验证的最优控制策略进行实验。结果表明,在模糊PID控制的调节下,不同速度变化下的缠绕张力相对于无控制得到较好改善,提高了柱形容器在缠绕时的线性稳定性和张力稳定性。模糊PID控制对缠绕时的张力调节精度优于滑模控制,为大型管道缠绕设备提供了新的研究思路。

一种高性能的纤维缠绕CAD/CAM软件——WINDSOFT

纤维缠绕成型是制造高强度复合材料制品的一种重要的工艺方法。为了有效地应用这一工艺方法,需要符合纤维缠绕工艺特点的CAD和CAM技术的有力支持。将CAD/CAM技术应用于纤维缠绕成型工艺过程中。介绍了WINDSOFT缠绕软件的整体架构和实现过程。结合缠绕成型工艺的特点对CAD/CAM系统各个组成模块和功能进行了分析和讨论。

机器人纤维缠绕装备的研究进展

我国纤维缠绕技术历经60多年的发展,已经成为我国复合材料行业的关键成型技术之一。为了深入了解国内外机器人缠绕装备的发展态势,基于传统的纤维缠绕技术特点概述了机器人和纤维缠绕技术相结合的工艺,论述了有芯模纤维缠绕工艺、无芯模纤维缠绕工艺以及空间纤维缠绕工艺三种形式;重点从国内和国外两个维度概述了机器人纤维缠绕装备研究以及缠绕软件开发的进展。研究得出,基于机器人的纤维缠绕成型装备由于具备的高速度、高精度、高柔性等多重优点使其成为复合材料成型技术的研究热点,也是未来复材成型装备行业的发展趋势。

卷绕机常见故障浅析

对实际生产中的卷绕机各类故障进行分析,以便能及时发现与解决问题,达到提升卷绕机上机成功率的目的。卷绕机在运行过程中,理论上应保持良好的运行环境,避免接触到灰尘、油污、废丝,但在实际使用过程中仍然不能避免卷绕机内侧积油、废丝缠入,导致轴承失效、线路老化、涨块磨损等故障,这已经成为影响卷绕机使用寿命的主要原因。因此要及时采取相应防范措施,消除这些不利因素。

卷绕头横动拨叉机构对丝饼成型的影响分析

为进一步提升产品效能,分析FDY卷绕头横动拨叉机构的工作原理。根据卷绕头横动拨叉的结构特性的演变过程,分析了TMT卷绕机的两轴两叶型拨叉较其他类型拨叉存在的差异。结合拨叉的设计及运动特点,改变拨叉机构成型板、拔叉叶片及八字形瓷件的定位及尺寸,满足丝饼同卷径增质量的运行条件。生产实践结果表明:所使用的拨叉机构通过相关设计改造及调整相应工艺参数可以达到提升产品运输包装效率和节约能耗的目的。

缠绕用改性双马来酰亚胺树脂体系性能的研究

采用T型双马来酰亚胺树脂和脂肪族双马来酰亚胺树脂为基体树脂,通过添加稀释剂、增韧剂、不饱和芳烃型固化促进剂,制备了一种适用于缠绕工艺的低粘度改性双马来酰亚胺树脂体系,通过DSC法确定了树脂体系的固化制度,考察了树脂固化物的耐热性能,采用缠绕工艺制备了国产T800复合材料单向板并测试了力学性能。结果表明,在35℃时,树脂体系粘度为760 MPa·s,固化物的玻璃化转变温度为287.7℃,复合材料单向板0°拉伸强度为2457.44 MPa,模量为162.55 Gpa,弯曲强度为1554.28 MPa,层间剪切强度为62.45 MPa,纤维与树脂匹配性能良好,力学性能优异。