Filament Winding Machine

Project Name – Filament Winding Machine Project Number – P09226 Project Family – Competitive FSAE Autosports Systems Project Leads – Shijo George (ME) – Alex Sandy (ME) Start Term – planned academic quarter for MSD1 End Term – planned academic quarter for MSD2 Faculty Guide – Dr. Alan Nye (Mechanical Engineering) Faculty Consultant – TBA (Dr. Ghoneim, Dr. Kempski) Primary Customers – Formula SAE, Mini Baja SAE

Filament Winding Machine Mission Statement: To develop a low cost, first generation filament winding machine which produces simple composite tubing that can be further developed by future senior design teams Roadmap Objective: Fundamental step in developing carbon fiber tubing to be used in space frame of Formula Racing vehicles

Objectives and Project Deliverables Test strength and stiffness of tubing Produce composite tubing Failure analysis of composite design Design and build a filament winding machine

Filament Winding The process by which a continuous strand of impregnated fibers is wound onto a mandrel with specific fibers’ orientation which is controlled by computer. After the resin has cured, the mandrel is withdrawn Components produced include pipe work, pressure vessels, storage tanks, and helicopter blades

Schematic of the wet filament winding process

Layout

Staffing 1 Computer Engineer Design – Develop program/controls for relative speed of mandrel to feed eye (determines fiber orientation) Build 4 Mechanical Engineers Design – CAD Design – Determine speed, tension, machine layout – Determine fiber orientation, tube specifications (based on testing capabilities) Build – Build set-up based on design (new machine system or off of existing lathe) Test – Determine strength of tubing in tension, bending, torsion

Preliminary Work Breakdown Structure Team MemberWeek 1Week 2Week 3 ME (Project Manager) Establish team values and norms Initiate brainstorming Establish individual team member roles Establish project direction and provide future WBS ME (Chief Engineer) Provide team with technical background information and design constraints Analyze proposed designs for feasibility Begin theoretical composite analysis ME Develop understanding of project and consider possible designs Determine feasibility of proposed designs Determine machine criteria (rpm, fiber tension, etc.) ME Determine machine design layout CE Research applicable control components Begin control system design

Concerns and Constraints Project o Sponsor(s) o Advisor(s) o Build Space for filament winding machine o Finalize Budget o Raw Mat’l $800-$900 o Motor and misc. $600- $700 Design o Fiber/Resin/Mandrel material o Control of fiber orientation angle o Existing lathe vs. build from scratch