1. Carbon Fiber Filament Winding
Hal Peterson
Rob Haglin

2. Overview
Design and build a machine capable of carbon fiber filament winding
Empirically test and optimize mandrel

3. 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

4. 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.

5. 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.

6. Winding
Three types of winding
Helical
Circumferential
Polar

7. The machine 2 axis movement Variable speed spindle to hold mandrel
Computer controlled
Various diameters and lengths of shafts
Wide range of wrapping angles

8. The Machine

9. Resin Delivery 2 main forms Pre-preg (pre-coated with resin)
Resin bath impregnation

10. Resin bath Advantages Disadvantages Cheaper Easy to store
Curable at room or elevated temp.
Disadvantages
Inconsistent
Messy

11. Pre-preg – our choice Advantages Disadvantages 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

12. 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

13. Curing Room temp (can take long time) Oven (elevated temp)
Only for resin bath-impregnated
Oven (elevated temp)
Increased pressure

14. Machine Design issues Design for versatility Gearing
Wear of pre-preg on eyelet
Machine parts filling up with resin.

15. General Control Scheme

16. User Interface Needed Information What happens Fiber Angle
Tube diameter
Tube length
Desired speed - optional
What happens
Instruction set generated from parameters

17. What happens

18. Instruction Set Object Oriented Approach
Visual Basic .NET
Decreases programming time
Use supporting programs from Galil
Developers kit
Advanced servo tuning
ActiveX controllers - $695

19. Questions

20. References http://www.fibercote.com/pabo6.html
Manufacturing processes for Engineering Materials, 5th Ed.
Material Science and Engineering 6th Ed
Galil user documentation