SMALL-SCALE FILAMENT WINDING MACHINE FOR PRODUCING FIBER COMPOSITE
Finite Element Modeling of the Filament Winding … Element Modeling of the Filament Winding Process...
Transcript of Finite Element Modeling of the Filament Winding … Element Modeling of the Filament Winding Process...
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Finite Element Modeling of the Filament Winding Process
Liyang Zhao, Reed McPeak, Susan C. Mantell
Department of Mechanical Engineering University of Minnesota
David Cohen Toray Composites America
Sponsored by Alliant Techsystem
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Overview
Background
Objective
Theoretical Model
Material Characterization
FEA Approach
Validation
Summary
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Background on Filament Winding
The oldest manufacturing process in composite industry (since 1940’s)
Applications: rocket nozzles, motor cases, jet engine components...
Structure geometry: cylindrical, spherical, and others
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Schematic of Filament Winding
Main Process Variables • Tow Tension • Lay-up • Temperature • Winding time/speed
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Material Properties
Fibers: High strength to weight ratio glass fibers; organic fibers; carbon and graphite fibers;
Resin System: Low-temperature cure Long pot life High flexibility Low toxicity
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Objective
Geometry
Material Properties
Processing Conditions (Time, Temp, Pressure)
Product Quality
Final dimensions Fiber/matrix volume fractions Final degree of cure Stress state
1. Material Characterization 2. Finite Element Simulation 3. Experimental Validation
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Problem Statement
T o
T i
<Thermochemical> temperature, cure, viscosity
pressure
Fiber Tension
<Fiber Motion> fiber position, fiber volume fraction <Resin Mixing>
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Thermochemical Model
α < αgel
• Degree of Cure
• Viscosity
• Heat generation
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Fiber Motion Model
• Fiber bed stiffness
• Layer stiffness
for for
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Resin Mixing Model
• Uncured resin from previously wound layers can be squeezed into the new layer
• Evaluate the effective viscosity by rule of mixture
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Material Characterization
• Resin Characterization • Cure kinetics
• Viscosity
• Resin mixing
• Fiber Characterization
Nonlinear Stiffness
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Cure kinetics for HBRF-55A resin
• DSC test (Differential Scanning Calorimeter)
• Isothermal scan at 100, 115, 130, 145, and 160°C
• Dynamic scan at rate of 20°C/min
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Viscosity of HBRF-55A resin
• Rheology test (Dynamic Stress Rheometer)
• Dynamic scan at rate of 0.5, 1, and 2°C/min
• Room temp. test
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Resin Mixing
• Two resin samples (m1=77.9 Pa.s, m2=1.42 Pa.s)
• Mixture ratio: 1:3, 1:1 and 3:1
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Fiber Characterization
Fiber compaction test
IM7 graphite fiber R sized, W sized
Va = 0.857 (R size) Va = 0.891 (W size)
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Finite Element Approach
Why Finite Element? • Complex geometry (domes, joint region) • Viscoelastic materials • Commercial support/documentation • Import existing files
Approach • ABAQUS software • Standard elements • User defined subroutines
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FEM Implementation
Model Input
Load History Input
Result
node definition element definition material definition
Wind/hold times Step 1: Layer #1 Winding Step 2: Layer #1 Holding ............. Step n: Last Layer holding Cure cycle
data file (temp, stress, cure, ...) restart file (post processing)
Heat generation Nonlinear Material
User defined subroutines ABAQUS Solver
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Model Proof Run
Proof Run:
- 28 Layers - Initial Wind Stress = 50MPa
- All Hoop Winds - Constant Layer Wind Time = 1 Hr
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Model Proof Run
Proof Run:
- 28 Layers - Initial Wind Stress = 50MPa
- All Hoop Winds - Constant Layer Wind Time = 1 Hr
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Model Proof Run
Proof Run:
- 28 Layers - Initial Fiber Volume Fraction = 0.56
- All Hoop Winds - Constant Layer Wind Time = 1 Hr
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Experimental Validations (1)
Cylinder: Delta3 (CT1)
Fiber: Hexcel IM7
Resin: HBRF-55A
Num. of Layers: 15
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Experimental Validations (2)
Cylinder: Delta2 (CT5)
Fiber: Hexcel IM7
Resin: HBRF-55A
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Experimental Validations (3)
Cylinder: Titan B-4C
Fiber: Hexcel IM7
Resin: HBRF-55A
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Summary
Completed • Thermochemical • Fiber motion • Resin Mixing
Temperature Viscosity Degree of Cure Fiber Volume fraction
FEM