Tension Design Of Heated-mandrel Winding For Composite Shell

With the development of material science and manufacture process, theresin matrix composite is applied not only widely in the fields of the traditionaltransportation, construction and chemical but gradually in the high technologyfields of aerospace and automotive as well. It can be easily taken place the metalmaterial with the advantages of high modulus, high strength, resistant corrosionand easy design. The winding tension is one of the important parametersaffecting the material performance in composite molding process. The shell canbear internal pressure at the same time by designing the rational tension systemand its overall performance is also well improved.In the traditional molding process, the composite is first wound and thencuring. The wound is carried out at room temperature. In this process, thecomposite dose not occur curing reaction. Hence, the study of the windingtension system dose not need take consideration of the influence of temperature.The heat winding is the process for the composite that makes winding and curingoccurs at the same time. The winding tension will be subjected to the thermalstress caused by the changed temperature, the curing shrinkage stress caused bythe curing reaction and the each changed parameter caused by the changedtemperature. Obviously, the tension system design method without consideringthe changed temperature is not appropriate for the heating winding process.A tension system design method applied to heating winding process isproposed in this paper. Firstly, this method is based on the composite basicmechanics theory. The internal stress of the heating winding process is detailanalyzed taking the fiber trim arrangement of each layer and the equal stress statedistribution of ring to the direction of each fiber layer as the principle afterwinding. Secondly, the influence producing by the tension system to the shell isanalyzed and the influence for the ring to the direction stress of the shell including the thermal stress caused by the changed temperature, the curingshrinkage stress caused by the curing reaction and the each changed parametercaused by the changed temperature are all considered during winding. Taking theafterburner winding process equivalent to the thin ring superimposed andadopting the analytical design method and designing the tension system appliedto the heating winding process. Finally, MATLAB and Finite Element Analysissoftware are applied respectively to take the numerical simulation analysis of thering internal stress and radial residual stress-strain during the heating winding.By the test of the performance, further verify the correctness of the tensionsystem.Taking the consideration of the influence of curing factors to the shell stressduring winding in this paper, the simulation shows that the ring internal stress offiber layer can reach basically the default stress values by using the methods,ensure the fiber to bear the pressure uniformly and reduce the radial residualstrain of the shells. This research provides a new idea to realize the tensionsystem with heated-mandrel winding，and it is the important foundation forperformance optimization of shells.