Analysis On Resin Flow/Fiber Compaction In Filament Winding Process

Filament winding process is one main method of the manufacture for advanced composite materials. The process takes advantages in saving raw materials, easy automation and high product quality. There are complex and interrelated physical and chemical phenomena during the curing process, such as heat conduction, chemical reaction heat, change of resin viscosity, resin flow and so on. The process parameters are very hard to measure. Traditional process of winding method requires tests, long development period and high cost. Compared with experimental method, realizing various process parameters prediction during filament winding process by using numerical method is more economic and effective. At the same time, the numerical simulation method can provide the basis for the system of filament winding process to establish and optimize. Therefore, the numerical simulation method is of great importance to filament winding composites low-cost manufacturing.Based on the Squeeze-sponge model, a corresponding finite element model is developed to simulate resin flow and fiber compaction process in the curing process. Firstly, curing degree, resin viscosity, temperature influence and permeability of fiber winding composites are taken into account. The performing of resin flow is regarded as Newtonian fluid flow in porous media. Secondly, curing kinetics equation is used to simulate resin curing behavior by considering the change of fiber volume fraction. Finally, a model is developed to simulate resin flow and fiber compaction process in filament winding process by using APDL language of finite element analysis software ANSYS. The model is verified by comparing with the results of other researchers Based on the established finite element model, a curing process of filament winding cylinder is simulated. Resin flow, curing degree, fiber's volume fraction and temperature are attained by means of different winding parameters (winding tension, the initial solidification parameters) and geometric parameters of finite element model. Simulation results show that isotension design makes resin and fiber volume fraction distribute more uniformly than winding with constant tension. A reasonable improvement of the winding tension in the plies far away from resin outlet can give the fiber volume fraction a more uniform distribution in the structure. Under the same curing system, fiber volume fraction is proportional to winding tension; with the higher initial fiber volume fraction, the fiber volume fraction after curing is higher and resin distributes more uniformly; With the number of plies increase, the speed of resin flow become slower, resin distributes more nonuniform and fiber volume fraction become lower.