Analytical modelling of the filament winding process core. The emergence of thermoplastic composites as semi structural materials was. Jec 2004 lamontia tp filament winding and tape laying. The effect of winding speed and compaction force on the quality of the resulting parts was determined in order to optimize the process. Thermoplastic matrix filament winding head thiokol.
Advanced materials and processes preparing for the new millennium, 31. Thermoplastic filament winding university of plymouth. Thermoplastic composite parts were manufactured from tape prepreg apc. Process technology and operating efficiency process. Thermoplastic composite filament winding is an online consolidation process, where the composite experiences a complex temperature history and undergoes a number of temperature history affected microstructural changes that influence the structures subsequent properties. Iccm17 numerical modelling of the filament winding process. Thermoplastics are a class of polymers that can be softened and melted by the application of heat, and can be processed either in the heatsoftened state e. Heat transfer analysis of the thermoplastic filament winding. Apr 15, 2004 squeezing flow was adopted to model the processing of thermoplastic composites in filament winding. This paper will cover their process concept, how that concept was manifested in equipment, the material feedstocks, and the process capability in terms of cylindrical and flat stiffened parts that can be fabricated.
An abaqus transient heat transfer finite element model of the thermoplastic filament winding process was developed and used to predict the temperature inside the compositemandrel assembly. Pdf a new model allowing the simulation of the filament winding process of either thermosettings or thermoplastics is described. The governing equation of the cure kinetics of the resin was taken from literature 4 5. The polymer chains associate by intermolecular forces, which weaken rapidly with increased temperature, yielding a viscous liquid. A precision thermoplastic winding method and apparatus for forming heterogeneous pipe by winding a first hot thermoplastic strand on a mandrel, then applying a second strand of uncured thermosetting material on the first layer to form a second layer on the mandrel, and thereafter helically winding a hot thermoplastic strand on the second layer to form a third layer on the mandrel and to thus. Thermal residual stress simulation in thermoplastic. It is found that the resin flow is facilitated as a result of the slip condition, thus reducing the process times. Thermoplastic in situ process and equipment fibers and thermoplastic matrix resin are combined offline into impregnated tows for filament winding and impregnated tape for tapelaying 1. Online laser curing with preheating of thermoset composites. Jan 01, 2012 the thermoplastic filament winding process with bicomponent fibers is not as easy as the other winding methods. In wet winding the stability of filament pattern can be a problem until the resin matrix consistency becomes sufficiently high. Towpreg, filament winding, thermoplastic matrix composites. Korotkov, a few studies on online curing in filament winding. Prepreg winding usually involves heat curing, the initial resin softening favoring the slight rearrangement of fiber and matrix in the wound configuration.
It possesses a high melt flow rate and has been developed for thin wall i. This paper contrasts challenges in developing two thermoplastic in situ consolidation processes. There are several different variations of this process depending on their exact application 7,8. Wrinkling is one of the major failure mechanisms 30 and can be induced by consolidation. The filament winding process is a manufacturing technique in which a resin. Thermoplastic matrix filament winding head thiokol corporation. Firstly, analytical descriptions of the physical and thermochemical phenomena were developed for each phenomena. The quality of thermoplastic composites depends on the thermal history during processing.
One of the main issues in the fabrication of thermoplastic composites is the residual stresses that build up due to volumetric changes during solidification crystallization. Lionetto f, dellanna r, montagna f and maffezzoli a 2015 ultrasonic assisted consolidation of commingled thermoplasticglass fiber rovings. The filaments are fed from a vertically moving winding head onto the surface of a rotating mandrel. The filament winding section details the mechanical properties of as4peek and as4pekk 90 m0n cylinders fabricated by combining filament winding for 90 plies with tape placement for 0 plies. A frame for a game racquet such as a tennis racquet is formed by helically winding a tow of filament material and thermoplastic material over an elongated mandrel to form a tube. This preform is heated to melt the thermoplastic while the interior of the tube is. The models relate the processing conditions applied temperature, pressure and processing speed to parameters of interest such as composite temperature, viscosity, manufacturing stresses and strains, void sizes, as well as degrees of cure, fiber position and fiber tension for thermosets, and crystallinity, degrees of consolidation and bonding for thermoplastics. These include models that describe the heat transfer, consolidation and crystallization processes that occur during fabrication of a filament wound composites structure. Mantell and springer 3 published manufacturing process models for thermoplastic composites applicable also to filament winding.
The force applied to an element must be balanced by the pressure inside the element. This paper will cover their process concept, how that concept was manifested in equipment, the materials, and the process capability in terms of cylindrical and flat stiffened parts that can be fabricated. Material feedstock requirements were met with polyimide and polyetherketone placementgrade tows and tapes from cytec engineered materials. Processing of high performance thermoplastic composites. Thermal phenomena in fiberreinforced thermoplastic tape. Thermoplastic filament winding tape laying has achieved autoclave level properties in thin and thick right circular cylinders for submersible applications. Some authors have analyzed the generation of wrinkling during consolidation both in experimental studies and finite element simulations 31,32. Laserassisted thermoplastic tape winding pressure vessels made of carbon fiber composites are usually manufactured in thermosetting filament winding processes 6 which are established for mass production purposes. Pdf manufacturing of hybrid yarn thermoplastic composites.
Process combinations of filament winding with onlineimpregnation of fibre. Thermoplastic filament winding with online impregnation. The model relates the material properties, the winding speed, and the hotgas heater temperature to thermal response of the composite. Processing models and characterization of thermoplastic. Ultrasonic assisted consolidation of commingled thermoplastic. Nov 01, 2002 the process technology offers the interesting possibility to vary the fibre volume content within a component. The aim of this chapter is to give an overview about the thermoplastic filament winding process and to explain the most important specific process aspects. It includes specific physical features inherent to the filament winding process. Process thermoset tow thermoplastic tow ex powder ex commmgling ex melt ex solvent resin throughput cost rates x x 1.
In this part, a comprehensive study of process parameters was conducted. The vessels consist on a thermoplastic liner wrapped with a filament winding glass fibre reinforced polymer matrix structure 1. The filament winding 1 all tows and tapes referred to in this paper were fabricated by cytec engineered materials cem using either the apc or the tiff. A novel filament winding process technology has been realized which allows to combine online solution impregnation with insitu consolidation for a kind of high performance thermoplastic, poly. The matrix materials can be either thermoset or thermoplastic resins. Therefore it is important to determine the temperature distribution in. Jan 01, 2004 process induced thermal stresses in thermoplastic filament winding, sampe technical conference. Automated thermoplastic filament winding, tape laying, and fiber placement have been demonstrated by manufacturing thermoplastic reinforced carbonfiber laminates and stiffened parts using in situ consolidation. The stressstrain relationship for each layer is computed in a local coordinate system. Pressure vessels made of carbon fiber composites are usually manufactured in thermosetting filament winding processes 6 which are established for mass. Request pdf thermoplastic filament winding with onlineimpregnation. New direct inline filament winding technology from. Heat transfer analysis of the thermoplastic filament winding process. The consolidation pressure and winding speed for thermoplastic filament winding were studied.
The filament winding process is a lowcost, automated composite manufacturing technique. For the industries where use of the thermoplastic matrix and their advantages is of primary concern for our customers, we designed and produced special model of filament winding machine. Filament winding process in thermoplastics request pdf. Heat transfer analysis of the thermoplastic filament. Korotkov, a few studies on online curing in filament winding have been reported in. In filament winding of thermoplastics, localized melting solidification can reduce the residual stresses and allow for improved dimensional stability and performance. Plasticomps unique pultrusion process enables the company to introduce dfw materials that offer improved benefits to customers at a significantly lower cost compared to competitive products. These shortcomings were recognized in the early days of composites, and as a result the filament winding manufacturing process was developed to automate and mass produce composites. A comprehensive thermal model of the thermoplastic filament winding process.
To achieve a complete fuel storage system, manufacturing processes for lightweight, polymer composite, pressure vessels include fabrication of the polymeric or metallic liner, filament winding of the composite shell, thermal processing of the resin, pressurization and leak tests, and the subsequent. A thermoplastic, or thermosoftening plastic, is a plastic polymer material that becomes pliable or moldable at a certain elevated temperature and solidifies upon cooling most thermoplastics have a high molecular weight. However, automated tow placement was used to make the flat panels. Nov 01, 2018 filament winding is now used to produce a range of composite structures including golf club and driveshafts, yacht masts, oarspaddles, bicycle rims and forks, small aircraft fuselages, spacecraft structures, car wheels and pressure vessels, the latter ranging from firefighter oxygen bottles and liquid propane gas lpg tanks to cryogenic fuel tanks for spacecraft measuring 510m in diameter. Thermoplastic matrix composite cylinders, pipes, and other hollow bodies are formed by a winding technique using thermoplastic filaments. The tube is positioned in a mold having the shape of a game racquet frame and auxiliary pieces for handle and yoke sections are added.
A precision thermoplastic filament winding process for forming into pipe or similar articles by winding strands comprised of semihardened thermoplastic material on a rotating mandrel to form a layer thereon. A continuous reinforcement is impregnated with resin and laid down on the surface of a rotating mandrel along a predetermined path. An electrical current is passed through the filament means during the winding to thermally alter or melt the thermoplastic binder as the filament means are wound on the mandrel. Song 4 developed a filament winding model for thermoplastics. Single or multiple component, unreinforced andor continuously reinforced filament wound cylindrical products are continuously produced by winding, at least an inner layer of thermoplastic material upon a. A thermoplastic, or thermosoftening plastic, is a plastic polymer material that becomes pliable or moldable at a certain elevated temperature and solidifies upon cooling. Plasticomp announces an exciting advancement in the development of direct inline filament winding dfw of fiber reinforced thermoplastic compounds. Sirosh, in encyclopedia of electrochemical power sources, 2009 manufacturing processes. Filament winding is a widely used processing routine for continuous fibre.
An apparatus with a constant dead weight was employed to characterize the rheology of the thermoplastic composite in filament winding. Maw 20 fb31 fph6 filament winding machine with integrated fiber placement assisted winding head for thermoplastic roving. The assessment of operating efficiency based on a rough cost comparison calculation with thermoplastic filament winding using preimpregnated tapes was conducted. Autoclave processing of thermoplastic composites continuous belt lamination thermoplastic composite pultrusion thermoforming stamp forming automated tape laying processing thermoplastic composite filament winding additive manufacturing thermoplastic lcm processing of high performance thermoplastic composites 322. Thermoset and thermoplastic resin systems are considered and modeled. An electrical current is passed through the filament means during the winding to thermally alter or melt the thermoplastic binder as the filament means are wound on. A precision thermoplastic winding method and apparatus for forming heterogeneous pipe by winding a first hot thermoplastic strand on a mandrel, then applying a second strand of uncured thermosetting material on the first layer to form a second layer on the mandrel, and thereafter helically winding a hot thermoplastic strand on the second layer to form a third layer on the mandrel and to thus seal and. Atp, and filament winding combined with tape laying.
Thermoplastic filament winding offers the possibility to build up continuous fiber reinforced layups with welldefined fiber orientation and accurate positioning of. Plasticomps unique pultrusion process enables the company to introduce dfw materials that offer improved benefits to customers at a. Single or multiple component, unreinforced andor continuously reinforced filament wound cylindrical products are continuously produced by winding, at least an inner layer of thermoplastic. Jan 01, 1994 filament winding process models where p. Just as ice is a solid material when it is frozen, it melts with heat and becomes a liquid. A filament winding process for a meltprocessable, thermoplastic matrix material, and a reinforcing fiber. Request pdf thermoplastic wet filament winding so far, the classic wet winding process has basically been limited to thermosetting resin systems. Fibre reinforced thermosetting and thermoplastic matrix filament wound pressure vessels for large scale market applications have been studied in this work.
Diode laser assisted filament winding of thermoplastic. A statistical approach was used to determine the significant processing parameters and their effect on the mechanical and physical properties of composite cylinders. Filament winding process in thermoplastics sciencedirect. It could be shown that moderate speeds are sufficient for profitableness. Thermoplastic filament winding with onlineimpregnation. The pellets are melted to a liquid state and fibers are pulled through the resin to form a continuous fiber reinforced thermoplastic tape. Pdf numerical modelling of the filament winding process. Modeling of thermoplastic composite filament winding. Pdf online consolidation of thermoplastic composites. An online consolidation system, which includes a computercontrolled filament winding machine and a consolidation head assembly, has been designed and constructed to fabricate composite parts from thermoplastic towpregs.
Thermoplastic composite filament winding is an online consolidation process, where the composite experiences a complex temperature history and undergoes a number of temperature history affected microstructural changes that influence the structures. Filament winding is a process for fabricating composite materials in which continuous fibers, either previously impregnated with a matrix material or impregnated during winding, are wound onto a rotating mandrel in a precise, predetermined pattern. An important example deals with filament winding process. In this work, a global process model is developed for the filament winding process. The thermoplastic tape winding process is an energy fficient technique for the production of fiber re inforced plastics. The filament winding process, used for the manufacture of a wide variety of. Autoclave processing of thermoplastic composites continuous belt lamination thermoplastic composite pultrusion thermoforming stamp forming automated tape laying processing thermoplastic composite filament winding additive manufacturing thermoplastic lcm processing of high performance thermoplastic composites 1222. Reference 7 discusses process development of insitu. Effect on downstream cost for filament winding 2 process thermoset tow thermoplastic tow ex powder ex commingling. Models are described which simulated the filament winding of thermosetting and thermoplastic matrix composite cylinders. Costs and aircraft applications of thermoplastic composites. It possesses a high melt flow rate and has been developed for thin wall injection. Huang and coworkers 39 demonstrated that the fibers, which consist of a polymer lower melting point and a liquid crystalline polymer higher melting point, are very sensitive to the processing temperature. Besides this manufacturing process being labourintensive, the material scrap rate is high and repeatability is limited.
Us5575875a filament wound fiber reinforced thermoplastic. Pdf manufacturing flat and cylindrical laminates and. A method and apparatus for filament winding an object from electrically conductive filament means impregnated with a thermomatrix binder. Beside the material used, the most adjustable process parameters are. The filament means are wound onto an appropriate mandrel defining the shape of the object. In the filament winding of thermoplastic materials, the winding head stays in contact with the mandrel or composite part making consolidation on the fly simpler.
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