A numerical method to predict the bursting strength of filament wound composite rocket motor case is proposed here.This method can evaluate the longitudinal stress evolution of each composite layer as impregnated fila...A numerical method to predict the bursting strength of filament wound composite rocket motor case is proposed here.This method can evaluate the longitudinal stress evolution of each composite layer as impregnated filaments with fiber tension are wound layer by layer,and consider the effects of accumulated stress and deformation during filament winding on the bursting strength of composite case.Taking∅520 mm composite cases as a case study,the filament-winding-process-induced stress and deformation as well as progressive damage behavior are numerically predicted,followed by a comparison with experimental results.The numerical results show that the predicted bursting pressures for composite cases manufactured on the mandrels with and without a flexible component are 14.20 MPa and 21.40 MPa,respectively.These values exhibit slight deviation from the measured pressures of 13.50 MPa and 21.57 MPa.Moreover,the predicted damage locations,situated respectively in the dome and cylinder,agree well with the experimental observation.These observations indicate that use of flexible component reduces the load-bearing capacity of the domes.Furthermore,it validates the reliability and accuracy of the proposed numerical method in predicting the bursting strength of composite cases.展开更多
As energy crisis and environment pollution all around the world threaten the widespread use of fossil fuels,compressed natural gas(CNG)vehicles are explored as an alternative to the conventional gasoline powered vehic...As energy crisis and environment pollution all around the world threaten the widespread use of fossil fuels,compressed natural gas(CNG)vehicles are explored as an alternative to the conventional gasoline powered vehicles.Because of the limited space available for the car,the composite pressure vessel(TypeⅡ)has been applied to the CNG vehicles to reach large capacity and weight lightening vehicles.High pressure vessel(TypeⅡ)is composed of a composite layer and a metal liner.The metal liner is formed by the deep drawing and ironing(D.D.I.)process,which is a complex process of deep drawing and ironing.The cylinder part is reinforced by composite layer wrapped through the filament winding process and is bonded to the liner by the curing process.In this study,an integrated design method was presented by establishing the techniques for FE analysis of entire processes(D.D.I.,filament winding and curing processes)to manufacture the CNG composite pressure vessel(TypeⅡ).Dimensions of the dies and the punches of the 1 st(cup drawing),2 nd(redrawing-ironing 1-ironing 2)and 3 rd(redrawing-ironing)stages were calculated theoretically,and shape of tractrix die to be satisfied with the minimum forming load was suggested for life improvement and manufacturing costs in the D.D.I.process.Thickness of the composite material was determined in the filament winding process,finally,conditions of the curing process(number of heating stage,curing temperature,heating rate and time)were proposed to reinforce adhesive strength between the composite layers.展开更多
The constant winding tension can make the filament arranged in order. The stress distribution between the filament balance fully gives play to the enhancement of filament, and increases the intensive workload of the c...The constant winding tension can make the filament arranged in order. The stress distribution between the filament balance fully gives play to the enhancement of filament, and increases the intensive workload of the composite winding material. This paper conducts the mechanical analysis for the unwinding roller and tension measuring roller of the cylindrical winding machine so that gets the mechanical model, gives error compensation formula caused by the radius change of the yarn group in the unwinding side, designs the closed-loop control system and utilizes the dynamical- integral PID control strategy to achieve the tension control during the process of the cylindrical winding.展开更多
The FW process is a prefect method of manufacturing FRP composite air vessel resisting high pressure and aerial press vessel.In this paper FW pattern of FRP composite air vessel resisting high pressure was analyzed in...The FW process is a prefect method of manufacturing FRP composite air vessel resisting high pressure and aerial press vessel.In this paper FW pattern of FRP composite air vessel resisting high pressure was analyzed in a nutshell.The stability of FW patterns on end head is very sensitive to changing of pattern parameter.Consequently,its FW pattern was based on geodesic track.The FW angles and on equators depend on the dimension of end part and the condition of geodesic FW.Generally speaking, the polar holes of rocket engine shell are disproportional.Therefore,the FW angles of the shell column are changeable.The feasi- bility of nongeodesic FW of the shell column was discussed in this paper.Furthermore,it expounded the indispensable condition be- tween the length of shell column and the FW friction coefficient.At the same time,the general mathematic models of the movement control of nongeodesic FW were deduced.展开更多
Filament winding has emerged as the main process for carbon fiber reinforced plastic(CFRP) fabrication, and tension control plays a key role in enhancing the quality of the winding products. With the continuous improv...Filament winding has emerged as the main process for carbon fiber reinforced plastic(CFRP) fabrication, and tension control plays a key role in enhancing the quality of the winding products. With the continuous improvement of prod?uct quality and e ciency, the precision of the tension control system is constantly improving. In this paper, a novel tension control method is proposed, which can regulate the fiber tension and transport speed of the winding process by governing the outputs of three di erent driven rollers(the torque of the unwind roll, the torque of the magnetic powder brake roller, and the speed of the master speed roller) in three levels. The mechanical structures and dynamic models of the driven rollers and idle rollers are established by considering the time?varying features of the roller radius and inertia. Moreover, the influence of parameters and speed variation on fiber tension is investigated using the increment model. Subsequently, the control method is proposed by applying fiber tension in three levels accord?ing to the features of the three driven rollers. An adaptive fuzzy controller is designed for tuning the PID parameters online to control the speed of the master speed roller. Simulation is conducted for verifying the performance and sta?bility of the proposed tension control method by comparing with those of the conventional PID control method. The result reveals that the proposed method outperforms the conventional method. Finally, an experimental platform is constructed, and the proposed system is applied to a winding machine. The performance and stability of the tension control system are demonstrated via a series of experiments using carbon fiber under di erent reference speeds and tensions. This paper proposes a novel tension control method to regulate the fiber tension and transport speed.展开更多
A theory of composite material patch winding is proposed to determine the winding trajectory with a meshed data model. Two different conditions are considered in this study. One is Bridge condition on the concave surf...A theory of composite material patch winding is proposed to determine the winding trajectory with a meshed data model. Two different conditions are considered in this study. One is Bridge condition on the concave surface and the other is Slip line condition in the process of patch winding. This paper presents the judgment principles and corresponding solutions by applying differential geometry theory and space geometry theory. To verify the feasibility of the patch winding method, the winding control code is programmed. Furthermore, the winding experiments on an airplane inlet and a vane are performed. From the experiments, it shows that the patch winding theory has the advantages of flexibility, easy design and application.展开更多
Based on the elastic theory of cylindrical shells and the theory of composite laminates,a prediction model for the residual prestress of the simplified round composite barrel for railgun is established.Only the fibre ...Based on the elastic theory of cylindrical shells and the theory of composite laminates,a prediction model for the residual prestress of the simplified round composite barrel for railgun is established.Only the fibre pretension is considered in this model.A three dimensional numerical simulation for the residual prestress in the railgun barrel is carried out,by combining the temperature differential method with the element birth and death technology.The results obtained by the two methods are compared.It reveals that the distribution trends of residual prestress are consistent.And the difference for residual prestress in the filament wound composite housing of barrel is relatively small.The same finite element method is used to analysis the residual prestress in the non-simplified composite barrels for railgun,which are under different control modes of winding tension.The results mean that the residual prestress in barrel will increase while the taper coefficient for winding is decreasing.Therefore,the sealing performance in bore is improved,but the strength of the filament wound composite housing drops.In addition,the axial and circumferential residual prestress in the filament wound composite housing with constant torque winding are close to the ones in iso-stress design for barrel.展开更多
Based on analyzing the overlap appearance of random winding, basic principles of ribbon-free random winding and parametric selections for anti-overlap are discussed. The ribbon-free random winding control system and i...Based on analyzing the overlap appearance of random winding, basic principles of ribbon-free random winding and parametric selections for anti-overlap are discussed. The ribbon-free random winding control system and its related hardware construction as well as its software design are introduced by applying PCC technology to high speed spinning machine of synthetic filament.展开更多
A methematical model based upon the theory of differential geometry isestablished for the combination winding of revolving bodies and programs are developedfor the filament winding operations as well.Trial winding on ...A methematical model based upon the theory of differential geometry isestablished for the combination winding of revolving bodies and programs are developedfor the filament winding operations as well.Trial winding on a filament winding machineproved this model is right and useful.展开更多
Based on the theory of differential geometry, the geodesic equation of surfaces of rotation is derived and the mathematical model for geodesic winding of surfaces of rotation is established. It is the theoretical foun...Based on the theory of differential geometry, the geodesic equation of surfaces of rotation is derived and the mathematical model for geodesic winding of surfaces of rotation is established. It is the theoretical foundation of combination winding.展开更多
The pattern for filament wound toroidal vessels derived from differential geometry is presented. The pattern design and optimization procedure was put forward according to imposed design requirements. The mathematical...The pattern for filament wound toroidal vessels derived from differential geometry is presented. The pattern design and optimization procedure was put forward according to imposed design requirements. The mathematical model and movement equations of winding torns are obtained by analytic geometry. A computer simulation system of filament winding process based on optimal pattern design was developed to verify the correctness and practicability of the winding pattern. The optimum pattern and winding simulation were performed by this system. The simulation results show that the pattern satisfies both winding principles and structural optimization. The recommended design-oriented method can be applied to the preliminary design of filament wound toroidal vessels.展开更多
This article presents the results of experimental studies concerning the dynamic deformation and failure of a unidirectional carbon fiber reinforced plastic(T700/LY113)under compression.The test samples were manufactu...This article presents the results of experimental studies concerning the dynamic deformation and failure of a unidirectional carbon fiber reinforced plastic(T700/LY113)under compression.The test samples were manufactured through the filament winding of flat plates.To establish the strain rate dependencies of the strength and elastic modulus of the material,dynamic tests were carried out using a drop tower,the Split Hopkinson Pressure Bar method,and standard static tests.The samples were loaded both along and perpendicular to the direction of the reinforcing fiber.The applicability of the obtained samples for static and dynamic tests was confirmed through finite elementmodeling and the high-speed imaging of the deformation and failure of samples during testing.As a result of the conducted experimental studies,static and dynamic stress-strain curves,time dependencies of deformation and the stress and strain rates of the samples during compression were obtained.Based on these results,the strain rate dependencies of the strength and elasticity modulus in the strain rate range of 0.001-6001/s are constructed.It is shown that the strain rate significantly affects the strength and deformation characteristics of the unidirectional carbon fiber composites under compression.An increase in the strain rate by 5 orders of magnitude increased the strength and elastic modulus along the fiber direction by 42%and 50%,respectively.Perpendicular loading resulted in a strength and elastic modulus increase by 58%and 50%,respectively.The average strength along the fibers at the largest studied strain rate was about 1000MPa.The obtained results can be used to design structural elements made of polymer composite materials operating under dynamic shock loads,as well as to build models of mechanical behavior and failure criteria of such materials,taking into account the strain rate effects.展开更多
基金supported by the National Natural Science Foundation of China(No.11902231)the Major Program(JD)of Hubei Province,China(No.2023BAA004).
文摘A numerical method to predict the bursting strength of filament wound composite rocket motor case is proposed here.This method can evaluate the longitudinal stress evolution of each composite layer as impregnated filaments with fiber tension are wound layer by layer,and consider the effects of accumulated stress and deformation during filament winding on the bursting strength of composite case.Taking∅520 mm composite cases as a case study,the filament-winding-process-induced stress and deformation as well as progressive damage behavior are numerically predicted,followed by a comparison with experimental results.The numerical results show that the predicted bursting pressures for composite cases manufactured on the mandrels with and without a flexible component are 14.20 MPa and 21.40 MPa,respectively.These values exhibit slight deviation from the measured pressures of 13.50 MPa and 21.57 MPa.Moreover,the predicted damage locations,situated respectively in the dome and cylinder,agree well with the experimental observation.These observations indicate that use of flexible component reduces the load-bearing capacity of the domes.Furthermore,it validates the reliability and accuracy of the proposed numerical method in predicting the bursting strength of composite cases.
基金Supported by National Research Foundation of Korea(NRF)Korea Government(MSIT)(Grant No.2019R1F1A1058521)
文摘As energy crisis and environment pollution all around the world threaten the widespread use of fossil fuels,compressed natural gas(CNG)vehicles are explored as an alternative to the conventional gasoline powered vehicles.Because of the limited space available for the car,the composite pressure vessel(TypeⅡ)has been applied to the CNG vehicles to reach large capacity and weight lightening vehicles.High pressure vessel(TypeⅡ)is composed of a composite layer and a metal liner.The metal liner is formed by the deep drawing and ironing(D.D.I.)process,which is a complex process of deep drawing and ironing.The cylinder part is reinforced by composite layer wrapped through the filament winding process and is bonded to the liner by the curing process.In this study,an integrated design method was presented by establishing the techniques for FE analysis of entire processes(D.D.I.,filament winding and curing processes)to manufacture the CNG composite pressure vessel(TypeⅡ).Dimensions of the dies and the punches of the 1 st(cup drawing),2 nd(redrawing-ironing 1-ironing 2)and 3 rd(redrawing-ironing)stages were calculated theoretically,and shape of tractrix die to be satisfied with the minimum forming load was suggested for life improvement and manufacturing costs in the D.D.I.process.Thickness of the composite material was determined in the filament winding process,finally,conditions of the curing process(number of heating stage,curing temperature,heating rate and time)were proposed to reinforce adhesive strength between the composite layers.
文摘The constant winding tension can make the filament arranged in order. The stress distribution between the filament balance fully gives play to the enhancement of filament, and increases the intensive workload of the composite winding material. This paper conducts the mechanical analysis for the unwinding roller and tension measuring roller of the cylindrical winding machine so that gets the mechanical model, gives error compensation formula caused by the radius change of the yarn group in the unwinding side, designs the closed-loop control system and utilizes the dynamical- integral PID control strategy to achieve the tension control during the process of the cylindrical winding.
文摘The FW process is a prefect method of manufacturing FRP composite air vessel resisting high pressure and aerial press vessel.In this paper FW pattern of FRP composite air vessel resisting high pressure was analyzed in a nutshell.The stability of FW patterns on end head is very sensitive to changing of pattern parameter.Consequently,its FW pattern was based on geodesic track.The FW angles and on equators depend on the dimension of end part and the condition of geodesic FW.Generally speaking, the polar holes of rocket engine shell are disproportional.Therefore,the FW angles of the shell column are changeable.The feasi- bility of nongeodesic FW of the shell column was discussed in this paper.Furthermore,it expounded the indispensable condition be- tween the length of shell column and the FW friction coefficient.At the same time,the general mathematic models of the movement control of nongeodesic FW were deduced.
基金Supported by National Natural Science Foundation of China(Grant No.51575018)
文摘Filament winding has emerged as the main process for carbon fiber reinforced plastic(CFRP) fabrication, and tension control plays a key role in enhancing the quality of the winding products. With the continuous improvement of prod?uct quality and e ciency, the precision of the tension control system is constantly improving. In this paper, a novel tension control method is proposed, which can regulate the fiber tension and transport speed of the winding process by governing the outputs of three di erent driven rollers(the torque of the unwind roll, the torque of the magnetic powder brake roller, and the speed of the master speed roller) in three levels. The mechanical structures and dynamic models of the driven rollers and idle rollers are established by considering the time?varying features of the roller radius and inertia. Moreover, the influence of parameters and speed variation on fiber tension is investigated using the increment model. Subsequently, the control method is proposed by applying fiber tension in three levels accord?ing to the features of the three driven rollers. An adaptive fuzzy controller is designed for tuning the PID parameters online to control the speed of the master speed roller. Simulation is conducted for verifying the performance and sta?bility of the proposed tension control method by comparing with those of the conventional PID control method. The result reveals that the proposed method outperforms the conventional method. Finally, an experimental platform is constructed, and the proposed system is applied to a winding machine. The performance and stability of the tension control system are demonstrated via a series of experiments using carbon fiber under di erent reference speeds and tensions. This paper proposes a novel tension control method to regulate the fiber tension and transport speed.
基金Foundation item： Aeronautical Science Foundation of China （50175020）
文摘A theory of composite material patch winding is proposed to determine the winding trajectory with a meshed data model. Two different conditions are considered in this study. One is Bridge condition on the concave surface and the other is Slip line condition in the process of patch winding. This paper presents the judgment principles and corresponding solutions by applying differential geometry theory and space geometry theory. To verify the feasibility of the patch winding method, the winding control code is programmed. Furthermore, the winding experiments on an airplane inlet and a vane are performed. From the experiments, it shows that the patch winding theory has the advantages of flexibility, easy design and application.
文摘Based on the elastic theory of cylindrical shells and the theory of composite laminates,a prediction model for the residual prestress of the simplified round composite barrel for railgun is established.Only the fibre pretension is considered in this model.A three dimensional numerical simulation for the residual prestress in the railgun barrel is carried out,by combining the temperature differential method with the element birth and death technology.The results obtained by the two methods are compared.It reveals that the distribution trends of residual prestress are consistent.And the difference for residual prestress in the filament wound composite housing of barrel is relatively small.The same finite element method is used to analysis the residual prestress in the non-simplified composite barrels for railgun,which are under different control modes of winding tension.The results mean that the residual prestress in barrel will increase while the taper coefficient for winding is decreasing.Therefore,the sealing performance in bore is improved,but the strength of the filament wound composite housing drops.In addition,the axial and circumferential residual prestress in the filament wound composite housing with constant torque winding are close to the ones in iso-stress design for barrel.
文摘Based on analyzing the overlap appearance of random winding, basic principles of ribbon-free random winding and parametric selections for anti-overlap are discussed. The ribbon-free random winding control system and its related hardware construction as well as its software design are introduced by applying PCC technology to high speed spinning machine of synthetic filament.
文摘A methematical model based upon the theory of differential geometry isestablished for the combination winding of revolving bodies and programs are developedfor the filament winding operations as well.Trial winding on a filament winding machineproved this model is right and useful.
文摘Based on the theory of differential geometry, the geodesic equation of surfaces of rotation is derived and the mathematical model for geodesic winding of surfaces of rotation is established. It is the theoretical foundation of combination winding.
文摘The pattern for filament wound toroidal vessels derived from differential geometry is presented. The pattern design and optimization procedure was put forward according to imposed design requirements. The mathematical model and movement equations of winding torns are obtained by analytic geometry. A computer simulation system of filament winding process based on optimal pattern design was developed to verify the correctness and practicability of the winding pattern. The optimum pattern and winding simulation were performed by this system. The simulation results show that the pattern satisfies both winding principles and structural optimization. The recommended design-oriented method can be applied to the preliminary design of filament wound toroidal vessels.
基金This research was supported by the Russian Science Foundation(Grant No.21-19-00563,https://rscf.ru/en/project/21-19-00563/)H.M.Sedighi is grateful to the Research Council of Shahid Chamran University of Ahvaz for its financial support(Grant No.SCU.EM1401.98)。
文摘This article presents the results of experimental studies concerning the dynamic deformation and failure of a unidirectional carbon fiber reinforced plastic(T700/LY113)under compression.The test samples were manufactured through the filament winding of flat plates.To establish the strain rate dependencies of the strength and elastic modulus of the material,dynamic tests were carried out using a drop tower,the Split Hopkinson Pressure Bar method,and standard static tests.The samples were loaded both along and perpendicular to the direction of the reinforcing fiber.The applicability of the obtained samples for static and dynamic tests was confirmed through finite elementmodeling and the high-speed imaging of the deformation and failure of samples during testing.As a result of the conducted experimental studies,static and dynamic stress-strain curves,time dependencies of deformation and the stress and strain rates of the samples during compression were obtained.Based on these results,the strain rate dependencies of the strength and elasticity modulus in the strain rate range of 0.001-6001/s are constructed.It is shown that the strain rate significantly affects the strength and deformation characteristics of the unidirectional carbon fiber composites under compression.An increase in the strain rate by 5 orders of magnitude increased the strength and elastic modulus along the fiber direction by 42%and 50%,respectively.Perpendicular loading resulted in a strength and elastic modulus increase by 58%and 50%,respectively.The average strength along the fibers at the largest studied strain rate was about 1000MPa.The obtained results can be used to design structural elements made of polymer composite materials operating under dynamic shock loads,as well as to build models of mechanical behavior and failure criteria of such materials,taking into account the strain rate effects.
