WINDING AND CONSOLIDATION ANALYSIS FOR CYLINDRICAL COMPOSITE STRUCTURES

A general process model for the winding and consolidation of a cylindrical composite structure is presented. A key feature of this model is that it includes the elastic deformation of the fiber bundle and its influence on the process physics. Two important cases are discussed in detail. In one case, the resin flow time is short compared to the winding time. Hence the fiber distribution and other important parameters are determined almost solely by the fiber deformation behavior. This situation is common in wet filament winding. In the other case, the resin flow time is long compared to the winding time. Here we use a quasi-elastic analysis to determine the fiber distribution and stresses during winding. These conditions are then used as the inputs to the consolidation process. The consolidation process may occur while the wound structure is sitting, while it is being debulked, or while it is being cured and solidified. This case would apply to the winding of prepreg tapes. Finally, simulation experiments were performed to verify both the winding and the consolidation models.