外文翻译---低成本纤维缠绕机的设计与制造.doc

Design and fabrication of low cost filament winding machineF.H. Abdalla, S.A. Mutasher, Y.A. Khalid, S.M. Sapuan *,A. M.S. Hamouda, B.B. Sahari, M.M. HamdanB.AbstractIn general, the composite pipes are fabricated using glass fiber and polyester resin matrix by hand lay-up and also by 2-axis filament winding machine. In this work, a filament winding machine was designed and developed for the fabrication of pipes and round shape specimens. A lathe-type machine and a wet winding method were used in the design of the machine. It provides a capability for producing pipe specimens with an internal diameter up to 100 mm and lengths up to 1000 mm. The range of the winding angle, or the fiber orientation angle, starts from 20 to 90 depending on the mandrel diameter used. Mandrel speed is kept constant as 13.6 revolutions per minute (rpm) while the speed of screw of delivery unit varies from 0 rpm to a maximum of 250 rpm. In the filament winding process used, a single glass roving is drawn through a bath of pre-catalyzed resin which is mounted on the lead screw by the rotating mandrel. A control unit was used to control the whole process and achieve regular winding and good surface finish. Tube samples and other circular specimens of different dimensions were produced using this machine for the different mechanical tests and applications.Keywords: Filament winding; Composite tube; Glass fiber; Matrix; Fiber orientation angle1. IntroductionFilament winding has emerged as the primary process for composite cylindrical structures fabrication at low cost. In this process, composite layers are successively wound on a rotating mandrel, as presented in Fig. 1.The layers may be wrapped at different angles varying from hoop layers, which are perpendicular to the cylinder axis, to helical layers which are at an angle to the cylinder axis. The construction of composite cylinder by filament winding consists of three major steps 1, the first is the design, which includes the selection of materials, geometry, and fiber orientations while the second is fiber placement, the mechanical means by which the fibers are placed in their proper positions. Finally, the third is the selection and control of conditions which must be maintained during the Fig. 1. Schematic of the wet filament winding process 1.manufacturing process. A process for fabricating a composite structure in which continuous reinforcements (filament, wire, yarn, tape, or other), either previously impregnated with a matrix material or impregnated during the winding, are placed over a rotating and removable form or mandrel in a prescribed way to meet certain stress conditions. The reinforced fibers are usually made of glass, Kevlar or carbon. Owing to simplicity of process, the hardware configuration is quite standard, and generally involves two main sub-systems; the rotary assembly and the delivery system.The rotary assembly consists of two structural blocks;one fixed and the other linearly movable unit in which a 2-axis mechanically driven mandrel is mounted onto its holders. On the fixed end, the holder is connected to a rotating shaft, which is coupled to either a gear or a chain or belt reduction system, or directly to the motor unit. Generally, an AC or servo-motor is used because of its greater torque capabilities and accuracy when operating under conditions of heavy loading. For delivery system, rolls of continuous fibers are fed into a resin bath which is mounted onto the carriage rails that are commonly placed overhead to provide greater workroom. Generally, the shape is a surface of revolution and may or may not include end closures. When the required number of layers is applied, the wound form is cured and the mandrel removed. The material properties in each layer are constant but may vary from layer to layer. The mandrel is represented by a hollow cylinder with uniform effective wall thickness. The mandrel and the cylinder are of equal length and are axisymmetrical, so that neither the geometry nor the properties vary in the circumferential direction. Filament winding is defined as 2 a technique which produces highstrength and lightweight products; consists basically of two ingredients; namely, a filament or tape type reinforcement and a matrix or resin. The concept of filament winding process had been introduced in early 1940s and the first attempt was made to develop filament-winding equipment. The equipment that was designed in 1950s was very basic; performing thesimplest tasks using only two axes of motion (spindle rotation and horizontal carriage). By mid-1970s, machine design once again made a dramatic shift. This time the advancement of servo technology entered the realm of the machine design. High-speed computers allowed for rapid data processing, resulting in smoother motion and greater fiber placement accuracy. The 1980s and 1990s saw the increased use of computer technology. Computers and motion control cards became the essential pieces of hardware that were included in almost every machine. Machine speed control was greatly improved; computer control systems could track position and velocity with increased accuracy. Additional axes of motions were also incorporated into machine design;allowing for four, five and even six axes of controlled motion.2. Manufacturing techniquesThe properties of a composite product are not only dependent on the properties of fiber and resin matrix, but are also dependent on theway by which they are processed.There are a variety of processing techniques for fabricatingcomposite parts/structure; resin transfer moulding, autoclave moulding, pultrusion and filament winding. Out of these processes, filament winding involves low cost and is the fastest technique for manufacturing of fiber reinforced cylindrical components as high-pressure pipes and tanks.3. Winding methodsThere are two different winding methods: (I) wet winding, in which the fibers are passed through a resin bath and wound onto a rotating mandrel (II) prepreg winding, in which the preimpregnated fiber tows are placed on the rotating mandrel. Among these winding methods, wet winding is more common and widely used for manufacturing fiber reinforced thermosetting matrix composite cylinders. Compared with prepreg winding,wet winding has several advantages: low material cost; short winding time; and the resin formulation which can be easily varied to meet specific requirements.3.1. Winding patternsIn filament winding process, the winding tension can easily be controlled. Winding tension, winding angle and/or resin content in each layer of reinforcement can be varied until the desired thickness and strength of the composite are achieved. The properties of the finished composite can be varied by the type of winding pattern selected. In general, there are three basic filament winding patterns which are as follows.3.1.1. Hoop windingIt is known as the girth or circumferential winding. In hoop winding, a high-angle helical winding approaches an angle of 90. Each full rotation of the mandrel advances the band delivery by one full bandwidth as shown in Fig. 2.Fig. 2. Circumferential or hoop winding . Helical windingIn helical winding, the mandrel rotates at a constant speed while the fiber feed carriage transverses back and forth at a speed regulated to generate the desired helicalangles as shown in Fig. . Polar windingIn polar winding, the fiber passes tangentially to the polar opening at one end of the chamber, reverses direction, and passes tangentially to the opposite side of the polar opening at the other end. In other words, fibers are wrapped from pole to pole, as the mandrel arm rotates about the longitudinal axis as shown in Fig. 4. It is used to wind almost axial fibers on domed end type of pressure vessels. On vessels with parallel sides, a subsequent circumferential winding would be done.Fig. 3. Helical winding 2.Fig. 4. Polar winding 2.4. The proposed filament winding machineSchematic layout of the hardware configuration for proposed filament-winding machine is shown in Fig. 5. It consists of three main units: the rotary assembly unit, the delivery unit and the control unitFig. 5. Schematic diagram for proposed winding machine.Fig. 6. Setup of the specimen on the winding machine.4.1. The rotary assembly unitThe rotary assembly consists of two pillar blocks which were held onto horizontal frame work and motor with a gearbox. One of the two blocks is fixed and serves as a reference, while the other one is movable and can be adjusted linearly for varying the mandrel length. Once the mandrel is seated properly into two freely rotating cup holders, the movable pillar block is then locked. At the fixed pillar end, the holder is coupled to the motor gearbox by a system of pulleys and belt. The gear ratio between the motor and the gearbox is selected as 1:60 and the reduction ratio between the pulleys was taken as 1:2, so that the velocity of the mandrel is fixed to 13.6 rpm as shown in Fig. 6.4.2. The delivery unitThe delivery unit consists of filament fibers holder, carriage and lead screw with a guide shaft. The lead screw is driven by a reversible variable speed motor. The filament fiber holder is just a table with two shafts, one used for carrying one or more of the filament fiber rolls while the other one is used as a guide for the filament fiber during the fabrication process. The carriage consists of a container and a system of polished guide pins. The container was used for carrying the resin mixture while the pins were used as a way to guide the fiber to the resin bath and to smear off excess resin from the wetted fibers after the resin bath. Also, the pins were used to generate tension in the wetted fibers before reaching the mandrel. A simple mechanism was used to bring back the smeared resin from the wetted fiber to the container and reused again in order to reduce the amount of resin used for preparing the product. An optimum tension of 10 N has been used through this work. This gave a fairly consistent volume fraction of fibers. It was found 3 that it is important to generate tension in the later stage of the resin path when the fibers are well wetted to avoid fiber damage. Greater tension on wetted fiber produced excessive fiber damage and low tensions produced specimens with unacceptably small fiber fractions.4.3. The control unitThe control unit consists of relays, limit switches, timer and counter as shown in Fig. 7. The function of the control unit is to control the winding process in order to get the proper winding sequence, which is difficult to reach manually, and to safeguard the motor during operation. The control unit also controls the amount of end over wind which is required to prevent slippage of the roving when the traverse is reversed and the mandrel indexing to ensure that each roving slightly overlaps the previous one to produce a uniform lay-up of fibers.5. Specimen fabricationThe setup of the specimen on the winding machine is shown in Fig. 6. The fabrication process consists of five steps as follows: the first step is to fix the mandrel which may be as aluminum or plastic PVC tubes or any different cylindrical mandrel shape on the machine blocks using end fixtures. The second step is to prepare the resin bath, which is a mixture of epoxy resin and hardener, using a specific ratio and putting it in the container. The type of epoxy resin and hardeners used in this investigation were MW 215 TA and MW 215 TB, respectively.They were mixed in a ratio of 4:1, respectively. The third step is to pass the fiber tow through the resin bath and then on the mandrel through a series of pins. These pins make the fiber straight and reduce the amount of resin in the fibers. The fourth step is to control the speed of screw to give the proposed winding angle. The fifth step comes after the layers of fibers were wound onto the mandrel, the specimen left to rotate on the mandrel for 3 h at room temperature to prevent resin dropping, then after solidification the specimen pulled off the mandrel and then cut to the required lengths. The relation between winding angle and the speed of the screw for mandrel of diameter 12.7 mm is shown in Fig. 8. This has been calculated using the relations belowwhere h is the winding angle, r is the Mandrel radius, Nm is the Mandrel speed, VC is the carriage linear velocity.where NS is the screw speed, d is the screw thread distance.It has been found 4, especially for angles between 0_ and 90_, that the pattern is considered as a complete cover of glass on the mandrel. This has been obtained after several passes of the carriage forward and backward so that one cover will be consisting of U that means one cover is actually consisting of two layers. Samples of the final specimens of different dimensions after fabrication and machining are shownin Fig. 9.6. ConclusionIn a filament winding process, a band of continuous resin impregnated rovings or monofilaments is wrapped around a rotating mandrel and then cured either at room temperature or in an oven to produce the final product. The technique offers high-speed and precise method for placing many composite layers. The mandrel can be cylindrical, round or any shape that does not have re-entrant curvature. Among the applications of filament winding are cylindrical and spherical pressure vessels, pipe lines. Modern winding machines are numerically controlled with higher degrees of freedom for laying the exact number of layers of reinforcement. Mechanical strength of the filament wound parts not only depends on the composition of component material but also on process parameters like winding angle, fiber tension, resin chemistry and curing cycle. Good products of different dimensions were produced using this machine.AcknowledgmentsThe authors express their gratitude and sincere appreciation to the Ministry of Science, Technology and Innovation, Malaysia (MOSTI, Project No. 09-02-04-0824-EA001) for the financial support, and the Department of Mechanical and Manufacturing Engineering of the University Putra Malaysia for supporting the group in undertaking the project.References1 Gutowski TG. Advanced composites manufacturing. New York: Wiley; 1997.2 Babu MS, Srikanth G, Biswas S. Composite fabrication by filament winding-an insight, 2000. Available from: http:/www.Tifac. org.in/news/acfil.html.3 Hull D, Legg MJ, Spencer B. Failure of glass/polyester filament wound pipe. Composites 1978.4 Mallick PM. Fiber reinforced composites, materials, manufacturing and design. 2nd ed. New York: Marcel Dekker, Inc.; 1993.低成本纤维缠绕机的设计与制造F.H.阿卜杜拉，S.A. Mutasher，Y.A.哈立德，S.M. sapuan*A.M.S. hamouda，B.B. Sahari，M.M.哈姆丹机械及制造工程 马来西亚博特拉大学，43400沙登，雪兰莪州，马来西亚3月2日2005年，2005年6月20日，2005年8月24日摘 要一般情况下，复合管是手工制作而成，采用玻璃纤维和聚酯树脂基，也由轴丝绕线机缠绕而成。而在缠绕技术中，缠绕机设计在机械制造发达国家中技术逐渐成熟。车床型机和湿法缠绕方法被用来在机器的设计。它提供了一个生产内部直径达100毫米，长度可达1000毫米的管道标本。蜿蜒的范围角度或纤维取向的角度，从所用芯轴直径20度达到90度。芯棒的速度保持不变，而作为交货单元的螺杆速度从0 rpm至250 rpm甚至最大达到13.6每分钟转速（RPM）变化着。在纤维缠绕过程中使用的单一的玻璃粗纱是通过制芯棒率先安装了预催化树脂旋转拧制而成。控制单元是用来控制整个过程，实现定期绕组和良好表面完成。的功能。使用这台机器的不同管样品和其他不同尺寸的圆形标本力学性能测试和应用。关键词：纤维缠绕复合管；玻璃纤维；矩阵；纤维取向角一、介绍 1、在低成本制造过程中，复合材料缠绕成圆柱结构是主要的过程。在这个过程中，复合层先后在一个旋转的芯棒缠绕，见图1。包裹层可在不同的角度箍层，这是垂直于气缸轴的螺旋层，为一个角度气缸轴。复合气瓶的制造缠绕包括三个主要步骤。首先，是材料的选择、几何、纤维取向的设计。第二，是纤维铺放的机械方法，通过其中的纤维被放置在适当的位置。最后，是条件的选择和在制造过程中必须保持控制。2、用于制造复合结构的过程中（长丝，丝，纱，磁带，或连续增援除外），无论是在绕组材料以前的浸渍，通过旋转和移动的形式被放置或在规定的芯棒方式，以满足一定的压力条件。钢筋纤维通常由玻璃、芳纶或碳组成。由于工艺简单，硬件配置标准，一般涉及两个主要的子系统；旋转装配系统和输送系统。旋转装置由两个结构块：一个固定装置和另一个线性移动装置，其中12轴机械驱动的芯棒安装到合理位置。在固定端支架连接到旋转轴，这是耦合到一个齿轮或链或皮带的系统，也可直接连接到电机。一般来说，交流伺服电机的使用，因为其更大的扭矩能力和在重载条件下准确性。为输送系统连续进行纤维辊送入树脂浴缸中，电机通常置于顶部，以提供更大的工作空间。材料在每一层的属性是不变的，但可能会有所不同在层与层之间。芯棒是一个中空的均匀有效的壁厚缸。芯棒气缸的长度相等，是轴对称的，因此，既不是几何，也不是物业在圆周方向的变化。3、长丝的概念 缠绕工艺已在5月初推出20世纪40年代，第一次尝试了发展长丝卷绕设备。设备设计在20世纪50年代是非常基本的执行最简单的任务，只用两个运动轴（主轴旋转和水平运输）。到70年代中期，机械设计，再次作出了戏剧性的转变。这伺服技术的进步进入机设计的境界。允许高速计算机快速的数据处理，造成更顺畅议案和更大的光纤定位精度。 “20世纪80年代和90年代看到，越来越多地使用计算机技术。电脑和运动控制卡成为几乎包括硬件的重要部分每一台机器。机速度控制是大大改善;计算机控制系统可以跟踪位置提高精度和速度。图1. 湿纤维维缠绕工艺原理二、制造技术复合产品的性能不仅依赖于纤维和树脂基体的性能，但也依赖于theway通过他们处理。也有各种用于制造加工技术复合材料部件/结构;树脂传递成型，蒸压成型，拉挤和缠绕。出这些过程中，纤维缠绕涉及成本低，是最快的光纤制造技术增强高压管道和坦克的圆柱组成部分。三、绕线方法绕线方法有两种不同的缠绕方法：（1）湿绕组，其中纤维通过树脂传递浴缸和伤口上一个旋转的芯棒（2）浸缠绕，纤维丝束预浸放在旋转的芯棒。其中绕组法，湿法缠绕较为常见，并广泛应用于用于制造纤维增强热固性矩阵复合气瓶。与预浸绕组，湿法缠绕有几个优势：材料成本低;清盘时间短;和树脂配方可以很容易地改变，以满足特定的要求。3.1清盘模式在缠绕过程中，卷绕张力很容易得到控制。卷绕张力，卷绕角和/或树脂加固的每一层中的内容可以直到所需厚度和强度变化复合材料的实现。成品的属性绕组类型可以是多种多样的复合模式选择。在一般情况下，有三个基本长丝清盘模式如下。3.1.1圈绕组圈绕组它被称为周长或环形绕组。在箍绕组，高角度的螺旋缠绕方法90角。每个完整的旋转芯棒一个全带宽的进步乐队交付。如图2图2 圆周或圈绕组图3 螺旋式绕组3.1.2螺旋绕组螺旋绕组，在一个恒定的旋转芯棒速度的同时，纤维饲料马车横材和来回调节的速度，以产生所需的螺旋在图的角度。如图3所示 3.13极绕组在极绕组，纤维通过切向极地室的一端开放，改变方向，并通过切向对面在另一端的极性开幕。换句话说，纤维包裹从南极到北极，作为芯棒臂旋转关于