Modeling and Simulation of Voids in Composite Tape Winding Process Based on Domain Superposition Technique
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Modeling and Simulation of Voids in Composite Tape Winding Process Based on Domain Superposition Technique Bo Deng 1 & Yaoyao Shi 1
Received: 13 October 2017 / Accepted: 25 October 2017 # Springer Science+Business Media B.V. 2017
Abstract The tape winding technology is an effective way to fabricate rotationally composite materials. Nevertheless, some inevitable defects will seriously influence the performance of winding products. One of the crucial ways to identify the quality of fiber-reinforced composite material products is examining its void content. Significant improvement in products’ mechanical properties can be achieved by minimizing the void defect. Two methods were applied in this study, finite element analysis and experimental testing, respectively, to investigate the mechanism of how void forming in composite tape winding processing. Based on the theories of interlayer intimate contact and Domain Superposition Technique (DST), a threedimensional model of prepreg tape void with SolidWorks has been modeled in this paper. Whereafter, ABAQUS simulation software was used to simulate the void content change with pressure and temperature. Finally, a series of experiments were performed to determine the accuracy of the model-based predictions. The results showed that the model is effective for predicting the void content in the composite tape winding process. Keywords Composite tape winding . Void content . Finite element analysis . Domain Superposition Technique
1 Introduction Composites have demonstrated many benefits in aerospace, military, industry and civil applications etc. since the 1950s. The performances of composite structure depend on the material itself and, more importantly, rest with the molding method and parameters in process [1–4]. As a significant method of composite manufacturing, the tape winding process has been
* Yaoyao Shi [email protected]
1
The Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of Education, Northwestern Polytechnical University, Xi’an 710072, China
Appl Compos Mater
used to fabricate solid rocket motor nozzle, ablation resistance and heat protection material parts, missile nose cones, launch tube and special equipment for aerospace aircraft. In the process of tape winding, attention must be paid to the following processing variables: tape tension, tape temperature, pressure and winding speed. The winding is performed with prepreg tapes which are plain weave fiber impregnated with resin. The prepreg tapes are deposited under tension by a hot compaction roller moving at speed V parallel to the mandrel axis. Simultaneously, the positive pressure is applicated to the tape by using the cylinder. Afterwards, the winding products with mandrel are cured in autoclave. Nonetheless, during the winding process, voids and airs exist inevitably in the prepreg tapes. Finally, some of these voids or airs are also retained in the winding products even if the products have been cured by autoclave [5]. The residual voids will reduce the mecha
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