Plasticomp announces an exciting advancement in the development of direct inline filament winding dfw of fiber reinforced thermoplastic compounds. Single or multiple component, unreinforced andor continuously reinforced filament wound cylindrical products are continuously produced by winding, at least an inner layer of. We are investigating the use of different resin systems processes for the winding of thermoplastic tapes. Thermoplastic processes majority of the processes are one shot process quick processes you get the required output. Application of taguchi method in the optimisation of. Successive layers are added until the required thickness is reached.
A fibers temperature, b winding speed, c number of layers, d number of roving. Filament winding process in thermoplastics request pdf. The thermoplastic is heated past their glass transition temperature inside the hotend the filament is extruded and deposited by an extrusion head onto a build platform where it cools. Song 4 developed a filament winding model for thermoplastics. Processing of high performance thermoplastic composites. Request pdf filament winding process in thermoplastics thermoplastic filament winding offers the possibility to build up continuous fiber reinforced lay ups. Filament winding creates hollow structures of incredible strength.
Filament winding is a process used to produce tanks, pipes, pressure vessels and other roundform products that require a high degree of structural integrity. Process technology and operating efficiency process. Filament winding, one of the oldest composite manufacturing processes, was used to produce solid rocket motor cases after world war ii. One primary tool used in the filament winding process is a precise ground mandrel on which the fiber with resin matrix is wound. Computational simulations and experimental validations, authoryves toso and paolo ermanni and dimos poulikakos, journaljournal of composite materials, year2004, volume38, pages. Application of taguchi method in the optimisation of filament. Modeling of thermoplastic composite filament winding vtechworks. Keywords tape winding process, filament winding process, tape laying process, in situ consolidation of fiberreinforced thermoplastic tapes, thermal simulation, convective coefficient of gas torches, fiberreinforced thermoplastic tape. Thermal residual stress simulation in thermoplastic.
Request pdf filament winding process in thermoplastics thermoplastic filament winding offers the possibility to build up continuous fiber reinforced layups. Spring semester 2017 1504800l manufacturing of polymer composites joanna wong 23 march 2017 22. Filament winding process in thermoplastics sciencedirect. A suitable technique for manufacturing parts with adequate on. Towpreg, filament winding, thermoplastic matrix composites, processing abstract costeffective glassreinforced thermoplastic matrix towpregs produced by a powder coating line were used to manufacture composite pipes by filament winding. Autonational composites can integrate, automate, expand and upgrade any filament winding production process for high volume production. Diode laser assisted filament winding of thermoplastic matrix.
A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. This paper presents experimentally validated threedimensional transient simulations of the thermal phenomena of the tape winding process, as well as a method to determine separately the heat transfer between the hot gas originating from a torch and the composite material. If the viscosity of the resin system is overly high, it cannot completely penetrate into the fiber. Winding process simulations for thermoplastic filaments are important for the component quality. Spring semester 2017 1504800l manufacturing of polymer composites joanna wong 16 june 2017 15.
Thermoplastic filament windingtape laying has achieved autoclave level properties in. A conventional 6 axes filamentwinding equipment was adapted for processing such structures. Filament winding is the process of winding resin impregnated glass or advanced fiber around a rotating mandrel, to create a composite structure. Diode laser assisted filament winding of thermoplastic. By crossweaving continuous rovings of carbon fiber, fiberglass or aramid fiber, and embedding them in a resin matrix, the filament winding process results in an optimized product that is perfect for pressure vessels, aerospace components, golf clubs, military armaments, and hundreds. So, the thermoset filament winding process is less sophisticated. This work was conducted under the technical direction of dr. 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. In this process the thermoplastic prepreg tape what is prepreg where in which the resin is infused in the reinforcement and it is available to use is bound around a mandrill. Study of hybrid nanoparticles modified epoxy resin used in. Typical part geometries are axially symmetric ones, for example tubes or vessels. The process of transforming 3d printing filament into a 3d model the filament is fed into the fdm 3d printer. Thus, local heating by gas torch is widely adopted for thermoplastic winding and layup processes. Filament winding can be done with thermoset or thermoplastic resins and most continuous fiber forms.
Request pdf thermoplastic filament winding with onlineimpregnation. Our solutions are based on our standard modular winder program or on a dedicated winding solution as per your specifications. May 08, 2018 we are investigating the use of different resin systems processes for the winding of thermoplastic tapes. The polymer chains associate by intermolecular forces, which weaken rapidly with increased temperature, yielding a viscous liquid. The pattern is determined by mikrosams filament winding software to meet user defined structural properties based on the materials being used. Filament winding is an automated open molding process that uses a rotating mandrel as the mold. Fibre reinforced thermosetting and thermoplastic matrix filament wound pressure vessels for large scale market applications have been studied in this work. The automated fiber placement process has been developed for flat. While the typical attendee of this course is already familiar with the concept of filament winding, a basic overview of the process can help to clarify the steps needed to take a product from conception to a fully functional parts program. Contract nas316760 on filament winding s glasspolyimide resin composite processing studies.
Thermoplastic composite filament winding is an online consolidation process, where the composite experiences a complex temperature. Beside the material used, the most adjustable process parameters are. A consolidation apparatus was built by means of a cnc motion table, a stepper motor and a simple tensioner. Thermoplastic filament winding university of plymouth. The applied chemistry department of the chemistry and chemical engineering laboratory, applied technology division, was. 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. However, in insitu manufacturing techniques such as filament winding and. New direct inline filament winding technology from. A study of the use of thermoplastic powder coated towpregs in filament winding was conducted. Thermal phenomena in fiberreinforced thermoplastic tape. Nov 01, 2002 read thermoplastic filament winding with onlineimpregnation. Thermal residual stress simulation in thermoplastic filament winding process show all authors.
The aim of this chapter is to give an overview about the thermoplastic filament winding. Adaptation and study of a filament winding machine for in. The thermoplastic winding process is easier if the melting point difference between the polymers is high. The matrix materials can be either thermoset or thermoplastic resins. 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. 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 filament winding process is a lowcost, automated composite manufacturing technique. Mar 01, 1977 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. In part a of this paper, a novel process technology was presented which allows to combine thermoplastic filament winding with online melt impregnation of fibre bundles. Highspeed, precise placing of the composite fiber, at a precise tension in predeterminate pattern is the basis of the filament winding process. Applied science and manufacturing on deepdyve, the largest online rental service for scholarly research with thousands of academic publications available at your fingertips.
Application of taguchi method in the optimisation of filament winding of thermoplastic composites volume 28 issue 3 march 2007 a b fig. A conventional 6 axes filament winding equipment was adapted for processing such structures. Serafini of the lewis research center, cleveland, ohio. 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. Prediction of processinduced stresses for insitu thermoplastic filament winding of cylinders, third international conference cadcomp. In fiberglass winding process, the glass fiber is driven to. In this process, the tows are wound in prescribed directions over a rotating mandrel in the shape of the part. This prepreg can be used asis for thermoplastic pultrusion and filament winding. Home composites automation specialty machines thermoplastic filament winding thermoplastic filament winding insitu winding of cylindrical and axisymetric parts. An experimental study on the thermoplastic filament winding. The research gap is that arduino uno is selected to use in the portable filament winding machine with 3 axes. However, typical thermosetting matrix composites processes have to.
Unlike a 3d printer the filament is pulled rather than pushed through the nozzle to create the filament, the diameter of the filament is defined by the process that takes place after the plastic has been heated rather than the diameter of the extruder nozzle. Thermoplastic filament winding process jeffers, albert l. Jec 2004 lamontia tp filament winding and tape laying. A laboratory scale filament winding system is built to serve the purpose. Thermoplastic filament winding offers the possibility to build up continuous fiber reinforced layups with welldefined fiber orientation and accurate positioning of the fibers. 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. Fiber may be preimpregnated towpreg, pulled through a resin bath before being applied to the mandrel wet winding or wound dry and then infused with resin in a secondary process. The thermoset filament winding process and thermoplastic based tape winding process have their down advantage and disadvantages. Beckwith, sampe international technical director and president, btg composites inc.
Automated thermoplastic filament winding, tape laying, and fiber placement have. Read thermoplastic filament winding with onlineimpregnation. A method and apparatus for filament winding an object from electrically conductive filament means impregnated with a thermomatrix binder. 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. 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. The male mold configuration produces a finished inner surface and a laminate surface on the outside diameter of the product. At the end of the filament winding process, the fiber with resin matrix is cured, either at room temperature or in. The aim of this study is to design a 3axis filament winding machine with inexpensive control system on. Thermal residual stress simulation in thermoplastic filament winding process martin schlottermuller, haibo lu, york roth, norbert himmel, ralf schledjewski, and peter mitschang journal of thermoplastic composite materials 2003 16. 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. The thermoplastic filament winding process with bicomponent fibers is not as easy as the other winding methods. 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.
Thermoplastic filament winding with onlineimpregnation. This paper presents a threedimensional analysis for the prediction of process induced stresses and deformations which are developed during melting and consolidation of impregnated thermoplastic tows in a continuous filament winding manufacturing process employing a local heat source. 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. Description this process is primarily used for hollow, generally circular or oval sectioned components, such as pipes and tanks. Filament winding is a manufacturing process mostly suited to large volume jobs, and when it is the method of choice, the benefits are significant. Models are described which simulated the filament winding of thermosetting and thermoplastic matrix composite cylinders. Preliminary tests were performed in a hoop winding configuration. An important example deals with filament winding process. Iccm17 numerical modelling of the filament winding process. Thermal residual stress simulation in thermoplastic filament. In the filament winding process, the primary purpose of. Industrial technology co ltd of china is using a very long glass fibre reinforced thermoplastic composite from rtp company to. 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. The experimental apparatus for the laserassisted consolidation process consisted of a mandrel mounted on a rotational table, a fixed compaction roller, and an 80 w co 2 laser.
Mantell and springer 3 published manufacturing process models for thermoplastic composites applicable also to filament winding. Modeling of thermoplastic composite filament winding. The process illustration depicts circumferential winding, while the 2 smaller pictures show helical and polar winding. Maw 20 fb31 fph6 filament winding machine with integrated fiber placement assisted winding head for thermoplastic roving.
So, here it is fast thermoplastic is fast, but consolidation is a challenge consolidation is a. The vessels consist on a thermoplastic liner wrapped with a filament winding glass fibre reinforced polymer matrix structure 1. Composite filament winding machine page 3 of 8 stock of 116 thickness. The typical material adhesivity known as tack plays an important role in the material consolidation before curing in the oven. The main difficulty of the cfpa6 process impregnation consolidation curing is the consolidation step. The names people are trying to use it as thermoplastic filament winding process. Various different process setups and types of raw materials are used. Filament winding uses the narrowest prepreg unit availablethe yarn, or tow, of impregnated filaments. Manufacturing flat and cylindrical laminates and built up structure using automated thermoplastic tape laying, fiber placement, and filament winding mark a. A new consolidation method for the laserassisted filament winding of thermoplastic prepregs is discussed. The filament means are wound onto an appropriate mandrel defining the shape of the object.
Filament winding pulls ahead composites in manufacturing. Aug 01, 2005 filament winding can be done with thermoset or thermoplastic resins and most continuous fiber forms. Tension control system design of a filament winding structure. So, here it is fast thermoplastic is fast, but consolidation is a challenge consolidation is a challenge is a huge challenge consolidation as far as thermoplastic composite is concerned. As used in filament winding process, the viscosity of resin should be in a certain range, 2002000 mpas. Thermoplastic filament winding accudyne systems, inc. In filament winding, a machine, rather like a lathe, spins a mandrel. The computational model predicts the temperature of the incoming tape and the substrate during the winding process. Adaptation and study of a filament winding machine. A novel concept for filament winding with a thermoplastic matrix has been explored the impregnation of the unidirectional reinforcement is performed in line with the winding operation, and the impregnated reinforcement is wound into rings with in situ consolidation. This study focuses on experimentally verifying the feasibility of thermoplastic filament winding process using commingled yarns. The path generation needs to consider the filament widening in the winding process. Fibre tows are passed through a resin bath before being wound onto a mandrel in a variety of orientations, controlled by the fibre feeding mechanism, and rate of rotation of the mandrel. In the filament winding process, uncured resin from previously wound layers can flow.
A thermoplastic, or thermosoftening plastic, is a plastic polymer material that becomes pliable or moldable at a certain elevated temperature and solidifies upon cooling. Thermoplastic filament winding with online impregnation. This paper presents a threedimensional analysis for the prediction of processinduced stresses and deformations which are developed during melting and consolidation of impregnated thermoplastic tows in a continuous filament winding manufacturing process employing a local heat source. This thesis studies the automated filament winding process.
The fibre placement is guided by a machine with two or more axes of motion, as can be seen in the simple schematic diagram below. By the early 1960s and 70s, commercial winding machines were also being used to fabricate fiberreinforced pipes, pressure vessels and streetlight poles. An experimental investigation of consolidation in thermoplastic. Filament winding is an automated method for creating composite structures by winding filaments under tension over a rotating mandrel tool. Based in prilep, macedonia, mikrosam provides factory automation for modern composites manufacturing and has installed more than 240 composites production lines in. Regarding thermosetting matrix composites a continuous prepreg is wound on a machine mandrel and subsequently cured in an oven. If there is no adjustment, laps or gaps between the filaments can accrue which have negative quality effects.
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