Analytical Models for Low Cost Manufacturing of Composite Components by Filament Winding, Part I: Direct Kinematics

Abstract

Filament winding technique is not used to its overall capacity because of insufficient understanding of the kinematics of filament winding. In order to effectively utilize the capability of filament winding technique, a Geometric Approach based on the algebraic and trigonometric relations is presented to determine the machine motions for generating desired fiber distribution on axisymmetric, non-axisymmetric, cylindrical, and non-cylindrical mandrel shapes. Analytical models thus developed are found to be extremely useful tools for laying down the fiber on predetermined path in lieu of costly techniques such as teach-in-programming, simulation, CAD/CAM, etc. It is suggested that a sophisticated filament winding machine is not always necessary to fabricate a complex structure. A filament winding machine with two and three degrees of freedom can perform the same task on various types of mandrel surface with fewer driven parts, higher accuracy, and lower manufacturing cost. Present method determines the machine motion in a few seconds and provides exact solution in generating the desired fiber winding angle on certain types of mandrel surface which has polygonal cross-sections. Based on the Geometric Approach, a user friendly computer program "DIRECTIKIN" is developed to study the direct kinematics of filament winding. Using the program "DIRECIXIN, effects of location of the delivery point, fiber winding angle distribution, and mandrel shape geometry on winding motions are discussed. Experimental verification of the model is performed on a McClean Anderson filament winding machine for cylindrical and non-cylindrical mandrels.