Abstract
The extraordinary features of fibrous composites enable advanced industries to design composite structures with superior performance compared to traditional structures. Composite frame structures have been designed frequently as components of mechanical systems to resist lateral and gravity loads. The manufacturing of high-quality composite frames depends primarily on the accurate fiber winding on frames with different pro-files and curved shapes. The optimal fiber winding process on a nonbearing composite frame with a circular cross-section is described in previous works by the same authors. As an extension to that, this study focuses on the manufacturing of straight-line composite frames with different profile radii at multiple locations. Such production procedure allows continuous winding of fibers gradually on individual parts of the frame and generally with different angles of fiber winding. The winding procedure is performed using fiber-processing head and industrial robot. The procedure for calculating the distance of the winding plane of fibers on the frame from the guide-line of the fiber-processing head is targeted. This distance depends on the required angle of fiber winding, the radius of the frame, and the geometric parameters of the fiber-processing head. The coordination of the speed of winding the fibers on the frame and the speed of the passage of the frame through the winding head is also considered. Determining the correct distance of winding the fibers from the corresponding guide-line of fiber-processing head and right coordination of the winding speed and the speed of passage of the frame through the fiber-processing head ensure compliance of the required angles of fiber windings on the frame and homogeneity of winding fibers, which are the two of the most important prerequisites for producing a quality composite frame. The derived theory is well verified on a practical experimental example.
Highlights
In the past several decades, the revolution in the design of new advanced structures has forced many industries to produce structures of mechanical systems using composite materials with superior properties to replace the classic material like metal, wood, etc., [1,2].The main advantage of using composites lies in their low weight, flexibility, and strength, weather resistance, long life, maintenance-free, etc., [1,3,4,5]
Production of a higher quality composite frame with exceptional properties was found to be directly dependent on the quality of a homogenized and continuous fiber winding pattern [1,21,22,23]
This study presents a procedure enabling the optimization of the winding process of fibers of the nonbearing straight-line frame with a few parts with different radii of circular cross-section and, ensuring the production of a high-quality composite frame for such types of frames
Summary
In the past several decades, the revolution in the design of new advanced structures has forced many industries to produce structures of mechanical systems using composite materials with superior properties to replace the classic material like metal, wood, etc., [1,2].The main advantage of using composites lies in their low weight, flexibility, and strength, weather resistance, long life, maintenance-free, etc., [1,3,4,5]. Much research has been conducted on the manufacturing processes of composite structures to increase the structural stability and integrity [1,20] In this regard, production of a higher quality composite frame with exceptional properties was found to be directly dependent on the quality of a homogenized and continuous fiber winding pattern [1,21,22,23]. The fiber is wounded onto a nonbearing core frame with any type of complex geometries and profiles, which later is used to fabricate the composite frame through an injection molding process [1,25,29]
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