Abstract
The residual stress plays an important role in composite flywheel rotors composed of filament windings. The fiber tension during high-prestressed winding is the main source of the rotor deformation and residual stress of composite layers. In this study, the effect of the winding tension gradient on deformation was monitored in real-time. Two types of in-plane winding tension fluctuation methods were developed to investigate the effect of tension on deformation. Online and offline measurements were performed for the strain acquisition. A wireless strain instrument was used for online deformation monitoring and a laser scanner was used for the offline surface reconstruction. Additionally, different filament winding strategies were carried out to improve the efficiency of the winding tension by finite element analysis. The results indicated that the deviation between numerical and experimental results was within 8%. Based on the proposed numerical method, the influence of the in-plane and out-of-plane winding tension gradient distributions on the rotation process of the H-shaped rotor was analyzed. An in-plane winding strategy with variable tension was developed, which increased the initial failure speed by 160%.
Highlights
Victor TcherdyntsevWith the rapid development of electricity-related industries, the demand for energy storage has become more severe [1–4]
The strain of the composite flywheel rotors formed by the two winding tension systems went up with the winding process, indicating that the winding tension of the external fibers can be effectively transferred to the mandrel
The influence of winding tension fluctuations on rotor deformations was further discussed by Finite Element Analysis (FEA)
Summary
With the rapid development of electricity-related industries, the demand for energy storage has become more severe [1–4]. FRP composites are a perfect solution to the high-energy storage capacity flywheels [15–17]. Two-dimensional woven and 3D textile structure composite rotors have been proposed to enhance the radial strength [18–20] Their low fiber volume fraction and high manufacturing cost limit their wide application. Few studies paid attention to the mismatch between the design winding tensions and the residual stress caused by the complex relaxation in the manufacturing process. A finite element-based model was used to study the influence of winding tensions on the prestressing effect of a mandrel and the subsequent failure process. The outcome of this study provides a tension design model considering the manufacturing process, which is helpful for the wide application of continuous fiber-reinforced thermosetting composites on high-quality standard rotary components
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