Winding pattern design of composite cylinders considering the effect of fiber stacking

Abstract

Winding pattern design is a critical step in the production of composite cylinders. Traditional design methods often overlook the impact of stacking fibers layer by layer, leading to deviations between the actual and intended winding trajectories. To ensure consistence between the actual winding outcomes and design objectives, the effect of fiber stacking on the winding patterns was examined in this study. Two winding pattern design methods were proposed: the fixed tangent-point method (FTPM) and the minimum center angle deviation method (MCADM). A comparison was conducted on the variations in the number of tangent points, thread guide round trips, and the radius of the polar hole under the two different methods. Winding experiments were then employed to verify the feasibility of these approaches. The results showed that fiber stacking on the dome was the main reason for the change in winding patterns. Priority can be given to schemes within the design overlap domain for the design of multi-layer winding patterns. While FTPM ensures consistent fiber coverage and tape spacing, it may lead to hole expansion. Additionally, applying multiple layers can alter the dome's shape significantly from the original design. In contrast, MCADM offers slightly variable fiber coverage and spacing without causing hole expansion, achieving the desired dome shape more accurately.