Figure 2 - uploaded by O. K. Bergsma
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Schematic view of the experimental layup (the bold lines on the mandrel represent a coefficient of friction increment equal to 0.1).
Source publication
The design procedure of nongeodesic filament wound products requires well-determined values for the available friction situated between the applied roving and the supporting surface. In this paper, we propose a mandrel shape with a specially designed meridian profile that enables a linearly proportional relation between the feed eye carriage transl...
Contexts in source publication
Context 1
... the simplicity of various methods presented in Table 1, the deci- sion is taken in favor of the specially shaped convex mandrel, attached on a lathe-configured filament-winding machine; this combination is the only one satisfying the complete set of requirements. A schematic overview of the chosen configuration is presented in Figure 2. ...
Context 2
... latter ensures a tangential placement of the fiber bundle on the mandrel. However, since this movement is not of primary importance for the underlying kinematic model, it is not presented in Figure 2. ...
Context 3
... surface of the mandrel is polished. For a three-dimensional impression of the convex mandrel part, we refer to Figures 2, 9, and 10 (notice in Figure 2 the rings at several z-values indicating the coefficient of friction with incremental steps of 0.1, starting at ¼ 0 and ending at ¼ 1). ...
Context 4
... surface of the mandrel is polished. For a three-dimensional impression of the convex mandrel part, we refer to Figures 2, 9, and 10 (notice in Figure 2 the rings at several z-values indicating the coefficient of friction with incremental steps of 0.1, starting at ¼ 0 and ending at ¼ 1). ...
Citations
... This result is indeed consistent with several literature studies (Koussios et al., 2005;Koussios and Bergsma, 2006;Zu, 2012;Sofi et al., 2018) that describe the effects of lateral friction on the winding of filament fibres on curved mandrel surfaces. It also reveals how the lateral contact pressure component vanishes for geodesic configurations of the rod, i.e., when the geodesic curvature 2 = 0. ...
We develop a comprehensive geometrically-exact theory for an end-loaded elastic rod constrained to deform on a cylindrical surface. By viewing the rod-cylinder system as a special case of an elastic braid, we are able to obtain all forces and moments imparted by the deforming rod to the cylinder as well as all contact reactions. This framework allows us to give a complete treatment of static friction consistent with force and moment balance. In addition to the commonly considered model of hard frictionless contact we analyse in detail two friction models in which the rod, possibly with intrinsic curvature, experiences either lateral or tangential friction. As applications of the theory we study buckling of the constrained rod under compressive and torsional loads, finding critical loads to depend on Coulomb-like friction parameters, as well as the tendency of the rod to lift off the cylinder under further loading. Our results are relevant for many engineering and medical applications in which a slender structure winds inside or outside a cylindrical boundary.
... Different coefficients of friction in different profiles were analyzed, and a significant effect of using a non-geodesic trajectory was confirmed. Koussios et al. [27] investigated the applications of vessels under friction tests. The surface quality of the mandrel and the type of winding process (using wet versus dry fibers) significantly affected the outcomes. ...
Composite vessel; Internal pressure; Spherical cap; Numerical analysis; Experimental analysis. Composite vessels are widely used in industry due to their high strength and low weight. In this research, a composite vessel with a metal liner was designed, manufactured, and subjected to internal pressure. The liner of the tank is made of 304 steel, which is screwed on its main part with two patterns of polar and peripheral twisting. In this research, S-glass fibers and epoxy resin 5052 were used. The vessel was subjected to a pressure of 40 bars. Electric strain gauges were used to measure the strain, and stresses were calculated using Hooke's law. In addition to the experimental method, the vessel was also analyzed numerically. ABAQUS (finite element) software was used to examine the experimental data, and the simulation results showed good consistency with the experimental data. The results of the numerical analysis determined the location of the strain gauges. The results of the two methods were compared and discussed. It was found that at low pressures (pressures lesser than 40 bar), composites do not have a significant role in tolerating vessel stress. It has been observed that changes in the geometry of the structure (the joint of the spherical part and the cylinder) resulted in turbulences in the strain and stress curves near the change site.
... In non-geodesic winding, to avoid the tendency for slippage, it is always recommended to determine the required friction between the liner surface and the fiber yarn. Koussios and Bergsma provided an empirical method to determine this friction [169]. ...
Hydrogen fuel cell technology is securing a place in the future of advanced mobility and the energy revolution, as engineers explore multiple paths in the quest for decarbonization. The feasibility of hydrogen-based fuel cell vehicles particularly relies on the development of safe, lightweight and cost-competitive solutions for hydrogen storage. After the demonstration of hundreds of prototype vehicles, today, commercial hydrogen tanks are in the first stages of market introduction, adopting configurations that use composite materials. However, production rates remain low and costs high. This paper intends to provide an insight into the evolving scenario of solutions for hydrogen storage in the transportation sector. Current applications in different sectors of transport are covered, focusing on their individual requirements. Furthermore, this work addresses the efforts to produce economically attractive composite tanks, discussing the challenges surrounding material choices and manufacturing practices, as well as cutting-edge trends pursued by research and development teams. Key issues in the design and analysis of hydrogen tanks are also discussed. Finally, testing and certification requirements are debated once they play a vital role in industry acceptance.
... According to the experimental results, a winding nozzle with fewer voids and a smooth surface could be wounded by the invariable compaction force in the flexible winding system [8]. Many other researches in these aspects have been carried out [9][10][11][12][13][14][15][16][17][18][19][20][21] All were related to development of filament winding machine and techniques used for winding process. Although, there are a development in filament winding machine over the years, still there is a lag in producing composite products with complex shape and geometry. ...
This paper aims to design, modeling and manufacturing a prototype composite winding machine used to produce corrugated composite tubes. Seven different types of tubes can be produced: Radial Corrugated Tube (RCT), Radial Corrugated Surrounded by Cylindrical Tube (RCSCT), Cylindrical Tube (CT), Tangential Corrugated Tube (TCT), Tangential Corrugated Surrounded by Cylindrical Tube (TCSCT), Combined Radial and Tangential Corrugated Tube (CRTCT), and Combined Radial and Tangential Corrugated Surrounded by Cylindrical Tube (CRTCSCT). All types can be produced with different size. Although it is designed mainly for composites, however, paper, and thin sheet of metallic materials can be used as raw material too. Different fiber forms can be used such as knitted, woven roving, continuous filament, or chopped mat of glass or carbon fiber. Corrugation profile can be changed to any required shape such as sinusoidal, triangular, square, rectangular, trapezoidal, or combination of any two or more profiles. The machine uses a special technique utilizing a mandrel that can be driven manually as well as automatically. A prototype of a designed machine have been manufactured, and tested. Two different samples of prospected products have been produced successfully
... Since there are many possible non-geodesic paths, one is not restricted by the required winding angle determined in Equation (1); however, one must now determine the required friction between the surface and the fibre in order to stay on the path. Koussios and Bergsma [19] provide a method to determine friction. Although a relationship between the friction and surface curvatures will be briefly discussed, a detailed derivation can be found in [17]. ...
In this work, the stress distribution along cylindrical composite pressure vessels with different dome geometries is investigated. The dome contours are generated through an integral method based on shell stresses. Here, the influence of each dome contour on the stress distribution at the interface of the dome-cylinder is evaluated. At first, the integral formulation for dome curve generation is presented and solved for the different dome contours. An analytical approach for the calculation of the secondary stresses in a cylindrical pressure vessel is introduced. For the analysis, three different cases were investigated: (i) a polymer liner; (ii) a single layer of carbon-epoxy composite wrapped on a polymer liner; and (iii) multilayer carbon-epoxy pressure vessel. Accounting for nonlinear geometry is seen to have an effect on the stress distribution on the pressure vessel, also on the isotropic liner. Significant secondary stresses were observed at the dome-cylinder interface and they reach a maximum at a specific distance from the interface. A discussion on the trend in these stresses is presented. The numerical results are compared with the experimental results of the multilayer pressure vessel. It is observed that the secondary stresses present in the vicinity of the dome-cylinder interface has a significant effect on the failure mechanism, especially for thick walled cylindrical composite pressure vessel. It is critical that these secondary stresses are directly accounted for in the initial design phase.
... An unsuitable fiber path brings instability to the winding, deviation of fiber positioning and high vibration levels of the winding equipment [2]. Many process parameters are involved in the determination and modeling of the fiber path, including mandrel geometry, fiber/resin system, winding speed, fiber tensioning and fiber-mandrel friction coefficient [3]. ...
One of the main advantages of the filament winding (FW) process is the optimized fiber deposition, even though it is limited by the kinematics of the process and mandrel geometry. The determination of the optimum fiber path is a key challenge in the design of the FW process. In this work, the fiber path for composite nozzles is determined to seek the improvement of specific mechanical properties. The path determination follows differential geometry definitions and the shell internal stresses are calculated via both netting analysis and classical lamination theory. Both geodesic and non-geodesic fiber paths are considered. Obtained results show that the wound nozzle with a non-geodesic trajectory increases the ratio between the stress in the fiber direction and both shear stress and the one acting in the parallel direction, improving its mechanical performance with respect to the Tsai-Wu failure criterion. Moreover, the closer the trajectory is to the obtained by the netting analysis, the better when considering the aforementioned criterion.
... It can also be expressed by the relation between normal ðk n Þ and geodesic curvature ðk g Þ or the normal (R n Þ and geodesic ðR g Þ radii of curvature [25,26,34,39,[74][75][76]: ...
... The common method to determine the coefficient of friction is to observe the starting point of the slippage while performing hoop winding. An overview of existing methods has been given by Koussios [74]. Several mandrel forms and influence factors have been tested in the last decades. ...
... They determined the coefficient of friction by circumferential winding on a sphere. Confirmed by various experiments of other authors [26,72,74,79,80], they also found out that the influence of the winding speed and of the fiber tension on the friction factor is negligible. Wells and McAnulty [26] then replaced the spherical with an elliptical mandrel to improve the accuracy of the measurements. ...
Filament winding is a well-established process to manufacture composite parts. With the advancement of automation and process control technologies, the winding of dry fibers to manufacture a preform for liquid composite molding (LCM) processes is feasible. This study presents an overview of dry fiber winding and explains the most important process aspects. It addresses the application of differential geometry to the winding technique. The formulation of geodesic and non-geodesic equations and their solution is discussed. Besides, non-analytical methods to generate winding trajectories are introduced. The influence of the friction coefficient on process-related parameters is covered. Considering technology trends the study gives an overview of developments in winding systems and equipment. Novel research areas can be identified in the development of new path generation methods, considering detailed friction influences. Fiber depositing and guidance systems must also be adapted. Alternations of the process parameters and their influence on subsequent impregnation processes must be investigated.
... 6,7 For the friction between fiber and support surface, Koussios and Bergsma addressed a mandrel shape with a specially designed meridian profile for nongeodesic filament wound products and then the optically obtained measurements can be translated into the coefficient of friction. 8 Considering the lateral tow slippage on the surface of mandrel, Finkenwerder et al. illustrated the influences of geodesic and nongeodesic winding path on the tow's tensile force. 9 Zu et al. investigated fiber trajectory stability of nongeodesic wound toroidal pressure vessels and adopted the variable slippage coefficients to design winding trajectory for achieving the toroid with improved performance. ...
As an inevitable issue in the filament winding technology, the process-induced friction has gained increasing attention. The purpose of this study is to illustrate the experimental investigation of friction between prepreg tape and hot compaction roller in prepreg tape hoop winding system. Based on the modified version of Howell’s equation, the friction model is established to offer an indirect method for measuring the frictional coefficient during the actual composite fabricating process. Three types of prepreg tapes, namely T300/Y69 unidirectional prepreg tape, T300/DFQS-3 and BWT260-82/DFQS-3 orthogonal prepreg tapes are selected to discuss the effect of process parameters on friction under different processing conditions. The experimental results reveal that the friction behavior transfers from resin-dominated friction to fiber-governed friction as the temperature rises. Besides, acceleration of the spindle speed on the frictional coefficient can be markedly improved due to the increase of resin strain rate. Meanwhile, the fiber has a stronger ability to increase friction than resin. It is also observed that the friction plays a role in amplifying the winding tension by comparing the winding tension with the outgoing winding tension.
... Hwang et al. [4] conducted experimental tests using an analytical approach to verify the size effect on the fiber strength of a composite pressure vessel. The effect of pretension is found to be negligible in some studies [14]. Koussios and Bergsma [14] performed several experiments corresponding to the variation of typical filament windingrelated process parameters: fiber speed, roving tension, roving dimensions, wet versus dry winding, and surface quality of the mandrel. ...
... The effect of pretension is found to be negligible in some studies [14]. Koussios and Bergsma [14] performed several experiments corresponding to the variation of typical filament windingrelated process parameters: fiber speed, roving tension, roving dimensions, wet versus dry winding, and surface quality of the mandrel. They neglected the effect of the pretension in their study. ...
... However, the effect of pretension is assumed to be negligible in some studies. For example, Koussios and Bergsma [14] performed several experiments corresponding to the variation of typical filament winding-related process parameters: fiber speed, roving tension, roving dimensions, wet versus dry winding, and surface quality of the mandrel. They neglected the effect of the pretension in their experiments. ...
The present study has investigated the effect of the roving tension (pretension force) on the strength of continuous carbon fiber used in the Filament Winding (FW) process. Pretension force is generally applied to composite products manufactured by FW technology to lay out the carbon fiber onto the cylindrical tube in a correct way. However, a considerable amount of damage occurs in the fibers during fiber movement trough pulleys in the pretension unit. A winding system was designed to simulate the process to understand the effects of the parameters such as roving tension, pulley diameter, and contact angle between pulley and fiber. Several experimental tests have been performed by changing pulley diameters and tension forces to understand the effect of these parameters. According to these experiments, the angle between the pulley and the amount of force applied to the carbon fiber generate the damage on the carbon fiber. Tension tests were also conducted to evaluate the strength of the damaged and undamaged carbon fiber. Experimental results indicate that the tensile strength of carbon fiber is reduced by 10 to 43% because of a change to the roving tension (pretensioning) parameters.
... Several authors have studied various structural problems related to filament-wound, metal-lined cylinders under internal pressure or impact [2][3][4][5][6][7], but these studies focused on the product strength, not on the fiber strength that is used to wound the product. For example, Koussios and Bergsma [8] performed several experiments corresponding to the variation of typical filament winding-related process parameters: fiber speed, roving tension, roving dimensions, wet versus dry winding, and surface quality of the mandrel. In their study, the effect of the pretension is neglected. ...
