This is a two-part paper where part 1 presents details of a modified wet-filament winding process. Here, the resin bath was replaced with a resin injection system that impregnated the fibres prior to winding them onto a rotating mandrel. The resin and hardener were stored in separate containers and pumped on-demand via a pair of precision gear-pumps to a static mixer. The mixed resin system was then supplied to a custom-designed resin impregnation unit. The theoretical basis for the design of the resin impregnation unit is presented along with simulations of the various parameters that influence the impregnation time and the degree of impregnation. Part 2 of this series papers presents the experimental data on the performance of the resin impregnation unit and a comparison of the physical and mechanical properties of the tubes manufactured using the conventional and modified wet-filament winding techniques.
Fibre-reinforced composites consist of three key components: the reinforcing fibres, the matrix and the interface between the fibre and the matrix. The efficient impregnation of the reinforcing fibre bundle by the matrix is a primary prerequisite for the production of advanced fibre-reinforced composites. This process can be significantly enhanced by spreading the filaments in the reinforcing fibre bundle. The authors previously reported on a manual technique for spreading the filaments in a bundle. This involved subjecting a fibre bundle to a series of reciprocating motions over a rod. The effect of releasing the tension on the bundle was also considered. On the basis of the observations made in the previous study, a mechanised rig was designed, manufactured and optimised to enable the lateral spreading of the filaments in a bundle of E-glass fibres. A Taguchi-based approach was used to optimise the variables on the rig such as the number and configuration of rollers, haul-off speed of the fibre bundle, pre-tension in the bundle and the rotational speed of the roller carrier hub. The maximum degree of fibre spreading achieved for a commercially available 2400 tex E-glass fibre bundle was 250%.
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