Effects of Tape Tension on Residual Stress in Thermoplastic Composite Filament Winding

Abstract

Thermoplastic composite filament winding is a viable technique for manufacturing composite-reinforced pressure pipes and vessels. Residual stresses developed during the filament winding process have already received much attention in the past. Unreasonable residual stresses may result in distortion, matrix cracking, and interply delaminations. A model containing four submodels is developed in a previous research work. Some methods, such as adjusting tape tensions and temperatures are found to control the residual stress profile. The residual stress profile can be adjusted to a satisfactory level, which can avoid defects and even reduce weight and save material. Adjusting the tape tension is one of the parameters that controls the residual stress in thermoplastic composite filament winding. From a practical point of view, it is easy to realize even on an industrial scale. Experiments on two materials (glass fiber–polypropylene (G–PP) and carbon fiber–poly(ether-ether-ketone) (C–PEEK)) are made by using a variety of different tape tensions. The results proved the conclusions of theoretical work and agree well with the model predictions.

Thermal stresses in rings of thermoplastic composites made by automated fiber placement process

“…The effect of temperature to material properties was neglected in the stress-strain submodel. Lu et al [17] applied this model to adjust the residual stress profi le to a satisfactory level, which can avoid defects and even reduce weight and save material.…”

Determination of Residual Stress and Design of Process Parameters for Composite Cylinder in Filament Winding

“…erefore, based on the assumption of micromechanics, the thermal and chemical shrinkage stress models of the composite cylinder had been established during the curing process [11][12][13][14]. To accurately determine the residual stress model and predict the stress profile, some authors considered the coupling effects of winding tension and cure parameters on the residual stresses [15][16][17][18].…”

Diode Laser Assisted Filament Winding of Thermoplastic Matrix Composites

“…Experimental tests were carried out on carbon fiber reinforced PEEK and glass fiber reinforced PP; a gas torch was used as thermal source for the prepreg consolidation in combination with a consolidation roller. Subsequently (2005), this study was extended to evaluate the effect of the tape tension on residual stress and a tape tensioner was added to the consolidation apparatus [8]. Similar experiences were also made by Toso et al who discussed computational simulations and experimental validations for the winding process of glass fiber reinforced PP tapes [9]; also in this case a hot gas torch was used as thermal source.…”