Abstract:The extraordinary features of fibrous composites enable advanced industries to design composite structures with superior performance compared to traditional structures. Composite frame structures have been designed frequently as components of mechanical systems to resist lateral and gravity loads. The manufacturing of high-quality composite frames depends primarily on the accurate fiber winding on frames with different pro-files and curved shapes. The optimal fiber winding process on a nonbearing composite fra… Show more
“…These conditions are described in detail in previous works by the same authors. 1,9 Figure 4.Model of the winding process that shows the formation of the first fiber layer on the composite frame; the frame goes through a winding head (Figure 2(a)) represented by three coil rings, and three layers of fiber are created. The schema of the first fiber layer formation is shown in this figure.…”
Section: Materials and Winding Optimizationmentioning
confidence: 99%
“…As already mentioned in subsection fiber winding , it is necessary for right winding the frame passes perpendicularly to the winding plane of fiber rovings (see Figures 4 and 2(b), detail is described in the literature). 1,8,9…”
Section: Materials and Winding Optimizationmentioning
confidence: 99%
“…Optimization of the robot trajectory for such cases using a differential evolution algorithm is described in detail in previous works. 1,9 After winding the fibers, the frame is impregnated with resin and then thermally cured using, for example, (resin transfer molding) RTM technology. 42…”
Section: Fiber Windingmentioning
confidence: 99%
“…As already mentioned in subsection fiber winding, it is necessary for right winding the frame passes perpendicularly to the winding plane of fiber rovings (see Figures 4 and 2(b), detail is described in the literature). 1,8,9 It was assumed torus is connected to the robot-end-effector, rotates around its center S and goes through the winding head (and therefore through rotated coil ring k1 which forms the first layer of wound fibers, similar to Figure 4) and orthogonally goes through the winding plane ρ 1 (i.e. its axis o orthogonal to ρ 1 , see Figure 11(b)).…”
Section: Winding a Curved Part Of The Framementioning
confidence: 99%
“…6,7 Fiber-reinforced polymer composite frames are used in the aerospace industry (e.g. as fuselage reinforcements, attaching windows to the fuselage, reinforcing the helicopter cabin), 1,8,9 automotive applications (e.g. as car chassis, cab and door reinforcement), 8 and also in shipbuilding.…”
Light-weight fibers reinforced polymer (FRP) composite frames are essential parts of vehicles body in the aerospace and automotive industries. Composite frames are often designed in complex curved 3D geometry through the dry winding process. The winding process of homogeneously wound-up layers of fibers without overlapping and gaps is the main challenge in the fabrication of frames with consistent thickness and acceptable quality. In this study, an industrial robot and winding head are set with a novel optimum process to wind the dry fiber with the specified angles on the frame, to fabricate it with minimum overlapping and local commulation of fibers, yet without gaps. Mathematical models and algorithms are developed to determine the optimal number of simultaneously wounds rovings of fibers in a given layer. In addition, this study addresses the optimum dry winding of curved parts of frames that form a torus geometry. It is shown that the combination of layers of rovings wound successively on the frame at angles of 45°, 90° (i.e. the rovings are laid along with the frame), and −45°, is the most used variant of winding that provides the composite frame with higher strength. Results indicated that an optimal selection of the number and width of the rovings minimizes the overlap of the wound rovings, which saves up to 20% of the utilized fibers. The derived theory is verified on practical tests and experiments, which confirms the development of new suitable procedures to improve the fabrication of FRP composite frames.
“…These conditions are described in detail in previous works by the same authors. 1,9 Figure 4.Model of the winding process that shows the formation of the first fiber layer on the composite frame; the frame goes through a winding head (Figure 2(a)) represented by three coil rings, and three layers of fiber are created. The schema of the first fiber layer formation is shown in this figure.…”
Section: Materials and Winding Optimizationmentioning
confidence: 99%
“…As already mentioned in subsection fiber winding , it is necessary for right winding the frame passes perpendicularly to the winding plane of fiber rovings (see Figures 4 and 2(b), detail is described in the literature). 1,8,9…”
Section: Materials and Winding Optimizationmentioning
confidence: 99%
“…Optimization of the robot trajectory for such cases using a differential evolution algorithm is described in detail in previous works. 1,9 After winding the fibers, the frame is impregnated with resin and then thermally cured using, for example, (resin transfer molding) RTM technology. 42…”
Section: Fiber Windingmentioning
confidence: 99%
“…As already mentioned in subsection fiber winding, it is necessary for right winding the frame passes perpendicularly to the winding plane of fiber rovings (see Figures 4 and 2(b), detail is described in the literature). 1,8,9 It was assumed torus is connected to the robot-end-effector, rotates around its center S and goes through the winding head (and therefore through rotated coil ring k1 which forms the first layer of wound fibers, similar to Figure 4) and orthogonally goes through the winding plane ρ 1 (i.e. its axis o orthogonal to ρ 1 , see Figure 11(b)).…”
Section: Winding a Curved Part Of The Framementioning
confidence: 99%
“…6,7 Fiber-reinforced polymer composite frames are used in the aerospace industry (e.g. as fuselage reinforcements, attaching windows to the fuselage, reinforcing the helicopter cabin), 1,8,9 automotive applications (e.g. as car chassis, cab and door reinforcement), 8 and also in shipbuilding.…”
Light-weight fibers reinforced polymer (FRP) composite frames are essential parts of vehicles body in the aerospace and automotive industries. Composite frames are often designed in complex curved 3D geometry through the dry winding process. The winding process of homogeneously wound-up layers of fibers without overlapping and gaps is the main challenge in the fabrication of frames with consistent thickness and acceptable quality. In this study, an industrial robot and winding head are set with a novel optimum process to wind the dry fiber with the specified angles on the frame, to fabricate it with minimum overlapping and local commulation of fibers, yet without gaps. Mathematical models and algorithms are developed to determine the optimal number of simultaneously wounds rovings of fibers in a given layer. In addition, this study addresses the optimum dry winding of curved parts of frames that form a torus geometry. It is shown that the combination of layers of rovings wound successively on the frame at angles of 45°, 90° (i.e. the rovings are laid along with the frame), and −45°, is the most used variant of winding that provides the composite frame with higher strength. Results indicated that an optimal selection of the number and width of the rovings minimizes the overlap of the wound rovings, which saves up to 20% of the utilized fibers. The derived theory is verified on practical tests and experiments, which confirms the development of new suitable procedures to improve the fabrication of FRP composite frames.
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