COMPOSITE FILAMENT WINDING Edited by S.T. Peters ASM International Materials Park, Ohio 44073-0002
Copyright 2011 by ASM International All rights reserved No part of this book may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of the copyright owner. First printing, September 2011 Great care is taken in the compilation and production of this book, but it should be made clear that NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE GIVEN IN CONNECTION WITH THIS PUBLICATION. Although this information is believed to be accurate by ASM, ASM cannot guarantee that favorable results will be obtained from the use of this publication alone. This publication is intended for use by persons having technical skill, at their sole discretion and risk. Since the conditions of product or material use are outside of ASM s control, ASM assumes no liability or obligation in connection with any use of this information. No claim of any kind, whether as to products or information in this publication, and whether or not based on negligence, shall be greater in amount than the purchase price of this product or publication in respect of which damages are claimed. THE REMEDY HEREBY PROVIDED SHALL BE THE EXCLUSIVE AND SOLE REMEDY OF BUYER, AND IN NO EVENT SHALL EITHER PARTY BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHETHER OR NOT CAUSED BY OR RESULTING FROM THE NEGLIGENCE OF SUCH PARTY. As with any material, evaluation of the material under end-use conditions prior to specification is essential. Therefore, specific testing under actual conditions is recommended. Nothing contained in this book shall be construed as a grant of any right of manufacture, sale, use, or reproduction, in connection with any method, process, apparatus, product, composition, or system, whether or not covered by letters patent, copyright, or trademark, and nothing contained in this book shall be construed as a defense against any alleged infringement of letters patent, copyright, or trademark, or as a defense against liability for such infringement. Comments, criticisms, and suggestions are invited, and should be forwarded to ASM International. Prepared under the direction of the ASM International Technical Book Committee (2010 2011), Michael J. Pfeifer, Chair. ASM International staff who worked on this project include Scott Henry, Senior Manager, Content Development and Publishing; Eileen De Guire, Senior Content Developer; Victoria Burt, Content Developer; Sue Sellers, Editorial Assistant; Bonnie Sanders, Manager of Production; Madrid Tramble, Senior Production Coordinator; and Diane Whitelaw, Production Coordinator. Library of Congress Control Number: 2011908767 ISBN-13: 978-1-61503-722-3 ISBN-10: 0-61503-722-5 SAN: 204-7586 ASM International Materials Park, OH 44073-0002 Printed in the United States of America
Composite Filament Winding S.T. Peters, editor Copyright 2011, ASM International All rights reserved. Contents Preface About the Editor v vi Chapter 1 Filament Winding Introduction and Overview 1 Chapter 2 Automated Filament Winding Systems 7 Chapter 3 Integral Design for Filament Winding Materials, Winding Patterns, and Roving Dimensions for Optimal Pressure Vessels 19 Chapter 4 Programming Techniques, Computer-Aided Manufacturing, and Simulation Software 35 Chapter 5 Fiber Trajectories on Shells of Revolution An Engineering Approach 49 Chapter 6 Control of Filament Winding Parameters 65 Chapter 7 Filament Winding Technology Learned 81 Chapter 8 Static Mechanical Tests for Filament-Wound Composites 95 Chapter 9 Pressure Vessel Design, Fabrication, Analysis, and Testing 115 Appendix 1 Specifications and Designations of Fibers and Resins 149 Appendix 2 Glossary of Filament-Winding Terms 151 Index 159
Composite Filament Winding S.T. Peters, editor Copyright 2011, ASM International All rights reserved. Preface THIS IS THE FIRST CONTEMPORARY BOOK to treat filament winding with a focus on automation. The purpose of this book is to provide detailed procedures for automated filament winding for complex shapes, to chronicle the progress that has been made in robotic filament winding along with ancillary processes that support the deposition process. It is also to show what has and what can be done to advance the process and science of low-cost composite fabrication by filament winding. The need for this book has been evident because the bulk of filament winding machinery purchases now have a greater number of control axes and substantial automation in ancillary operations, such as mandrel removal, and cure (Chapter 2). There has also been a geographical shift with the process. Literature searches have shown that more professional papers now emerge from Canada, South Korea, and the Netherlands than from the United States. Investigators at the Korea Advanced Institute of Science and Technology have developed two new iterations of the standard test and evaluation bottle (Chapter 8). This book builds on three previous publications, Filament Winding, Composite Structure Fabrication, SAMPE Publishers, 1991 and 1999; and, S. Koussios, Filament Winding, A Unified Approach, Delft University Press, 2004; along with the many individual publications and presentations of the authors of the present work. The previous books addressed mainly aerospace applications and offered hands-on instructions for making components using the rudimentary, by today s standards, winders. Among other areas, the previous books presented geodetic and nongeodetic roving trajectories, kinematics with collision control, and derived articulated pressurizable structures. Four of the nine chapters in this book (Chapters 2 to 5) address automation directly. Now the highest automation is used in the commercial arena, for example, pipes. The kinds of structures that can be produced are shown in Chapters 6 and 7. Finally, Chapter 9 addresses the actual processes of pressure vessel analysis, fabrication, and testing. I want to dedicate this book to two mentors and friends, Yuri Tarnopol skii and Lowrie McLarty, who both gently prodded me toward composite physical and mental activity and who corrected some of my more glaring errors. I still hold them in my memory. I would also like to acknowledge the excellent editorial staff at ASM International. They were thoroughly competent, professional, and furthermore, easy to work with. Stan T. Peters
Composite Filament Winding S.T. Peters, editor Copyright 2011, ASM International All rights reserved. About the Editor Mr. Stan T. Peters is General Manager of Process Research, an engineering consulting firm in Mountain View, Calif. He has been editor of the SAMPE Journal and remains a member of the editorial review board for the Journal of Advanced Materials. He has written or edited two books, Filament Winding: Composite Structure Fabrication, 1991, 1999; and Handbook of Composites, 2nd ed., Chapman and Hall, 1998; and has 32 publications and 3 patents. He was elected a SAMPE Fellow in 1990, was a Westinghouse Fellow Engineer, and received the Westinghouse Signature Award in 1990, the WEC ESG Special Achievement Award in 1992, and the Boeing Certificate of Achievement for the EELV/Delta IV program in May 2004. He is a professional engineer, manufacturing, State of California, and has taught or presented tutorials on composites in a number of venues.