“In Pursuit of Global Competitiveness”

Project Report on

“Design of filament winding machine for FRP butt joint ”

For the mini project of

Master of Engineering In
Production Engineering

Submitted By

Shaikh Juned. T

Under the Guidance of

Dr. R. N. LADHWE

Department of production Engineering

Government College of Engineering, Aurangabad
(An Autonomous Institute of Government of Maharashtra)
(2019-2020)
 CERTIFICATE

This is to certify that the Project entitled “Design of composite filament winding
machine” which is being submitted herewith for the award of the Mini project of ‘Master of
Engineering’ in ‘production Engineering’ of Government College of Engineering,
Aurangabad affiliated to Dr. Babasaheb Ambedkar Marathwada University, Aurangabad.
This above mini project design of composite filament winding machine report is
submitted by
Shaikh Juned. T

Under the guidance of Dr R. N. Ladhwe. Above work is successful completed and submitted
by him.

Place: Aurangabad.

Date: / /2020

Dr. R. N. LADHWE Dr. R. S. DALU

Guide Head
Dept. of Mechanical Engineering Dept. of Mechanical Engineering

Dr. P. B. Murnal
Principal
Government College of Engineering, Aurangabad
 CONTENTS
Sr. Contents Page No.
No.
1 Introduction 6

2 Literature survey 10

3 Filament winding process 12

4 Design of filament winding machine 24

5 Summary 32

6 Reference 35
 LIST Of FIGURE
Figure Figure Name Page Number
Number
Figure 3.1 Filament winding process 12
Figure 3.1.1 Typical lathe filament winding machine 12
Figure 3.2.1 Hoop winding 13
Figure 3.2.2 Helical winding 13
Figure 3.2.3 Polar winding 13

Figure 3.4.1 GFRP roll 16

Figure 3.4.2 CFRP sheet 17
Figure 4.1 schematic diagram of filament winding machine 27
Figure 4.2 Actual setup of filament winding machine 28

Figure 4.3 Filament winding machine 29

Figure 4.4 Winding angle relation with RPM 30

Figure 4.5 winding rod 30

Figure 4.6 Torque calculation for rod 31

Figure 4.7 specimen with CFRP butt joint 32

Figure 4.8 33
Actual specimen with CFRP butt joint
 NOMENCLATURE

Φ Winding angle

ρ Carbon fiber density

τm Torque requirement for mandrel

τt Torque requirement due to fiber tension

D Mandrel diameter

L Distance moved by carriage per revolution of mandrel

lm Mandrel length

lr Mandrel radius

rs Radius of screw rod

RPMm RPM of mandrel motor

v Volume of fiber on mandrel

FOS Factor of safety

n No. of threads engaged

 1. INTRODUCTION
1.1 Background
This is an elaborate report on the making of a composite winding machine,
capable of fabricating cylindrical structures made of carbon fiber or other
composite materials by winding them at multiple winding angles on variable
diametric removable mandrels. This report includes the definition of keywords
and their meanings in the context of the scope of this project. The various phases
of completion of the report are elaborately stipulated in this report. Thereby
giving full account of the various de- sign and development stages of the filament
winding machine, the setbacks faced dur- ing these phases, various learning
points, and the results and outcomes consequentially achieved because of
completion of this project. This report also mentions the aims and objectives of
the project (to clarify the scope of the project and accurately identify the success
criterion of this project Technical details of the components used in the filament
winding machine have been given. The selection criterion based on which these
components were selected have also been given and various mechanisms to
control crucial parameters of the filament winding process have been covered in
depth. A brief introduction about the various composite structure fabrication
techniques being utilized in the manufacturing industry is given below
highlighting the importance and viability of composites in modern
manufacturing. Composite materials are taking over the modern manufacturing
industry on a rapid pace owing to the magnificent structural properties exhibited
by them. The strength to weight ratio of composite materials is far better than the
metals when compared. This gives them an edge over ordinary metals in
industrial applications specially where machines and parts are required to be light
weight yet oper- ate in hostile environment bearing load without failure. This
makes the use of composite materials ideal in the manufacturing of automotive
parts, aerospace manufacturing and in certain cases, even construction material.
Industries across the developed world have shifted to composites but these
fabrication techniques and processes are far from in- troduction in the industry in
the developing world. This gives an opportunity to take an initiative to introduce
this modern manufacturing aspect into the developing world.
In a recently developed method a fiber reinforced polymer (FRP) composites are
used to join two parts together. FRP is made of fibers (Glass/ Carbon) and a
thermoset matrix (epoxy). Fiber is used to carry the load and matrix helps in
bonding of fiber with adherends also it protect the fiber from abrasion and
environmental attack.
An composite Joint Advantages-
• This is cold working process so the joining can be easily done at room
temperature.
• This method can be used to join similar or dissimilar materials.
• This overcomes the limitations of welding in which similar or certain
pairs of materials can only be joined.
• Directional properties can be obtained by varying the orientations of fiber
in the composites
• This provides non-corrosive joint.
• The FRP joint offers high strength to weight ratio.

Due to the several advantages offered by FRP, now a days ,FRP is being
used in several industrial applications . Some of them are listed below:

1) Aircrafts
2) Auto Body
3) Auto Frame
4) Bridge Reinforcement
5) Shafts and Rods
1.2Project Aims and Objectives

1.2.1Project Scope
The scope of this project is defined and limited as follows:

Design of machine for the manufacturing of cylindrical parts

made of compos- ite fibers. The machine will be used in the
MRC to produce composite specimen for research purposes.

1.2.2Project Objectives
The objectives of this project are distinctly identified as follows:

• Designing of a composite winding system capable of fabricating

cylindrical composite structures by winding a resin impregnated
fiber on a removable mandrel.
• Winding system to be able to wind the composite fiber at a variety
of winding angles with constant fiber tension.
2)LITERATURE SURVEY

Tension is another very important factor which decides the mechanical properties
of composite parts. According to Hazra, Gu, and TaheriCohen(1, 2)tension is
responsible for≈ 70% of the stiffness and strength. So both winding angle and
fiber tension are Of extreme importance in filament winding process.

There should be some proper value of the tension chosen which ought to be
constant throughout winding process. If tension is less, fibers will be loosely
wound causing wrinkling. If tension is high, fibers may become damaged and
there will be chance of non-homogeneous compactness. So a tension value should
be such that it minimizes the empty spaces, wrinkling and folds.

In “Selection of optimal processing parameters in filament winding, a study was

performed on influence of primary primary processing parameters (i.e.
parameters that can be selected, monitored and controlled by the operator; e.g.
the tow tension) on secondary processing parameters (i.e. parameters that are not
directly controllable by the operator, e.g. the winding bandwidth) has been
reported.

In a study was performed about how to predict physical properties of the

composite parts. Cohen studied about manufacturing and design variables which
effect quality, strength & stiffness of composite vessels. It was found that
composite strength is affected by lam- inate stacking sequence, winding tension,
winding-tension gradient, winding time, and the interaction between winding-
tension gradient and winding time. Increased composite strength was related to
fiber volume in the composite.

Sharon and Lin,(3) designed a fully automated fiber optic winding machine
integrating active tension control with automatic error detection and correction.
Conventionally used tension control systems incorporate stationery pulley
system. For fine tension control, he separated the inertia of fiber spool and tension
mechanism. A servo controlled tenison arm has been designed and simulated
results have been verified with experiment. Vision based automatic error
detection plus correction, made this system very accurate.

Another tension system was proposed by Choi, Cheong, and Kim,(4), shown
which employed use of a electro-rheological brake actuator along with sliding
mode feedback controller. By applying electric fields to arabic gum based ER
fluid, static yield stresses were obtained. It was found that this type of ER based
tension control is very robust to strong external disturbance.

Mertiny and Ellyin,(5), did the experimental investigation the influence of the ap-
plied tow tension during filament winding on the physical and mechanical
properties of glass-fibre reinforced polymeric composite tubulars. He fixed the
winding angle and manufactured specimens using different winding tensions, and
mechanical testing was done using different loading ratios. Some conclusions he
made are[8]:

• Increasing the filament winding tow tension significantly increased

fibre compaction; thus the primary processing parameter ‘winding
tension’ is suited for controlling the fibre volume fraction of the
manufactured components
• Mechanical testing revealed that stresses at functional and structural
failure de- pend on the applied winding tension.
 • Comparison of test results from specimens wound with a low and
high tow tension indicated that the mechanical properties do not follow a
simple unidirectional trend. Generally, an increase in winding tension has
a beneficial effect on the component strength in the case of a fiber
dominated loading, whereas under a matrix dominated loading condition
a slight decrease in the failure strength was obtained by increasing fiber
compaction.

3) FILAMENT WINDING PROCESS

• Filament winding is process in which resin impregnated fibers are wound

over rotating mandrel at the desired angle.
• Filament winding process can be used to produce any product with
positive curved surface.
• Surface with reverse curvature (concave) are not suitable since the fiber
cannot take the contour of reverse curvature.
 Figure 3.1 filament winding process

3.1) working of filament winding process

Now hear it all these things are brought in proper tension and the spacing is
maintained and afterwards it is asked to pass through a resin bar. So, in this
resin bar we have a polymer which is predominantly a thermoset and we also
have other ingredients like hardener and then whatever it is other surfactant
whatever we want to add. So, this can be added, so that surfactant can be
added, so that we try to get the proper requirement. And then the after it
passes through the resin now we see there is a change in color of the glass
fiber or carbon fiber. So, the black has become golden color this golden color
means that resin is getting coated all along the fiber. And now this is passed
through nip rollers because you have to make sure excess resin should not
be there and this excess resin is removed by passing through these rollers.
So, that we doubly make sure that there is a uniform coating of polymer
around the glass fiber and then it is moved to a small ring or this is called as
a feeding post, feeding post. Now what you see that if this glass fiber
whatever comes out individual fibers are now twinned they get into a shape
and this the bundle of glass fibers are now wound over the mandrel. So, this
is a mandrel. Why do you need this mandrel? This mandrel is made out of
wood and then wood or metal whatever it is it can be it can be solid, it can
be collapsible also. That means, to say this entire thing can be made out of a
single piece or it can be made out of two halves depending upon your
requirement, Now the single glass the roving which came are now bundled
together and now this is allowed to wound over the mandrel, this mandrel is
rotating, So, now of what happens as and when you increase the glass fiber
roving on top of this mandrel the thickness increases. Now here depending
upon the feed rate, depending upon the rpm you can try to have varying hatch
patterns, this hatch patterns can be process controlled to get whatever you
 want. Now slowly-slowly this process gets repeated may be 1000 windings,
500 windings, 10 windings whatever it is you get and finally, what you get
is a cylinder which is completely made out of polymer matrix composite
which is reinforced with glass fiber and this angle of hatch pattern depends
on your strength what you are the properties what you want from this
composite. For example, the fluid can flow in this direction the pressures can
be high in this direction. So, you try to balance the hatching and the winding
angle to get the required composite. And by the way if you pass through the
bridges where and which these bridges have columns which are completely
in the river itself riverbed itself, that means, to say all the time water is
flowing of all the time a corrosive environment is there, so you have this
columns on top of which were cars and other things go on. So, these columns
are nowadays made out of composites. Two way exclusively composites
they are made or what they have done is they have taken the cement concrete
and then they had made a column and the column is protected by filament
winding process using glass fiber to avoid corrosion and to enhance the
strength property. The other thing is today they talk about self healing or
they talk about how do we make sure the defects whatever harness on the
concrete to be prevented further growth they use composite.

3.1.1) Filament winding machine

• Winding machine
a) Semi automatic
b) Two axes
c) Rotation of the mandrel

• Winding machine can broadly classified into three groups

a) Helical winding machine
b) Polar winding machine
 c) Advance winding machine

Figure 3.1.1 typical lathe filament winding machine

3.2.1) Types of filament winding

a) Hoop winding

Figure 3.2.1 Hoop winding

Winding pitch:- pitch is distance between two windings.

Bandwidth:- angle of fiber.

• Circumferential winding.
• Angle is close and below 90°.
• Each complete rotation of mandrel shifts the fibre band to lie alongside
previous band.

b) helical winding

Figure 3.2.2 helical winding

• Complete fiber coverage without the band.

• Having to lie adjacent to previously laid.

c) Polar winding
 Figure 3.2.3 polar winding

• For spherical component.

• Fiber constrained by bosses on each pole of component.

3.3.1) process parameters of filament winding

• Fiber tension is most important to control

a) Fiber volume fraction

b) Voids
c)Influence the strength and stifness of part

• Fiber tension is function of

a)Type of fiber
b) Diameter of part
c) Winding form
 • Problems encountered

1. Fuzziness:
2. Catenary formation
3. Wettability:

Fuzziness

• Fuzziness indicates fiber breakage.

• The fiber breakage during winding can lead to a problem of keeping
the filament integrity.
• The broken fibers tend to fall off, and the broken fibers accumulated
in the resin bath can increase the viscosity of resin, making resin
pickup uneven.
• Fuzziness must be controlled below the acceptable levels.

Catenary formation:

• Catenary means unequal tension of filaments within a strand or

roving.
• A roving is a collection of strands, which themselves are a collection
of filaments.
• If there is slackness in few filaments, then they form catenary. The
fiber that forms catenary may remain wavy in the wound product.
• This phenomenon will affect the product quality.
• Since the wavy fibers may not take the load.
 • Roving must be tested to ensure that the catenary formation is
absent.

Wettability:

• As the time available for fiber wetting during filament winding

process is very short., a suitable resin with short wetting time should
be selected.

3.4.1 Materials

Reinforcement

Fibers

Glass Fibers: Based on an alumina-lime-borosilicate composition, “E” or

“E-CR” glass produced fibers are considered the predominant
reinforcements for polymer matrix composites due to their high electrical
insulating properties, low susceptibility to moisture and high mechanical
properties. E-CR glass is further distinguished from E-glass by having
superior corrosion resistance properties. Other commercial compositions
include “S” glass, with higher strength, heat resistance and modulus, H-glass
with higher modulus, and AR glass (alkali resistant) with excellent corrosion
resistance. Glass is generally a good impact resistant fiber but weighs more
than carbon or aramid. Glass fibers have excellent mechanical
characteristics, stronger than steel in certain forms. The lower modulus
requires special design treatment where stiffness is critical. Glass fibers are
transparent to radio frequency radiation and are used in radar antenna
applications.

Figure 3.4.1 GFRP Rool

Carbon Fibers: Carbon fibers are made from organic precursors, including
PAN (polyacrylonitrile), rayon, and pitches, with the latter two generally
used for low modulus fibers. The terms “carbon” and “graphite” fibers are
typically used interchangeably, although graphite technically refers to fibers
that are greater than 99 percent carbon composition, versus 93-95 percent
for PAN-based carbon fibers. Carbon fiber offers the highest strength and
stiffness of all the reinforcement fibers. High temperature performance is
particularly outstanding for carbon fibers. The major drawback to PAN-
based fibers is their high relative cost, which is a result of the cost of the base
material and an energy-intensive manufacturing process. Carbon fiber
composites are more brittle than glass or aramid. Carbon fibers can cause
galvanic corrosion when used next to metals. A barrier material such as glass
and resin is used to prevent this occurrence.
 Figure 3.4.2 carbon fiber sheet

Aramid Fibers (Polyaramids): The most common synthetic fiber is aramid.

Aramid fiber is an aromatic polyimid that is a man-made organic fiber for
composite reinforcement. Aramid fibers offer good mechanical properties at
a low density with the added advantage of toughness or damage/impact
resistance. They are characterized as having reasonably high tensile strength,
a medium modulus, and a very low density as compared to glass and carbon.
Aramid fibers are insulators of both electricity and heat and increase the
impact resistance of composites. They are resistant to organic solvents, fuels
and lubricants. Aramid composites are not as good in compressive strength
as glass or carbon composites. Dry aramid fibers are tough and have been
used as cables or ropes, and frequently used in ballistic applications. Kevlar
is perhaps the best known example of aramid fiber. Aramid is the
predominant organic reinforcing fiber replacement for steel belting in tires.

New Fibers: Polyester and nylon thermoplastic fibers have recently been
introduced both as primary reinforcements and in a hybrid arrangement with
fiberglass. Attractive features include low density, reasonable cost, and good
impact and fatigue resistance. Although polyester fibers have fairly high
strengths, their stiffness is considerably below that of glass. More
specialized reinforcements for high strength and high temperature use
include metals and metal oxides such as those used in aircraft or aerospace
applications.

• Reinforcement Forms

Regardless of the material, reinforcements are available in forms to serve a

wide range of processes and end-product requirements. Materials supplied
as reinforcement include roving, milled fiber, chopped strands, continuous,
chopped or thermoformable mat. Reinforcement materials can be designed
with unique fiber architectures and be preformed (shaped) depending on the
product requirements and manufacturing process.

Multi-End and Single-End Rovings: Rovings are utilized primarily in

thermoset compounds, but can be utilized in thermoplastics. Multi-end
rovings consist of many individual strands or bundles of filaments, which
are then chopped and randomly deposited into the resin matrix. Processes
such as sheet molding compound (SMC), preform and spray-up use the
multi-end roving. Multi-end rovings can also be used in some filament
winding and pultrusion applications. The single-end roving consists of many
individual filaments wound into a single strand. The product is generally
used in processes that utilize a unidirectional reinforcement such as filament
winding or pultrusion.

Mats & Veils: Reinforcing mats and non-woven veils are usually described
by weight-per-unit-of-area. For instance, a 2 ounce chopped strand mat will
weigh 2 ounces per square yard. The reinforcement type, the fiber
dispersion, and amount of binder that is used to hold the mat or veil together
dictate differences between mat products. In some processes such as hand
lay-up, it is necessary for the binder to dissolve. In other processes,
particularly in compression molding, and pultrusion the binder must
withstand the hydraulic forces and the dissolving action of the matrix resin
during molding. Therefore, from a binder point of view, two general
categories of mats or veils are produced and are known as soluble and
insoluble binders.

Woven, Stitched, Braided & 3-D Fabrics: There are many types of fabrics
that can be used to reinforce resins in a composite. Multidirectional
reinforcements are produced by weaving, knitting, stitching or braiding
continuous fibers into a fabric from twisted and plied yarn. Fabrics can be
manufactured utilizing almost any reinforcing fiber. The most common
fabrics are constructed with fiberglass, carbon or aramid. Fabrics offer
oriented strengths and high reinforcement loadings often found in high
performance applications. Fabrics allow for the precise placement of the
reinforcement. This cannot be done with milled fibers or chopped strands
and is only possible with continuous strands using relatively expensive fiber
placement equipment. Due to the continuous nature of the fibers in most
fabrics, the strength to weight ratio is much higher than that for the cut or
chopped fiber versions. Stitched fabrics allow for customized fiber
orientations within the fabric structure. This can be of great advantage when
designing for shear or torsional stability.

Unidirectional: Unidirectional reinforcements include tapes, tows,

unidirectional tow sheet and roving (which are collections of fibers or
strands). Fibers in this form are all aligned parallel in one direction and
uncrimped, providing the highest mechanical properties. Composites using
unidirectional tapes or sheets have high strength in the direction of the fiber.
Unidirectional sheets are thin and multiple layers are required for most
structural applications. Typical applications for unidirectional
 reinforcements include highly loaded designed composites, such as aircraft
components or race boats.

Prepreg: Prepregs are a ready-made material made of a reinforcement form

and polymer matrix. Passing reinforcing fibers or forms such as fabrics
through a resin bath is used to make a prepreg. The resin is saturated
(impregnated) into the fiber and then heated to advance the curing reaction
to different curing stages. Thermoset or thermoplastic prepregs are available
and can be either stored in a refrigerator or at room temperature depending
on the constituent materials. Prepregs can be manually or mechanically
applied at various directions based on the design requirements.

Milled: Milled fibers are chopped fibers having very short fiber lengths
(usually less than 1/8”). These products are often used in thermoset putties,
castings, or syntactic foams to prevent cracking of the cured composition
due to resin shrinkage.

Matrix
There are three main types of composite matrix materials:

• Ceramic matrix - Ceramic matrix composites (CMCs) are a subgroup of

composite materials. They consist of ceramic fibers embedded in a ceramic
matrix, thus forming a ceramic fiber reinforced ceramic (CFRC) material.
The matrix and fibers can consist of any ceramic material. CMC materials
were designed to overcome the major disadvantages such as low fracture
toughness, brittleness, and limited thermal shock resistance, faced by the
traditiontechnicalceramics.
• Metal matrix - Metal matrix composites (MMCs) are composite materials
that contain at least two constituent parts – a metal and another material or
a different metal. The metal matrix is reinforced with the other material to
improve strength and wear. Where three or more constituent parts are
present, it is called a hybrid composite. In structural applications, the
matrix is usually composed of a lighter metal such as magnesium, titanium,
or aluminum. In high temperature applications, cobalt and cobalt-nickel
alloy matrices are common. Typical MMC's manufacturing is basically
divided into three types: solid, liquid, and vapor. Continuous carbon,
silicon carbide, or ceramic fibers are some of the materials that can be
embedded in a metallic matrix material. MMCs are fire resistant, operate
in a wide range of temperatures, do not absorb moisture, and possess better
electrical and thermal conductivity. They have also found applications to
be resistant to radiation damage, and to not suffer from outgassing. Most
metals and alloys make good matrices for composite applications.

• Polymer matrix - Polymer matrix composites (PMCs) can be divided into

three sub-types, namely, thermoset, thermoplastic, and rubber. Polymer is
a large molecule composed of repeating structural units connected by
covalent chemical bonds. PMC's consist of a polymer matrix combined
with a fibrous reinforcing dispersed phase. They are cheaper with easier
fabrication methods. PMC's are less dense than metals or ceramics, can
resist atmospheric and other forms of corrosion, and exhibit superior
resistance to the conduction of electrical current.
4 DESIGN

Figure 4.1 schematic diagram of filament winding machine

FRP Winding Machine

Firstly, dry carbon fiber roving was wound on a wooden feeder spool as shown
in Figure4.1. The one end of carbon fiber roving from the spool was passed
between the tension control rods. The dead weight was applied with the help of
cantilever section to generate required tension in the dry roving.

The dry roving carbon fiber is pass over five fixed rods of brass material. A bowl
was placed around the bottom of two rods, which contained the mixture of epoxy
resin. As the roving carbon fiber passed under a fixed Brass rod, the epoxy resin
was pressed firmlyas there was a wedging action. Consequently, the resin passed
through the individual fibers of the roving and the wetting of fibers is achieved.

The excess epoxy resin was removed with the help of an eye.

Figure 4.2 Actual setup of filament winding machine

 Mandrel

Figure 4.3 Filament winding machine mandrel

Mandrel (steel) moment of inertia5 = 4.42 × 10−3kgm2

Ρ(steel rod) = 1000kg/m3

As the mandrel is cylindrical and made of wood so we can calculate the moment
of inertia.

Lm = 0.5m
Dm = 0.1m

Moment of inertia of mandrel = 4.42 × 10−3kgm2

Therefore, the total moment of inertia comes out to be 23.495 × 10−3kgm2.

Winding angle relation

RPMm = 22
Mandrel makes one revolution in 60/22 seconds
1X-winder has a mini filament winding machine. Its dimensions are comparable to
our machine so at most of the times this machine was used as a reference to size different
parts of our machine.
2Lowest ϕ at which machine is designed to wind.

Figure 4.4 Winding angle relation with RPM

Type equation here.

L = D × tan ϕ

Linear speed =D × tan ϕ ÷60/22 mm/s

Linear velocity = radius× rotational velocity

Rotational velocity=(Rev/min) × 2π÷60

Linear velocity = (Rev/min) × 2πD/(2 × 60)

Converting to mm/min gives us 22D tan ϕ solving for RPM

rev/min=32D tan ϕ×60÷12/π

Replacing D with 2πr for the helix angle normal parameter gives us a final
equation of:

rev/min =11D tan ϕ÷6

Figure 4.5 winding rod

Mechanism

Conventional filament winding machines use screw rod for transverse

movement. Torque calculations for carriage are done in accordance to screw
rod mechanism but later on a maximum linear speed of 0.3m/s was
calculated for a winding angle of 30◦. For an M8 screw rod, the RPM
required would have been in excess of 300. Considering a stepper motor’s
normal operating limits, it was not deemed feasible and a belt-pulley system
was adopted instead.

Figure 4.6 Torque calculation for rod

Total moment of inertia calculation

Total moment of inertia;

I = 4.42 × 10−3 + 2.3 × 10−3 + 3.05 × 10−3 = 16.775 × 10 − 3

Carbon Fiber .

Using a hollow cylinder model for the carbon fiber wrapped around the
mandrel, as-
suming a maximum fiber width of 10mm

Fiber moment of inertia = 1÷2× M × (b2 + a2)

Carbon fiber ρ = 1.6g/m3

lm = 500mm

lr = 100mm (the maximum we are designing for)

ϕ = 60◦

Layer height = 10mm

The total length of carbon fiber used = 2 × π × r×v3 = 3298.67cm3

Mass of carbon fiber = ρ × v = 5.5kg

Moment of inertia of fiber = 16.775 × 10−3kgm2

Specimen

Figure 4.7 specimen with CFRP butt joint

 Figure 4.8 Actual specimen with CFRP butt joint

As the epoxy get cured at room temperature, it is post cured in

oven at 80-100°C for time period of 4-5 hours.
5 SUMMARY

Filament winding – advantages

• Highly repetitive and accurate fiber placement.

• The capacity to use continuous fibers over the whole component
area without joints. Large and thick-walled structures can be built
that Ability to manufacture a composite with high fiber volume
• Mandrel costs can be lower than other tooling costs because there is
usually only one tool.
• Lower cost for large numbers of components than many other
processes because there can be less labor and economical material
(fiber).

Filament winding – disadvantages

• Products with surfaces having complicated profiles and reverse

curvature are difficult to make.
• Not suitable to make a product with very small end opening, since
it will be difficult to release the mandrel.
 • The interlaminar shear strength and compressive strength of the
filament wound parts are low.
• The external surface finish is poor unless external molds or
compaction devices are used.
• The quality of filament wound components is generally lower than
that of the components made by autoclave molding.
• Filament wound products have higher void content than autoclave-
molded products

Application

Products currently being produced using this technique range from

• Pipes,
• Golf clubs,
• Reverse Osmosis Membrane Housings
• oars,
• Bicycle forks, bicycle rims
• Power and transmission poles,
• Pressure vessels to missile casings.
• Aircraft fuselages and lamp posts and yacht masts.
 6 REFERENCE

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between pipes, 1-29.

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[3] W. Polini and L. Sorrentino, “Influence of winding speed and winding

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[4] P. Mertiny and F. Ellyin, “Selection of optimal processing parameters in

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