Influence of resin curing cycle on the deformation of filament wound composites by in situ strain monitoring

Abstract

The residual stress of metal liners wrapped by composite materials has a significant influence on the service performance of rotating parts, such as flywheel rotors and motor jackets. However, the deformation of the liners, the flow of resins, and the temperature variation during the winding process make it difficult to predict and control this residual stress. In this paper, the process-induced strains were monitored online by a strain gauge with the help of a wireless strain meter. The evolution of this strain during the manufacturing process was fully discussed. A rapid curing resin system was used and its curing properties were tested by differential scanning calorimetry. The mechanical properties of the resin matrix and its composite were characterized. The effect of the curing cycle on the evolution of the residual strain was discussed in detail through comparative experiments. The experimental results show that the use of infrared radiation has a significant advantage regarding residual stress accumulation. This advantage is greater when carbon fiber is used than when glass fiber is used. The prestress in composites of glass fiber and carbon fiber increases by 5.9% and 41.7%, respectively, after cooling.

Influence of Filament Winding Tension on the Deformation of Composite Flywheel Rotors with H-Shaped Hubs

“…The relationship between the deformation and the applied stress had been derived in our previous study [33].…”

“…The initial curing temperature, peak curing temperature, and end curing temperature were 64 °C, 91 °C, and 123 °C, respectively. [ 33 ]. Aluminum 7075 (Al7075) was used as the hubs of flywheel rotors.…”

“…The relationship between the deformation and the applied stress had been derived in our previous study [ 33 ]. where ε θ is the deformation of the mandrel; F is the winding tension, MPa; E is the modulus of the mandrel, MPa; and a and b is the inner and outer radius of the mandrel, mm.…”

Theoptical‐thermalmodeling of carbon black filled glass fiber reinforced poly‐ether‐ether‐ketone in laser assisted tape winding

“…Moreover, due to the low longitudinal-transverse modulus ratio, the components winding by GF exhibit a significantly stress retention rate than by CF, thus the GF reinforced thermosetting composites are often used as key materials in flywheel rotors. 38 Compared to the GF reinforced thermosetting composites, the GF/PEEK can offer higher load-bearing during the winding process, leading to substantial reductions in materials usage and cost savings, which show a significant potential for application in the field of flywheel rotors winding forming. Therefore, the present research group has conducted extensive studies on the application of GF/PEEK in LATW.…”

Multi-Objective Optimisation of Curing Cycle of Thick Aramid Fibre/Epoxy Composite Laminates

“…The conventional autoclave curing cycle recommended by the prepreg manufacturer is only used for the manufacturing of thin laminates; when thick laminates are cured under the same cycle, the low thermal conductivity of the EP matrix hinders heat release, causing the temperature at the centre of the thick laminate to increase instantaneously during the exothermic reaction [ 17 , 18 ]. This overheating temperature phenomenon leads to matrix degradation, thermal residual stresses, and uneven curing [ 19 ], therefore affecting the final mechanical properties of the composites [ 20 ]. Some scholars have studied the curing of thick composites.…”