USU Filament Winder
1
USU Filament Winder Project The USU Composites Lab needs a filament winder for creating composite tubes. The filament winder student team used the following guidelines to design and construct a filament winder: • This winder will be available for students to use for future senior design projects and research. • The winder needs to have a minimum of two axes for control and movement. • The winder must support parts up to 36" long and 3" in diameter with an even larger capacity being desirable. • The winder must wrap composite fiber at angles between 30° and 150°. Methods The filament winder winds composite tubes using the following process: • The user enters their desired wind pattern using the winder software. • The winder software sends commands to the winder controller which drives the winder motors. • One motor drives a carriage holding the fiber. The other motor spins a mandrel. • As the carriage moves and the mandrel spins, fiber is pulled off the fiber spool and wraps around the mandrel. • The relative speeds of the mandrel and carriage control the angle of the wind pattern. • The fiber is pulled through a bath of resin so that it is saturated with resin before it is wrapped onto the mandrel. • A tensioner on the spool keeps the fiber taught as it wraps around the mandrel. Conclusion The team verified the functionality of the machine by winding dry fiber. • The tolerance on the wrap angle is ±0.5°. • The machine can accommodate the required mandrel sizes. • Because the team used T-slot to build the winder frame, the winder can be adjusted easily. • In the course of building and designing the winder, the team was able to apply finite element methods, machine design principles, numerical methods, computer programming, and principles of composites. • This winder can be expanded by future design teams to add additional functionality. System Brennan Baer Jeff Fonnesbeck Joel Fronk Josh Mathews Coy Weber Angle control of composite wind pattern Composite wound tubes Composite fiber spools Dry composite fiber tows Dry wind composite samples
Transcript of USU Filament Winder
USU Filament WinderProject
The USU Composites Lab needs a filament winder for creating composite tubes. The filament winder student team used the following guidelines to design and construct a filament winder:• This winder will be available for students to use for future senior design projects and
research.• The winder needs to have a minimum of two axes for control and movement.• The winder must support parts up to 36" long and 3" in diameter with an even larger capacity
being desirable.• The winder must wrap composite fiber at angles between 30° and 150°.
MethodsThe filament winder winds composite tubes using the following process:• The user enters their desired wind pattern using the winder software.• The winder software sends commands to the winder controller which drives the winder motors.• One motor drives a carriage holding the fiber. The other motor spins a mandrel.• As the carriage moves and the mandrel spins, fiber is pulled off the fiber spool and wraps around
the mandrel.• The relative speeds of the mandrel and carriage control the angle of the wind pattern.• The fiber is pulled through a bath of resin so that it is saturated with resin before it is wrapped onto
the mandrel.• A tensioner on the spool keeps the fiber taught as it wraps around the mandrel.
ConclusionThe team verified the functionality of the machine by winding dry fiber.• The tolerance on the wrap angle is ±0.5°.• The machine can accommodate the required mandrel sizes.• Because the team used T-slot to build the winder frame, the winder
can be adjusted easily.• In the course of building and designing the winder, the team was able
to apply finite element methods, machine design principles, numerical methods, computer programming, and principles of composites.
• This winder can be expanded by future design teams to add additional functionality.
System
Brennan Baer
Jeff Fonnesbeck
Joel Fronk
Josh Mathews
Coy Weber
Angle control of composite wind pattern
Composite wound tubesComposite fiber spools Dry composite fiber tows
Dry wind composite samples
