This research has previously developed a program to compute stress and strain state, fiber volume fraction, temperature, and cure state variables during filament winding. While this program is generally easy to use and provides very accurate modeling of the filament winding process, it is somewhat difficult to maintain and make necessary modifications.
Follow-up research involved the use of a commercial finite element analysis package to model the winding process and calculate the associated variables. This work incorporated abaqus, a general-purpose finite element software package, for performing the manufacturing analysis. The scope of this research was limited to an axisymmetric filament wound structure. Results of this research were favorable, matching experimental data very well. One shortcoming of this approach is that fiber tension is not evaluated throughout the winding process due to the use of axisymmetric elements.
Current work involves three-dimensional analysis of the filament winding process using abaqus. A number of filament winding models are being used to generate initial conditions and winding calculations. Previously generated subroutines are then modified for the three-dimensional analysis.
Reed McPeak, Graduate Student Researcher
Chunhui Wu, Graduate Student Researcher
Incorporating a three-dimensional element allows for a prescribed fiber tension in each filament wound layer. This results in a radial compaction force applied to previously wound layers. As this better simulates the actual filament winding process, more accurate calculations of fiber volume through the wall thickness of the structure are obtained. Results of the three-dimensional analysis is then compared to results of previous works and experimental data.
Further work is selecting a polymer that is compatible with potable water and capable of withstanding high pressure and hot water. Until now, several materials have been recommended based on extensive research work. The primary challenge is in designing the polymer structure that can be used for ten years under high pressure, temperature, and moisture. Based on the long term material behavior obtained from the tests, analytical and numerical methods are being used to study the structural performance under the specified conditions. Finite element method is used for stress, and strain analysis is being used for the polymer structure.
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