Article Dans Une Revue Journal of Failure Analysis and Prevention Année : 2024

Tackling Severe Shear Distortion in Filament Winding of Complex Geometries: Strategies for Towpreg Stability Enhancement

Erik Vargas-Rojas
Francis Collombet

Résumé

This investigation reveals the reasons behind severe shear distortion of carbon fiber towpreg observed during a series of winding sequences involving a geometry consisting of a hyperbolic hyperboloid attached to two cylinders at its open sides. The roving severely distorts at the transition zones, tending to slip and lose track, while the robust winding machine undergoes noticeable and unexpected vibrations. The DO IT root cause analysis problem-solving method is applied to understand the failure mechanism using flow and causal diagrams, along with CNC data analysis. The winding angle at geometric transitions is measured using photographs. Additional data analysis involves evaluating the limits of mathematical functions used to construct the mandrel meridian profile, along with analyzing winder kinematics. The results reported here reveal numerical singularities that adversely affect solutions at all levels by impacting the mathematical definition of the meridian profile. This explains the shear-type distortion of the towpreg, speed changes surpassing ISO 10816-1 standards on mechanical vibration, alongside peaks in acceleration and jerk. Moreover, it is suggested that Coulomb’s friction law may surpass its limits due to a viscous and tacky interface promoted by the non-rigid nature of the stranded towpreg. Preventive actions involve meeting the requirements of the Theory of Curves and Surfaces for mandrel meridian profile construction. Additionally, incorporating observed viscoelastic and shear strength phenomena into theoretical approaches is advised, alongside addressing discrepancies in measuring the filament winding angle and validating numerical solutions against CNC data.

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Dates et versions

hal-04907933 , version 1 (23-01-2025)

Identifiants

Citer

Erik Vargas-Rojas, Francis Collombet. Tackling Severe Shear Distortion in Filament Winding of Complex Geometries: Strategies for Towpreg Stability Enhancement. Journal of Failure Analysis and Prevention, 2024, 24 (5), pp.2393-2421. ⟨10.1007/s11668-024-01988-6⟩. ⟨hal-04907933⟩
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