CNC_0008
MAKE: Workbench -
Filament Winder - Overview|
Overview: |
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Information related specifically to the filament winding usage of the workstation. |
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The G-code for the filament winding is being developed on Access database [CNC Winding Generator.mdb]; not from DXF drawings converted to G-code. |
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Notes:
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Y-axis:
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Z-axis:
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A-axis:
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B-axis:
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C-axis:
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Creel ~ Thread Dispenser:
Not shown. yet: Actually it will probably be a separate item.
http://www.zoltek.com/technical_resources/cf_users_guide.pdf ~ Have hard copy.
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Tension Control:
Not shown. yet: Actually it will probably be a separate item.
"A final adjustment was aimed at ensuring adequate and adjustable fiber tension on each spool. "In order for the D-rings to work and spread the fiber," says Rasmussen, "about 2 lb to 3 lb of counter-tension or drag is required on each spool to keep the tow taut." Spool tension can be applied with a closed-loop servo control mechanism, in which a load cell senses the tension, or by using a simpler, spool-diameter-compensated, constant voltage brake, both of which are manufactured by Entec, he explains. But the amount of filament breakage and subsequent fuzz is directly related to fiber tension as the fiber unspools, he adds, so fiber tension at the creel can't be too high."
http://www.mccleananderson.com/products/tensioning/tensioning.htm
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Filament Length Balance when Winding Torque Tube:
Concern about the equal consumption of filaments as a tow is being wound.
The spool may have to rotate at the same rpm as the A-axis (at least for the torque tube and possibly other tapered items). This requirement would be the result of the fact that some of the tow's filaments are being laid down at a slightly different rate as other in the same tow (same problem with width as trying to lay unidirectional tape on a tapered mandrel. This will also probably necessitate that the spool be some distance from the tensioner. A similar situation may exist if the thickness of the tow, which is being laid down, is fairly thick. It should also be noted that if the filament is combed to an increased width, to eliminate the problem with thickness, it will increase the width problem. Smaller size tows may reduce this potential problem.
Hopefully, the taper is too small for this to be a problem. Reference golf club taper.
With a hoop winding, such as used on the torque tube, the back winding may absorb the slack in some filaments that was created during the forward wind.
Spreading (band width) will have an effect on strand length differential within a tow. This is because a wider band will mean that the strands are wrapping around the part at the same radius.
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Resin Bath:
Not shown. yet: Actually it will probably be a separate item. See Outside Comments: below.
http://www.mccleananderson.com/products/resinbaths/resin_baths.htm
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Cog Belt: (synchronous belt)
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Mandrel Extractor:
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Manufacturing of Rotorhub:
If there is the intent to use this machine to produce a filament wound rotorhub then the clearance about the A-axis must have a clearance of 12" radius.
Consider winding the rotorhub on an additional 'table' attached to end of the current table. The A-axis would be extended outboard of the existing one and the B-axii could possibly be used as a linear axis to serve as a supplemental X-axis on this 'side table'.
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Core Cutting:
This CNC tool could serve for very light core cutting, such as the core inside the torque tube. However, the Clean room / Dirty room aspect will have to be considered.
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Potential Applications for Filament Winding:
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DESIGN: |
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Unicopter ~ Torque tube: |
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Unicopter ~ Pultruded Spar: |
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Unicopter ~ Tail Boom |
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Unicopter ~ Rotorhub |
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SynchroLite ~ Tail Boom |
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SynchroLite ~ Lower Tube |
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Control Rods |
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Collective and Cyclic Sticks |
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Landing gear and Skids |
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Shims for elastomeric bearings |
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Fuselage etc. ~ If the distance is large between the X-axis and the tow feed location. |
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Suppliers of Filament Winders:
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http://www.mccleananderson.com/products/filament_winders/WLH.htm |
OK |
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http://www.mccleananderson.com/products/filament_winders/filament_winders.htm |
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Outside Comments:
"Bubbles, voids, incomplete wetting, trapped moisture. Look at your fibers under an EM. Every little pocket is a nucleation site for cracking and bulk failure unless it is wetted by and filled with matrix rather than air or moisture. There be monsters here. "
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"The reasons for using pre-pregs are really that quality control is potentially better, but there have been lots of vessels wound with glass fibre and epoxy wet resin, which have been blasted off into space.
The main thing is to control the tension in the fibre as it is fed onto the mandrel. "
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Related Web Pages:
Outside Sites Related to Filament Winding:
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This Site:
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Related Patents:
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Last Revised: June 8, 2007