Determination of Residual Stress and Design of Process Parameters for Composite Cylinder in Filament Winding

As there is increasing usage of composite components with a closed-end shape, filament winding technology has been applied extensively in engineering practice. However, the residual stresses are readily caused by process parameters in composite manufacturing process. Hence, it is necessary to design the reasonable process parameters for obtaining the expected residual stresses. This study proposed a reverse derivation method to design the winding tension based on the residual stress model of the composite cylinder. To analyze the development of residual stresses, the thermal deformation behavior and a micromechanics model of resin shrinkage are considered to calculate thermal strains and instantaneous shrinkage strains of the hoop wound cylinder during the curing process. Combining the contribution of winding tension to the stresses, the simple model of residual stresses is established based on the superposition principle. Then inversely solving the analytic model, the design method of winding tension is illustrated to guarantee that the hoop wound cylinder with an inner liner has a uniform residual hoop stress. The model accuracy of residual stresses is validated by the destructive slitting experiment. The result indicates that the present model can be used to estimate the residual stresses and design the winding tension for the hoop wound cylinder.