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4 Axis filament winding process

4 Axis Filament Winding Process

Filament winding is a process used to manufacture composite parts, particularly those with cylindrical or spherical geometries. Continuous fiber tows, typically glass, carbon, or aramid, are wound onto a rotating mandrel in precise patterns controlled by a CNC (Computer Numerical Control) system. The fibers are passed through a resin bath containing a thermosetting resin (like epoxy) before winding, ensuring that they are saturated with resin.

The fiber tension during winding is critical, usually controlled between 5 N and 30 N to ensure that the fibers lay properly without wrinkling or voids. The CNC machine determines the winding angles, typically ranging from 15° to 90°, which directly affect the final strength and stiffness of the product. The curing process involves heating the wound structure in an oven at temperatures between 100°C and 150°C, depending on the resin system used.

Filament winding is a process used to manufacture composite parts, particularly those with cylindrical or spherical geometries. Continuous fiber tows, typically glass, carbon, or aramid, are wound onto a rotating mandrel in precise patterns controlled by a CNC (Computer Numerical Control) system. The fibers are passed through a resin bath containing a thermosetting resin (like epoxy) before winding, ensuring that they are saturated with resin.

The fiber tension during winding is critical, usually controlled between 5 N and 30 N to ensure that the fibers lay properly without wrinkling or voids. The CNC machine determines the winding angles, typically ranging from 15° to 90°, which directly affect the final strength and stiffness of the product. The curing process involves heating the wound structure in an oven at temperatures between 100°C and 150°C, depending on the resin system used.

Filament winding provides excellent control over fiber placement, allowing for optimal mechanical properties based on specific load-bearing requirements. For example, parts can achieve tensile strengths up to 2500 MPa along the fiber direction. The process can produce parts with very high fiber content, up to 70%, making the components exceptionally strong and lightweight. The technique is highly automated, leading to consistent and high-quality production with minimal material waste.

Filament winding is used in industries requiring high-strength, lightweight structures. In aerospace, it is employed for manufacturing pressure vessels and rocket casings with burst pressures exceeding 70 MPa. In the oil and gas industry, filament-wound pipes are used, particularly in corrosive environments, as these pipes can handle pressures up to 50 bar. The process is also utilized in the wind energy sector to manufacture wind turbine blades with lengths exceeding 80 meters.

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