Roughened Mandrel Surface for Precise FRP Tow Placement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Achieving optimal fibre placement during the manufacture of fibre-reinforced polymer (FRP) structures, particularly in complex shapes, is challenging due to slipping of fibre tows under winding tension, which affects performance and consistency.
Innovation Solution
Using a tubular mandrel with a roughened outer surface to provide a high friction interface with continuous fibre tows, mitigating slipping and allowing for better alignment and application of fibre tows at optimal angles, even in complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a smooth mandrel surface is used for fibre winding, then the fibre tows can be applied with consistent tension, but the tows slip and cannot maintain optimal placement on curved or domed portions
Solution Approach 1:
The mandrel surface roughness parameter is changed from smooth to a specific roughness range (Ra 0.4-0.8 μm) to optimize the friction coefficient between the mandrel and fibre tows, preventing slip while maintaining application consistency
Solution Approach 2:
The mandrel surface is treated with a uniform micro-roughness texture that creates localized friction zones along the fibre path, providing grip exactly where needed without affecting the overall winding process
2Reliability
If the mandrel surface is roughened to prevent fibre slip, then fibre placement reliability improves, but the surface roughness may affect the inner surface quality of the finished FRP structure
Solution Approach 1:
The mandrel surface roughness is controlled within a specific range (Ra 0.4-0.8 μm) that provides sufficient friction to prevent fibre slip while being fine enough to produce an acceptable inner surface finish on the FRP structure
Solution Approach 2:
The micro-roughness treatment creates localized friction features that are sufficient to grip the fibres but distributed in a way that averages out to a smooth enough inner surface for the application
3Area of stationary object
If fibre tows are wound at steeper angles to achieve full coverage on complex geometries, then coverage improves, but the tows are more prone to slipping off curved surfaces
Solution Approach 1:
The mandrel surface roughness parameter is optimized to provide the friction necessary to maintain tow stability even at steeper winding angles required for complete coverage of complex geometries
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the reliability and consistency of fibre placement, improving the performance and enabling the production of lighter and more complex FRP structures by ensuring full coverage and alignment with expected loads.
Implementation Method 1
The roughened outer surface provides a high friction interface with the one or more tows of continuous fibre to mitigate slipping as the one or more tows of continuous fibre are applied to the tubular mandrel
Data Source
AI summary
A method of manufacturing a fibre-reinforced polymer structure. The method comprises providing a tubular mandrel with a roughened outer surface having an average surface roughness of at least 2 μm; applying one or more tows of continuous fibre to the roughened outer surface of the tubular mandrel under tension and introducing a polymer matrix resin either with or to the continuous fibre; and curing the polymer matrix resin to form a tubular fibre-reinforced polymer casing. The roughened outer surface of the tubular mandrel provides a high friction interface with the one or more tows of continuous fibre to mitigate slipping as the one or more tows of continuous fibre are applied to the tubular mandrel.