3D winding path modeling of overwrapped pressure vessels with novel mesh-based directional projection and normal adaptive convex helix algorithms

• Published in: Composite structures 2023-11, Vol.323, p.117447, Article 117447
• Main Authors: Tang, Jianbo, Wang, Jun, Xie, Ximing, Zhou, Xin, Yan, Wei, Li, Shuxin, Yu, Haitao, Xin, Shiqing, Xu, Jian
• Format: Article
• Language: English
• Subjects: 3D winding path; Composite overwrapped pressure vessels; Filament winding; Reaming process; Workpiece contour
• ISSN: 0263-8223; 1879-1085
• DOI: 10.1016/j.compstruct.2023.117447

Filament winding is a technique that precisely places continuous fibers along a preset path on a rotating mandrel. However, traditional 2D winding paths based on the original mandrel surface ignore the effect of thickness stacking on doffing points. To physically simulate the build-up of tows on the mandrel, a novel numerical method, including the mesh-based directional projection (MDP) and normal adaptive convex helix (NACH) algorithms, is proposed. The MDP algorithm is employed to sort out tow overlaps in the thickness direction, and is 200 times more efficient than the existing algorithms, such as the backward search algorithm. Subsequently, the “cliffs” generated in the overlap removal process are smoothed by the NACH algorithm. Furthermore, the advantages of these two algorithms in terms of efficiency, reliability, and universality are discussed in detail. In summary, a method for developing a physical-based 3D path and ever-updating workpiece contour of pressure vessels is proposed, which serves as an essential reference for high-precision winding and workpiece shape optimization.