Iranian Journal of  Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Development of a four-degree-of-freedom filament winding machine for manufacturing composite grid structures

Document Type : Original Article

Authors
1 Department of Mechanical Engineering, Ara.C., Islamic Azad University, Hadishahr, Iran
2 Department of Mechanical Engineering, Atatürk University, Erzurum, Turkey
3 Department of Mechanical Engineering, Ta.C., Islamic Azad University, Tabriz, Iran
Abstract
Composite grid structures have garnered significant attention across various industries due to their low weight, high strength, and economic advantages. This study focuses on developing of an advanced filament winding machine with four degrees of freedom to produce experimental specimens. The machine is designed to fabricate grid structures on cylindrical, conical, and complex surface. Integrated with three-dimensional modeling tools, custom control software enables the automated and efficient placement of fibers. Experimental specimens were manufactured using carbon fibers impregnated with epoxy resin and wound onto custom silicone molds. The filament winding technique was selected for its ability to achieve high fiber volume fractions, minimize voids, and enhance cost-efficiency. To validate the optimization results, grid structures featuring a Voronoi pattern were subjected to experimental testing. Buckling tests, conducted using a universal testing machine, evaluated the critical buckling loads and mechanical properties of the optimized specimens. According to the compressive buckling test data, the ratio of the critical buckling load to the weight of the structure is equal to 24,000 N/kg. Furthermore, the developed filament winding machine significantly reduced production costs compared to conventional methods. It also enabled the fabrication of structures with complex geometries and non-circular profiles, such as aircraft wings and hydrofoils. These capabilities enhance design flexibility and the application of advanced composite materials in engineering projects. The results demonstrate the efficacy of the developed machine and methodologies in producing high-performance composite grid structures while lowering manufacturing costs.
Keywords

[1]   Mangas C, Vilanova J, Diaz V, Samartin CR, Kiryenko S, Katajisto H, Perez-Alvarez J. Anisogrid payload adaptor structure for Vega launcher. InProceedings of the 14th European Conference on Spacecraft Structures, Materials and Environmental Testing (ECSSMET) 2016.
[2]   Totaro G, Spena P, Giusto G, De Nicola F, Kiryenko S, Das S. Highly efficient CFRP anisogrid lattice structures for central tubes of medium-class satellites: Design, manufacturing, and performance. Composite Structures. 2021 Feb 15;258:113368. doi: 10.1016/j.compstruct.2020.113368
[3]   Fadavian A, Davar A, Heydari Beni M, Eskandari Jam J. Statistical-experimental analysis of the effect of fabrication parameters on the strength of composite grid-stiffened cylinders under compressive axial load. Journal of Science and Technology of Composites. 2021 Aug 23;8(2):1543-55. doi: 10.22068/JSTC.2021.531397.1729
[4]   Mathew T, Chacko V, Thomas T. Parametric study of lattice conical adaptor. International Journal of Scientific and Engineering Research. 2013;4(8).
[5]   Bellini C, Di Cocco V, Iacoviello F, Sorrentino L. Performance index of isogrid structures: Robotic filament winding carbon fiber reinforced polymer vs. titanium alloy. Materials and Manufacturing Processes. 2022 Apr 4;37(5):559-67. doi: 10.1080/10426914.2021.1926489
[6]   Farhadi M, Davar A, Heydari Beni M, Eskandari Jam J. Experimental study and statistical optimization of fabrication parameters affecting the flexural strength of composite grid-stiffened panels. Iranian Journal of Manufacturing Engineering. 2022 Jan 21;8(11):1-5. [In Persian]
[7]   Ataei A, Ahmadi H, Farrokhabadi A. Experimental investigation of Buckling after impact strength of grid stiffened composite panels. Iranian Journal of Manufacturing Engineering. 2021 Jan 20;7(11):34-41. [In Persian]
[8]   Rojas EV, Chapelle D, Perreux D, Delobelle B, Thiebaud F. Unified approach of filament winding applied to complex shape mandrels. Composite structures. 2014 Sep 1;116:805-13. doi: 10.1016/j.compstruct.2014.06.00
[9] Zhang P, Han Z, Gu J, Sun S, Fu H. A strategy of parallel winding of circumferential ribs and helical ribs for composite cylindrical grid structures. Composite Structures. 2021 Nov 1;275:114351. doi: 10.1016/j.compstruct.2021.114351
[10] Gibson RF. Principles of composite material mechanics. CRC press; 2007 May 30.