Abstract
Composite conical shells have a wide range of applications. The 3D printing technology based on FDM constrains the fibers in a plane and it is difficult to fill the fibers in the thin wall. This paper proposes a rapid prototyping method for composite materials based on curved surface fiber placement. The conical shell is divided into a series of equidistant offset surfaces. Then we designed three initial paths for fiber placement and rotated them to cover the surface of the conical shell. The resin paths are designed for filling the border layers and the gaps between the fibers. The placement process is simulated by MATLAB (R2016b) and we analyzed the parameter range, direction angle, curvature and fiber content of the three paths. When the critical parameters φ0 = [0°, 42°], ξ is equal to any value and C = (0, 0.032], the corresponding initial path can reach the top of the cone shell in this study. The direction of the constant curvature curve can be designed best; when C = 0.032, the direction angle range is −90 to 90. The curvature of the geodesic path is the smallest; when φ0 = 10°, the normal curvature is about 0.0001 and the geodesic curvature is equal to 0. The fiber content of the geodesic path is greatly affected by the parameter φ0, and the difference can reach 40 %. The fiber content of the linear curve is greater than 90 %. When ξ is equal to 4, the fiber content is 95 %. For the constant curvature curve, the fiber content is generally very low, about 20 %. We used a six-axis robot and a spindle to produce composite conical shell. The results show that the present design method for composite conical shell is reliable and is able to provide a useful reference for design and production of composite conical shell.
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Abbreviations
- r e :
-
Partial derivative of surface to θ
- r z :
-
Partial derivative of surface to z
- ds :
-
Arc length element
- I :
-
The first basic form of curved surface
- II :
-
The second basic form of curved surface kn: Normal curvature
- k g :
-
Geodesic curvature
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Acknowledgments
Opening Foundation of Shanghai Collaborative Innovation Center for High Performance Fiber Composites (Grant No. X12812001/047) and Opening Foundation of State Key Lab of Digital Manufacturing Equipment & Technology (Grant No. DMETKF2021019), Research Project of State Key Laboratory of Mechanical System and Vibration MSV202213 support this study.
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Kangmei Li is an Associate Professor and Master’s Supervisor at College of Mechanical Engineering, Donghua University, Shanghai, China. Her research interests include laser precision processing, surface texturing technology, manufacturing technique of composite structures.
Jun Hu is a Professor and Doctoral Supervisor at the Institute of Artificial Intelligence, Donghua University, Shanghai, China. His research interests include CNC technology and equipment, laser fine processing technology and manufacture technique of composite structures.
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Xu, H., Lu, J., Li, K. et al. Design and analysis of fiber placement for composite conical shell. J Mech Sci Technol 36, 1427–1436 (2022). https://doi.org/10.1007/s12206-022-0230-7
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DOI: https://doi.org/10.1007/s12206-022-0230-7