Simulation of filament winding in Simulink and mechanical modeling

Abstract

The filament winding method has been widely used since the 1960s for manufacturing complex structures such as pipes, shafts, and pressure vessels. This method enables the production of lightweight and durable structures with excellent weight-to-strength ratios. It involves winding high-strength fibers, which may or may not be impregnated with epoxy resin, at various angles onto a cylindrical surface (mandrel) to form composite constructions. Over the years, scientists have sought to optimize this process by understanding its underlying principles and analyzing how material parameters and characteristics affect the final product. The goal of this diploma thesis is to optimize the filament winding process by developing a digital twin. In recent years, many companies have embraced digital twin technology to enhance their products and processes. By combining digital twin technology with filament winding, we aim to manufacture improved composite products and optimize the filament winding process by reducing errors and predicting potential future failures. This project utilizes MATLAB code to generate results based on various input data, including mechanical properties of materials, fiber winding angles, and geometric characteristics. Additionally, Simulink is used to visually represent the manufacturing process of composite parts. Moreover, geometrical model is built in a CAD program utilizing MATLAB results, for transferring the geometry to a commercial fine element program Ansys. Finaly, complex pieces using finite element analysis.