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Fiber Winding CNC ELM 4702 Project II. By Somnang Rom. Background. What is Fiber Winding? Manufacturing method Thin fibers ( ex. Nylon, fiber glass carbon fiber) are wound on a shaped mandrel Epoxy resin is applied during (or after) the winding operation; allow to dry

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Fiber Winding CNC ELM 4702 Project II


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    1. Fiber Winding CNCELM 4702 Project II By Somnang Rom

    2. Background What is Fiber Winding? • Manufacturing method • Thin fibers ( ex. Nylon, fiber glass carbon fiber) are wound on a shaped mandrel • Epoxy resin is applied during (or after) the winding operation; allow to dry Creates a very light weight, corrosion resistant continuous structures.

    3. Background (con’t.) Typical Applications: • Helicopter blade and other airplane parts • Power poles • Ski poles, canoe paddles,hockey sticks

    4. Problem Statement: • Goal is to design and create a small-scale fiber winding machine to produce composite structures. • Produce at least two different patterns. • Fit on the desktop • At least two axis • produces parts minimum 28”X 12”X 12”

    5. Solution: • My design includes: • commercially available Master5 CNC; will be used to enter G-codes. • 3 Rutex servo motor controllers to drive primary motors • Solid base, 37”X 24” • One spool of fiber, nylon • User operates the system from a Laptop or PC Ideal design Reliance servo motor Reliance servo motor mandrel mandrel 1.5”x1/8”x24” angle iron Click on the picture Reliance servo motor Pitman dc motor Pitman dc motor

    6. System Overview Gcode Motor controller 125AC

    7. Mechanical Drawing of FWCNC mandrel mandrel axis Z axis 12.125” Y axis 37.5”

    8. Mechanical Designs 12” 24” Side view

    9. Mechanical Designs The inertia of the PVC plastics cylinder: Non hollow mandrel radius (r) = to zero mandrel M L (oz-in-sec2) J=.700*Pi *15* (54-4.8754)/768=2.585 oz-in-sec2 The inertia of the lead screw: W M L (oz-in-sec2) Densities of lead screw (oz/in3) Common Densities(oz/in3) GE plastics PVC---.700 Steel----------4.54 Length of lead screw Diameter of lead screw Inertia J=(4.54pi 15* .6254)/12352= .00264 oz-in-sec2 M=motor

    10. Mechanical Formulas 1/3 HP HP =(Torque x rpm)/52501/3HP = (.00175lb.900rpm)/5250 Torque=(1/3)(5250)/900rpm=.00175lb.ft

    11. Mechanical Designs The inertia of the PVC plastics cylinder: Non hollow mandrel radius (r) = to zero mandrel M L (oz-in-sec2) J=.700*Pi *15* (54-4.8754)/768=2.585 oz-in-sec2 The inertia of the lead screw: W M L (oz-in-sec2) Densities of lead screw (oz/in3) Common Densities(oz/in3) GE plastics PVC---.700 Steel----------4.54 Length of lead screw Diameter of lead screw Inertia J=(4.54pi 15* .6254)/12352= .00264 oz-in-sec2 M=motor

    12. Mechanical Designs The inertia of the PVC plastics cylinder: Non hollow mandrel radius (r) = to zero mandrel M L (oz-in-sec2) J=.700*Pi *15* (54-4.8754)/768=2.585 oz-in-sec2 The inertia of the lead screw: W M L (oz-in-sec2) Densities of lead screw (oz/in3) Common Densities(oz/in3) GE plastics PVC---.700 Steel----------4.54 Length of lead screw Diameter of lead screw Inertia J=(4.54pi 15* .6254)/12352= .00264 oz-in-sec2 M=motor

    13. State Diagram for Winding Logic start Delay 2sec. V= 120inches/ min. A=mandrel rotation if no V=120 inches/min yes no If Y=15 inches, A=120 rotations yes off

    14. Computer Numerical control (Gcode) G0 y0 ; move at max. N2 g4 p2 ; delay for 2 seconds N5 g1 y0 ; starting point N10 g1 y15 a 20 f120 ; count 15” at 20 rotations N20 y0 N30 y15 a30 f120 N40 y0 N50y16 a 400 f120 N60 y0

    15. Winding Patterned • The space of the • hop winding will be determine • the mandrel rotation Rotational ratio Feeder in/sec Hop winding • Helical winding pattern will depend on feeder speed. If the feeder Increase and the mandrel rotation must decreasing Helical winding Typical fiber winding patterns

    16. Electrical Overview PC parallel port Pin number step Servo motor control 4 M1 Y axis 5 dir 6 step Servo motor control M2 A axis rotational axis 7 dir M3 16 0 or 1 signal Spindle motor circuit

    17. Power supply overview 24Vout Manufacture Motor power supply - + Circuits board Transformer 5 V @3A 125V _ + 36V @ 10A

    18. Spindle motor control 4V 500 +42 V _ 1.2K 1.2K 2N7000 mosfet These circuit are use to control the spindle motor. I designed the circuit but at the end I found out that my design does not required motor spindle control circuit.

    19. Rutex servo motor controllers Step Dir input Y axis +42 V _ Step Dir input A axis + 42 V _

    20. Fiber Winding CNC schedule Fall Spring • Budget Existing technology using Master5CNC Wooden model for feasibility test Program writing g Code for winding patterns Power supply Determine speed and winding pattern Reliance/ pitman motor / drawing whole chassis Resin bath chassis design web site demonstration

    21. Summary • Pre-impregnate fiber with resins • The next part I will create a resin bath • There are a huge market for fiber winding CNC because • Fiber winding create a light composite structure.

    22. Acknowledge • Dr. John Kidder • David Jeremy • Rogers Howes • Professor St. Denis

    23. Questions