Chen Xiaodong, Li Yong, Huan Dajun, Liu Hongquan, Li Lisa, Li Yanrui
College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China.
National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China.
Polymers (Basel). 2022 Mar 14;14(6):1155. doi: 10.3390/polym14061155.
The residual stress plays an important role in composite flywheel rotors composed of filament windings. The fiber tension during high-prestressed winding is the main source of the rotor deformation and residual stress of composite layers. In this study, the effect of the winding tension gradient on deformation was monitored in real-time. Two types of in-plane winding tension fluctuation methods were developed to investigate the effect of tension on deformation. Online and offline measurements were performed for the strain acquisition. A wireless strain instrument was used for online deformation monitoring and a laser scanner was used for the offline surface reconstruction. Additionally, different filament winding strategies were carried out to improve the efficiency of the winding tension by finite element analysis. The results indicated that the deviation between numerical and experimental results was within 8%. Based on the proposed numerical method, the influence of the in-plane and out-of-plane winding tension gradient distributions on the rotation process of the H-shaped rotor was analyzed. An in-plane winding strategy with variable tension was developed, which increased the initial failure speed by 160%.
残余应力在由纤维缠绕组成的复合飞轮转子中起着重要作用。高预应力缠绕过程中的纤维张力是复合层转子变形和残余应力的主要来源。在本研究中，实时监测了缠绕张力梯度对变形的影响。开发了两种面内缠绕张力波动方法来研究张力对变形的影响。进行了在线和离线测量以采集应变。使用无线应变仪进行在线变形监测，使用激光扫描仪进行离线表面重建。此外，通过有限元分析实施了不同的纤维缠绕策略，以提高缠绕张力的效率。结果表明，数值结果与实验结果之间的偏差在8%以内。基于所提出的数值方法，分析了面内和面外缠绕张力梯度分布对H形转子旋转过程的影响。开发了一种变张力面内缠绕策略，该策略使初始失效速度提高了160%。
