Stability of Tubular Preforms from Multi-Layer Winding of Composite Tapes Prior to Thermoforming

Abstract:

Some composite preforms lose dimensional stability after mandrel removal during tube winding, leading to pronounced longitudinal expansion and radial contraction for specific layup configurations. This work presents an experimental method for tracking the reorganization of individual wound tapes during mandrel release and uses these measurements to validate a finite element (FE) model designed to capture the underlying deformation mechanisms. The experiments reveal a nonlinear dependence of ribbon elongation on the initial winding angle. Complementary FE parametric studies investigate the effects of tape geometry and mechanical properties, demonstrating that increased mechanical anisotropy amplifies the elongation response. The study also introduces a layer-equivalent stiffness formulation and concludes with FE simulations of multi-tape preforms. Together, these results support the development of improved winding strategies aimed at reducing defects, lowering production costs, and enhancing the structural performance of tubular composite components.

• Periodical: Solid State Phenomena (Volume 387)
• Pages: 21-31
• DOI: https://doi.org/10.4028/p-91sVZi
• Online since: April 2026
• Authors: Nagui Elgaby*, Guillaume Helbert, Nahiene Hamila, Rubén Campos, Audrey Sanchez, Bertrand Laine
• Keywords: Stability, Tape Winding, Tubular Composites

References

[1] S.M. Kennedy, R.J. Robert, R.M.R. Prince, G. Hikku and M. Kaliraj, "A comprehensive overview of the fabrication and testing methods of frp composite pipes," MethodsX, vol. 13, p.102990, 2024.

DOI: 10.1016/j.mex.2024.102990

[2] J. Singh, K. Singh, J. S. Saini, and Mohammed S.J. Hashmi, "Processing of Polymers and Their Composites: A Review," Elsevier eBooks, p.577–603, Jan. 2018.

DOI: 10.1016/b978-0-12-803581-8.11435-3

[3] M. Azeem, H. H. Ya, M. A. Alam, M. Kumar, P. Stabla, M. Smolnicki, L. Gemi, R. Khan, T. Ahmed, Q. Ma et al., "Application of filament winding technology in composite pressure vessels and challenges: a review," Journal of Energy Storage, vol. 49, p.103468, 2022.

DOI: 10.1016/j.est.2021.103468

[4] A. Brasington, C. Sacco, J. Halbritter, R. Wehbe, and R. Harik, "Automated fiber placement: a review of history, current technologies, and future paths forward," Composites Part C: Open Access, vol. 6, p.100182, 2021.

DOI: 10.1016/j.jcomc.2021.100182

[5] M. Volk, O. Yuksel, I. Baran, J. H. Hattel, J. Spangenberg, and M. Sandberg, "Cost-efficient, automated, and sustainable composite profile manufacture: A review of the state of the art, innovations, and future of pultrusion technologies," Composites Part B: Engineering, vol. 246, p.110135, 2022.

DOI: 10.1016/j.compositesb.2022.110135

[6] B. Laine and A. Azran, "Device for the manufacturing of an unconsolidated textile elongate member." Patent WO 2023/089 051 A1, WO 2023/089051 A1. May, 2023.

[7] M. Kropka, M. Muehlbacher, T. Neumeyer, and V. Altstaedt, "From ud-tape to final part–a comprehensive approach towards thermoplastic composites," Procedia CIRP, vol. 66, p.96–100, 2017.

DOI: 10.1016/j.procir.2017.03.371

[8] N. Chouaieb, A. Goriely, and J. H. Maddocks, "Helices," Proceedings of the National Academy of Sciences, vol. 103, no. 25, p.9398–9403, 2006.

DOI: 10.1073/pnas.0508370103

[9] A. Majumdar and A. Raisch, "Stability of twisted rods, helices and buckling solutions in three dimensions," Nonlinearity, vol. 27, no. 12, p.2841, 2014.

DOI: 10.1088/0951-7715/27/12/2841

[10] A. Goriely and M. Tabor, "The nonlinear dynamics of filaments," Nonlinear Dynamics, vol. 21,p.101–133, 2000.

DOI: 10.1023/a:1008366526875

[11] A. Borum and T. Bretl, "When is a helix stable?" Physical review letters, vol. 125, no. 8, p.088001, 2020.

[12] A. Goriely, M. Nizette, and M. Tabor, "On the dynamics of elastic strips," Journal of Nonlinear Science, vol. 11, p.3–45, 2001.

DOI: 10.1007/s003320010009

[13] A. Goriely and P. Shipman, "Dynamics of helical strips," Physical Review E, vol. 61, no. 4, p.4508, 2000.

DOI: 10.1103/physreve.61.4508

[14] Q. Guo, A. K. Mehta, M. A. Grover, W. Chen, D. G. Lynn, and Z. Chen, "Shape selection and multi-stability in helical ribbons," Applied Physics Letters, vol. 104, no. 21, 2014.

DOI: 10.1063/1.4878941

[15] Z. Chen, "Shape transition and multi-stability of helical ribbons: a finite element method study,"Archive of Applied Mechanics, vol. 85, p.331–338, 2015.

DOI: 10.1007/s00419-014-0967-2

[16] E. Starostin and G. Van Der Heijden, "Tension-induced multistability in inextensible helical ribbons," Physical review letters, vol. 101, no. 8, p.084301, 2008.

DOI: 10.1103/physrevlett.101.084301

[17] L. Prévost, A. Lindner, and O. Du Roure, "Pitch controls the flexibility of helical ribbons," Extreme Mechanics Letters, vol. 58, p.101923, 2023.

DOI: 10.1016/j.eml.2022.101923

[18] L. N. McCartney, "Predicting properties of undamaged and damaged carbon fibre reinforced composites," in The Structural Integrity of Carbon Fiber Composites: Fifty Years of Progress and Achievement of the Science, Development, and Applications. Springer, 2016, p.425–467.

DOI: 10.1007/978-3-319-46120-5_16

[19] E. Kurkin, M. Spirina, O. U. Espinosa Barcenas, and E. Kurkina, "Calibration of the pa6 short- fiber reinforced material model for 10% to 30% carbon mass fraction mechanical characteristic prediction," Polymers, vol. 14, no. 9, p.1781, 2022.

DOI: 10.3390/polym14091781