Fibre Tension-Induced Stresses in Filament-Wound Composites

Article Preview

Abstract:

Fibre tension is an important process parameter during filament winding. It strongly affects the void content and fibre volume fraction, which in turn determine the mechanical performance of the part. Fibre tension also contributes to the residual stresses that develop in the filament-wound material. This study focuses on how the fibre tension shapes the stress distribution in filament-wound composites. To this end, a numerical predictive model was developed. Experimental validation was conducted using a force sensor, and good agreement was observed between the model predictions and the experimental measurements. These findings provide deeper insight into the role of fibre tension in filament winding and offer practical guidance for optimising the process to enhance the performance of composite pressure vessels.

You have full access to the following eBook

Info:

Periodical:

Solid State Phenomena (Volume 387)

Pages:

53-60

Citation:

Online since:

April 2026

Funder:

The publication of this article was funded by the KU Leuven 10.13039/501100004040

Export:

Share:

Citation:

* - Corresponding Author

[1] Cohen D. Influence of filament winding parameters on composite vessel quality and strength. Composites Part A: Applied Science and Manufacturing 1997; 28: 1035–47.

DOI: 10.1016/S1359-835X(97)00073-0

Google Scholar

[2] Mertiny P, Ellyin F. Influence of the filament winding tension on physical and mechanical properties of reinforced composites. Composites Part A: Applied Science and Manufacturing 2002; 33: 1615–22.

DOI: 10.1016/S1359-835X(02)00209-9

Google Scholar

[3] Błachut A, Kaleta J, Detyna J, Kmiecik B, Ziętek G, Panek M, et al. Multiscale analysis of composite pressure vessel structures wound with different fiber tensile force. Composite Structures 2024; 337:118065.

DOI: 10.1016/j.compstruct.2024.118065

Google Scholar

[4] Lee S-Y, Springer GS. Filament Winding Cylinders: I. Process Model. Journal of Composite Materials 1990;24:1270–98.

DOI: 10.1177/002199839002401202

Google Scholar

[5] Hahn HT, Kempner EA, Lee SS. The stress development during filament winding of thick cylinders. Composites Manufacturing 1993;4:147–56.

DOI: 10.1016/0956-7143(93)90099-t

Google Scholar

[6] Kang C, Shi Y, Deng B, Yu T, Sun P. Determination of Residual Stress and Design of Process Parameters for Composite Cylinder in Filament Winding. Advances in Materials Science and Engineering 2018;2018:1821342.

DOI: 10.1155/2018/1821342

Google Scholar

[7] Zu L, Xu H, Zhang B, Li D, Wang H, Zi B. Filament-wound composite sleeves of permanent magnet motor rotors with ultra-high fiber tension. Composite Structures 2018;204:525–35.

DOI: 10.1016/j.compstruct.2018.07.119

Google Scholar

[8] Liu C, Shi Y. Analytical model for the winding process-induced residual stresses of the multilayered filament wound cylindrical composite parts. Mater Res Express 2019;6:105354.

DOI: 10.1088/2053-1591/ab3ef8

Google Scholar

[9] Liu C, Shi Y. Design optimization for filament wound cylindrical composite internal pressure vessels considering process-induced residual stresses. Composite Structures 2020;235:111755.

DOI: 10.1016/j.compstruct.2019.111755

Google Scholar

[10] Zu L, Xu H, Zhang B, Li D, Zi B. Design of filament-wound composite structures with arch-shaped cross sections considering fiber tension simulation. Composite Structures 2018;194:119–25.

DOI: 10.1016/j.compstruct.2018.04.018

Google Scholar

[11] Zu L, Xu H, Zhang Q, Jia X, Jin S, Li D. Investigation on mechanical behavior of composite electromagnetic gun barrel based on the high tension winding. Composite Structures 2020;248:112521.

DOI: 10.1016/j.compstruct.2020.112521

Google Scholar

[12] Xie X, Xie X, Li H, Shen L, Zhu J, Yu H, et al. Tension relaxation during the NOL ring winding process based on a novel tracking element method. Journal of Reinforced Plastics and Composites 2024:07316844241278554.

DOI: 10.1177/07316844241278554

Google Scholar

[13] Xu H, Wang Y, Song H, Li K, Hu J. Analysis of fiber stresses during high-tension winding molding of thermoplastic composites. Journal of Thermoplastic Composite Materials 2025:08927057251318714.

DOI: 10.1177/08927057251318714

Google Scholar

[14] Kempner EA, Hahn HT. The Effect of Radial Stress Relaxation on Fiber Stresses in Thick Filament-Wound Cylinders n.d.

Google Scholar

[15] Tekscan Inc. FlexiForce A201 Sensor Datasheet. (Rev I). Available at: https://www.tekscan.com/sites/default/files/resources/FLX-Datasheet-A201-RevI_1.pdf (accessed 11 December 2025).

Google Scholar

[16] Wang R, Jiao W, Liu W, Yang F, He X. Slippage coefficient measurement for non-geodesic filament-winding process. Composites Part A: Applied Science and Manufacturing 2011;42:303–9.

DOI: 10.1016/j.compositesa.2010.12.002

Google Scholar

[17] Toray Composite Materials America, Inc., T700G Technical Data Sheet, Technical datasheet, 2021. Available at: https://www.toraycma.com/wp-content/uploads/T700G-Technical-Data-Sheet1.pdf

Google Scholar

[18] Ng S-P, Tse P-C, Lau K-J. Numerical and experimental determination of in-plane elastic properties of 2/2 twill weave fabric composites. Composites Part B: Engineering 1998;29:735–44.

DOI: 10.1016/S1359-8368(98)00025-0

Google Scholar

[19] Kempner EA, Hahn HT. Effect of radial stress relaxation on fibre stress in filament winding of thick composites. Composites Manufacturing 1995;6:67–77.

DOI: 10.1016/0956-7143(95)99646-A

Google Scholar

[20] Lu S, Evans A, Turner T. Analysis of roller compaction pressure distribution in automated dry fibre placement. Composite Structures 2023; 316: 117048. https://doi.org/10.1016/j.compstruct. 2023.117048.

DOI: 10.1016/j.compstruct.2023.117048

Google Scholar

[21] Robitaille F, Gauvin R. Compaction of textile reinforcements for composites manufacturing. I: Review of experimental results. Polymer Composites 1998; 19: 198-216.

DOI: 10.1002/pc.10091

Google Scholar