Building a CF Tube

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joeman
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Building a CF Tube

Postby joeman » Fri May 03, 2019 11:03 pm

Hi,
Thought I'd create a post of my latest project - which is a Carbon Filament winding machine (as opposed to wrapping CF fabric around a mandrel).
Ultimately, I hope to use this winder to make myself some Carbon Fiber tubes for various rocketry projects into the future, including my L3 build which I hope to start a little later this year.

Why go to all this effort? (There is a lot of mucking around to get it working properly).
Figured I'd learn quite a bit from it....and that once I sort out the engineering issues I could wind tubes fairly easily with minimal effort.

Here are a list of "mechanical" issues I've had to contend with...
* Epoxy resin /Filament interactions (not too much, not too little, but just right amount of epoxy impregnated in Filament)
* Filament tension
* Filament winding width and spacing and angles - This is a biggy. Guides help to keep the Filament running straight.

Lots of headaches and it isn't cheap stuff, so I end up winding it back on to the reel after each test...rather than cutting off and binning.


Here is a very short Youtube video of two passes at 30 degree laydown.

https://youtu.be/kHR4sF1j6xI

I use LinuxCNC on an old server with a parallel port. It is connected to the network and runs a web server, which has a small program that I connect to using my browser to generate appropriate gcode files. Lots of programming, lots of maths (vectors!!) . Using stepper motors to turn the three axis...like the ones in home 3-D printers...except larger. 3-D printer has been my friend in this side project.

Hopefully I'll have some long CF tubes to show off in a month or so.

Anyhow, if anyone would like to know more about it, ask away... :)

Cheers

Joe
L1 - Callisto (H133) - 11-Jan-2016
L2 - March Fly (1633K940) - 18-Mar-2018 - RSO

joeman
Rocket Crew
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Posts: 361
Joined: Fri Mar 06, 2015 9:05 am

Re: Building a CF Tube

Postby joeman » Sun May 05, 2019 6:27 pm

Did a FULL layer today - dry run at 45 degrees without any issues.

Here is a photo of how it looked at the end of winding.

IMG_8543_SML.jpg
1 SINGLE run - 45 degrees (dry-run)


The Carbon Fiber makes very nice looking patterns. VERY happy with how it looks.


Hope to do a real-run with Epoxy sometime in the next week or so - three layers, varying angles.
L1 - Callisto (H133) - 11-Jan-2016
L2 - March Fly (1633K940) - 18-Mar-2018 - RSO

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SpaceManMat
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Location: Brisbane

Re: Building a CF Tube

Postby SpaceManMat » Sun May 05, 2019 10:49 pm

Very cool joe. I need to get off my arse and start using my 3D printer.
QRS: 124
AMRS: 32 L2 RSO
Highest Altitude: 13,647 feet
Fastest Flight: Mach 1.55
Largest Motor: CTI 1115J530 IM
Current Project: X Wing

strud
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Location: Central Tablelands, NSW

Re: Building a CF Tube

Postby strud » Mon May 06, 2019 7:49 am

Awesome work!

How much tension do you need ?

I assume the epoxy bath/applicator is a messy place....

Exciting

joeman
Rocket Crew
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Posts: 361
Joined: Fri Mar 06, 2015 9:05 am

Re: Building a CF Tube

Postby joeman » Tue May 07, 2019 7:17 am

Cheers!

Need about 5 N of tension. i.e. not too much. Aiming ideally for 50/50 by weight. (CF vs Epoxy)

If tension is too great, I find that when CF changes direction I can have issues with it not staying put on Mandrel. I'll probably use some Peel Ply I have here to help squeeze out excessive Epoxy.

More experimentation required.
L1 - Callisto (H133) - 11-Jan-2016
L2 - March Fly (1633K940) - 18-Mar-2018 - RSO


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