The Project Report

Entitled
“DEVELOPMENT OF FILAMENT WINDING
MACHINE”
Is Submitted To

THE MAHARAJA SAYAJIRAO UNIVERSITY OF

BARODA
In Partial Fulfilment for the Award of Degree of
Bachelor of Engineering
In
Mechanical Engineering

Submitted by
NIRAJ H. SORATHIYA
ASHIT J. PAREKH
PRATIK K. PATEL
SARTHAK M. MISTRY

Guided By
DR. PIYUSH P. GOHIL
ASSOCIATE PROFESSOR

Department of Mechanical Engineering

Faculty of Technology and Engineering
The Maharaja Sayajirao University Of Baroda
Vadodara
May 2019

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 Certificate
This is to certify that the project thesis entitled “DEVELOPMENT OF FILAMENT
WINDING MACHINE” is prepared and submitted by the following students in the
partial fulfilment of the requirement for the award of degree of Bachelor of
Engineering in Mechanical Engineering of Faculty of Technology & Engineering,
The Maharaja Sayajirao University of Baroda, Vadodara.

This is the record of their own work carried out under my guidance and supervision.
The matter embodied in the following thesis is true to the best of my knowledge.

Name Class Roll No University Exam No

Niraj H. Sorathiya 295 808036
Ashit J. Parekh 299 808040
Pratik K. Patel 301 808042
Sarthak M. Mistry 303 808044

Guided by

Dr. Piyush P. Gohil

Associate Professor

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  Acknowledgement

The presentation of this report gives us the feeling of fulfilment. As the final frontier
towards achieving a bachelor’s degree, the activity of going through industrial
orientation has abridged the gap between the academics and practical work. It has
prepared us to apply ourselves better to become good mechanical engineers. Naturally,
it required support of a lot of people to complete this project. We would like to take this
opportunity to acknowledge their support to us.

We take this opportunity to express our deep gratitude and sincere thanks to Dr. D. S.
Sharma, Head of Department of Mechanical engineering for permitting our group to
embark upon this project titled, “Development of Filament Winding Machine”.

We had the privilege to work under the esteemed guidance of Dr. Piyush P. Gohil,
Associate Professor of Department of Mechanical engineering who visualized our
concept and gave invaluable suggestions throughout the project which made this project
successful. His inspirational talks and suggestive ideas acted as the weapons against all
the obstacles in the successful completion of the project.

We would also like to thank Alpa Bhatt ma’am for helping us in finding better materials
and other related matter.

We express our gratitude towards Mr. Hitesh P. Mistry for helping us in fabrication
work.

Last but not the least, our family members and friends who not only patiently tolerated
us throughout this project but also gave us the necessary emotional and financial
support through hard times.

- Niraj H. Sorathiya

- Ashit J. Parekh

- Pratik K. Patel

- Sarthak M. Mistry

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  ABSRACT

The domain we select is manufacturing of composite material tube. The method we

focused on is filament winding. Though filament winding is well known and optimised
process, here we develop a simple filament winding machine to understand the design
procedure.

We first design and select components of machine based on assembly, cost and space
requirement and develop NX-CAD model of filament winding machine. We construct
actual machine which is slightly different than NX-CAD model and produce tubes of
different composite material on machie.we also study the effect of speed of travel on
winding pattern and change in diameter of tube after each winding cycle.

Earlier we thought that construction of machine seems to be easy but after many trail
we come to know that it is difficult and need proper skill and understanding of process.

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  TABLE OF CONTENT

ACKNOWLEDGEMENT

ABSTRACT

TABLE OF CONTENT

1. INTRODUCTION
1.1 Composite Materials
1.1.1 Matrix components of composites
1.1.2 Fibre components of composites
1.2 Comparison of Composite Materials & Metals
1.3 Manufacturing Methods
1.3.1 Pultrusion
1.3.2 Resin transfer moulding
1.3.3 Vacuum assisted resin transfer moulding (VARTM)
1.3.4 Compression Moulding
1.3.5 Filament winding
2. FILAMENT WINDING
2.1 Process of Filament Winding
2.2 Winding Patterns
2.2.1 Hoop winding
2.2.2 Helical winding
2.2.3 Polar winding
3. MATRIALS AND METHODS
3.1 Materials
3.2 Design Calculations
3.2.1 Design of leadscrew
3.2.2 Design of nuts
3.2.3 Selection of bearings
3.2.4 Selection of gears

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 4. DEVELOPMENT OF FILAMENT WOUND PIPES/TUBES
5. APPLICATIONS
6. CONCLUSION
7. REFERENCES

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 1. INTRODUCTION

In this chapter, a brief description of composites material will be presented. In more

details, the following section will describe components of composite materials.
Commonly used resin systems and fibres will be defined in details. In the third section,
metals and composite materials will be compared.

1.1 COMPOSITE MATERIALS

Composites are the materials that are composed of at least two components and form
a new material with properties different from those of the components. Most
composites are composed of a bulk material and a reinforcement material, generally
fibres.

The reinforcement materials usually have extremely high tensile and compressive
strength. However, these theoretical values are not achieved in structural form. This is
due to the surface flaws or material impurities, which results in crack formation and
failure of the piece below its theoretical strength. In order to overcome this problem,
reinforcement is produced in fibre form, which prevents crack formation through the
whole body. However, a matrix should be used to hold these fibers together, and
improve material properties in the transverse direction of the fibre. The matrix also
protects the fibre from damage, as well as spreading the load equally to each individual
fibre.

The material properties of a composite are determined by the properties of matrix and
fibre, volumetric ratio and orientation of the fibers. The volumetric ratio of fibers is
mainly determined by the manufacturing method used. The higher the volumetric
ratio, the closer will be the properties of composite and fibre. Orientations of the fibers
are also important, since fibers have superior mechanical properties along their
lengths.

Composites have an increasing popularity in engineering materials, with their stiffness

and strength combined with low weight and excellent corrosion resistance.

1.1.1 MATRIX COMPONENTS OF COMPOSITES

Considering matrix components, modern composites can be classified in three main
groups: Polymer Matrix Composites, Metal Matrix Composites and Ceramic Matrix
Composites.

The most common group Polymer Matrix Composites, which is also known as Fiber
Reinforced Plastics (FRP). The components of FRP are polymer-based resins (Epoxy,
Polyester, Vinyl ester, etc.) as the matrix and glass, carbon or aramid fibers as the

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reinforcement. Matrix components of FRP can be classified as thermoset and
thermoplastic, according to the effect of heat on their properties. Thermoset resins
perform a non-reversible chemical reaction. When heated above a certain temperature,
which is called the glass transition temperature, its molecular structure transforms into
a softer polymer structure. In this phase, mechanical properties are low and failure can
occur easily. When cooled, it reverses the event and if not deformed in soft phase, gets
its mechanical properties back. On the other hand, thermoplastics melt with heat,
reversing the curing operation. They do not lose their properties even if melted,
reshaped and cooled several times.

Although there are number of resins employed in industry, most common ones are
polyester, vinyl ester and epoxy.

Polyester is used with accelerators and catalyst. Accelerator makes it possible to cure
at low temperatures more rapidly, whereas catalyst simply starts the reaction and is
not involve in polymerization. The amount of mixed catalyst and accelerator affects
the resultant material properties. Fillers, such as fire resistance fillers, colour fillers,
etc., can be used to improve desired properties.

Polyester has low adhesive properties and high shrinkage up to 8%. Heat
decomposition temperature of polyester ranges from 60 to 205ºC. Elongation at break
is within a range of 5 to 12%.

Vinyl ester resins do not have high mechanical properties as epoxy, but are cheaper.
Since vinyl ester is less prone to hydrolysis when compared with polyester, it is used
as a coating material in marine industry. It has a tougher molecular structure and higher
adhesive strength when compared to polyester resin. Heat decomposition temperature
of vinyl ester resins range from 93 to 135ºC. Elongation at break is within a range of
3.5 to 5.5%.

Epoxy resins have high mechanical properties, as well as a high environmental

resistance. Depending on the type of curing agent, they can be cured at any
temperature. They have a high adhesive strength and they can be used as an adhesive
material. Therefore, they are preferred when a honeycomb structure is used. Their
shrinkage is as low as 1% and they have superior fatigue resistance. A hardener,
instead of a catalyst, cures epoxy resin. The amount of hardener used affects the
material properties, since it can also react with cured epoxy. Epoxy resins have a
coefficient of thermal expansion in a range of 50 to 80 m/m per ºC. Their poison
ratio ranges within 1 to 5%.

The amount of heat supplied and the type of hardener for epoxy; or the amount of
accelerator used for polyester and vinyl ester, affects curing time of the resin. As a
general rule for epoxy, higher the curing temperature, the higher will be the
mechanical properties. Post curing will also improve the mechanical properties and
affect the glass transition temperature of a resin system.

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A resin system should have high toughness, good adhesive and environmental
resistance properties. It should also have high stiffness and ultimate tensile strength
similar to fibre, as well as high failure strain. Failure strain of the matrix should be at
least equal to fibre failure strain. This will prevent matrix failure before fibre fails.
High failure strain is a sign of high toughness, which also indicates crack resistance
behaviour. In addition, adhesive properties are important that loads should be
transferred to each fibre equally and neither cracking and nor loosening should be
promoted. Other common resin systems used in composites are phenolic, polyimides
and silicones.

1.1.2 FIBER COMPONENTS OF COMPOSITES

There are four important characteristics of a fibre, which affects the mechanical
properties of the composite: mechanical properties of fibre, coating of fibre,
volumetric ratio of fibre, and orientation of fibre. Mechanical properties depend on the
material used to manufacture a fibre. Coating of a fibre is generally used in particular

Resin systems and they are announced within fibre specifications. Coating of a fibre
affects the bounding force between fibre and the matrix, which has a great influence
on strength. Volumetric ratio of the fibre is greatly affected by the production method
used. As a rule, stiffness and strength of a composite part increases as the volumetric
ratio fibre within composite increases. However, after a ratio of around 65%,
generally, strength of the composite part will start to decrease. The reason for this is
that, the matrix cannot hold fibre together properly. The stiffness of the composite part
will continue to increase even after a volumetric ratio of 65%.

There are four commonly used fibers in industry: E-Glass, S-Glass, Aramid and
Carbon.

E-Glass is the cheapest type of glass fibers. Strength and stiffness of E-Glass fibre are
high. However, impact resistance is not so good. Electrical resistance, fire resistance
and strain at failure of E-Glass are high. It is cheaper than other fibers, which are
mentioned.

S-Glass has higher tensile strength and stiffness than E-Glass, but it is more expensive
than E-Glass. It is commonly used in aerospace and defence industries. S-Glass is also
referred as R-Glass (Vetrotex-Europe) or T-Glass (Nittobo-Japan) in industry.

Aramid is the name used for the organic polymer, aromatic polyamide. Kevlar
(DuPont), Technora (Teijin) or Twaron (Akzo Nobel) are the trademark names, which
are commonly used for aramid. It has high strength and low density and thus specific
strength of aramid fibers is high when compared to that of other fibers. Impact
resistance is also high, which gives rise to ballistic applications of aramid fibers.
Chemical and abrasion resistances are good, but resistance to ultraviolet light is poor.
High fire resistance, high thermal insulation, low cost and low thermal expansion are

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other superior properties, while low compressive strength and low flexural strength
are bad properties of aramid fibre.

The most commonly known carbon fibre material is polyacrylonitrile. A high modulus
and high strength fibre can be produced from polyacrylonitrile. Carbon fibers can be
produced in between these two extremes to form desirable properties. They have high
tensile and compressive modulus, high compressive and tensile strength, high flexural
strength and modulus when compared with other types of fibers. Therefore, use of
carbon in a composite structure raises orthotropic behaviour. Fatigue resistance of
carbon fibre is also high. It has a low thermal expansion coefficient. On the other hand,
fire-resistance, impact resistance, electrical insulation and thermal insulation
characteristics are low. Carbon is the most expensive one of all fibre types.

Other types of fibers are polyester, polyethylene, quartz and boron. Boron fibre is
produced by coating carbon or metal fibers. Extreme cost of this fibre restricts usage
of boron fibre to space applications.

1.2 COMPARISON OF COMPOSITE MATERIALS AND

METALS
Regarding the design stage, composites and traditional metals are somewhat different.
Designing structural components, using metals are usually straightforward. The
geometry of the structural element is designated first, and then the material and
production method is defined at the final stage. However, composites require the
material to be designed along with the structure. Therefore, optimization of the design
and iterations are usually required in the first steps of composite design. The
verification of the complete design, which is done by testing, is also very important in
composite structures.

Considering geometrical form, composites can give large design flexibility for the
designers. Having a large number of manufacturing alternatives, almost all geometries
can be produced with a low cost production and tooling. Fasteners or parts can be
removed with a unique composite part production. This minimizes the cost and
increases weight efficiency of designed structures.

Electrical properties also make composites functional for designers. They can also be
used for conductor parts when they are produced with some filler types. Composites
have lower specific gravity when compared to traditional material.

Most of the composite materials have higher specific modulus of elasticity when
compared to traditional metallic materials. This is due to low specific gravity of
composite materials.

Both strength and specific tensile strength properties of composites are higher than
most of the traditional metallic materials.

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Composites also have a higher fatigue resistance. Therefore, aerospace and automotive
industry commonly employs high performance composite parts. Another important
characteristic of composites is their low coefficient of thermal expansion.

Composites are also resistant to rusting or corroding. So, they are widely used in
military, marine or water system applications. Acid resistance is another point, which
makes composites superior to metals. There are some chemicals, which effect
molecular structure of polymer based composite materials. Nevertheless, surface
coating can be solution to this problem.

Surface finishes of composites are also good. Although quality of a surface depends
on manufacturing method, composites generally do not require a surface treatment.
They can be directly painted with most of the metallic or non-metallic paints.

1.3 MANUFACTURING METHODS

There are many methods available for making of composite materials. However
following five methods are widely used.

1.3.1 PULTRUSION
Pultrusion is an automated continuous composite manufacturing process, where
materials of constant cross section are produced by pulling of fibers through resin over
a heated die. The process was developed by Goldsworthy. The major application of the
pultrusion process is in the fabrication of composite parts that have a prismatic cross-
section profile. The manufacturing process of pultrusion is suited ideally for mass scale
production.

1.3.2 RESIN TRANSFER MOULDING

In this process the layers of fibers or a fiber prepreg are placed between male and female
moulds, pressurized and injected with resin. The resin is injected to fill all voids within
the mould and thus penetrates and wets all surfaces of the reinforcing materials. A wide
variety of reinforcement materials can be used. This process offers low wastage and
reduced machining cost of the finished product. The process can be automated. The
major limitations of this process are that the manufacturing of complex shapes requires
lot of trial and error to ensure proper wetting; also the mould designing is complex.

1.3.3 VACUUM ASSISTED RESIN TRANSFER MOULDING

(VARTM)

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In VARTM, vacuum is applied to the mould and sucked into the fabric/fiber. In this
process, wetting of the fibre is dependent on the permeability of the preformed laminate
and architecture of the fibre. Viscosity of the resin has to be low. This process is very
safe from health hazard point of view as the entire system is under vacuum and can
yield very high quality products.

1.3.4 COMPRESSION MOULDING

Compression Moulding is used in manufacturing sheet moulding compound (SMC)

composites and bulk moulding compound (BMC). This process consists of three stages,
namely charging, compressing and ejecting. The material to be moulded is preheated
and placed in a mould in the charging stage. Then pressure and additional heat is applied
in the compression stage. Finally the finished product is removed from the mould after
sufficient curing time.

1.3.5 FILAMENT WINDING

Filament winding is an automated process for manufacturing advanced reinforced

composite structural components. It entails the winding of resin impregnated fibers
around a mandrel and then curing them so that the wound fibre can take the shape of
the mandrel. The fibers are placed on the rotating mandrel by a horizontal carrier. The
fibre orientation is controlled by controlling the speed of the horizontal carrier.
Subsequently curing is done for an appropriate time and temperature. After curing, the
wound composite is removed from the mandrel if the mandrel is not sacrificial; but,
sometimes the mandrel can be a part of the design. It is used to manufacture pipes,
tanks, gas cylinders, etc.

2. FILAMENT WINDING
Filament winding is a type of composite manufacturing process, where controlled
amount of resin and oriented fibers are wound around a rotating mandrel and cured to
produce the required composite part. It was initially used to produce pressure vessels,
water and chemical tanks. The development stage of filament winding goes back to dry
wire winding of rocket motor cases, which requires reinforcement.

2.1 PROCESS OF FILAMENT WINDING

Most filament winding machine looks like lathe. Mandrel is supported horizontally
between supports. Mandrel is made to rotate freely between supports. It is connected
with rotor through belt and pulley. Carriage is mounted on leadscrew, which slide as

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leadscrew rotates. Rotation of leadscrew is controlled by voltage regulator and DPDT
switch. Voltage regulator regulate the speed of travel and DPDT switch reverses
direction of rotation to reverse the travel direction.

Winding machines are characterized by their degrees of freedom. Two of these degrees
of freedoms are already defined: rotation of mandrel and horizontal movement of the
carriage. Other commonly used degree of freedoms is rotation of mandrel in horizontal
plane.

Fibers pass through a resin bath after tensioning system and gets wet before winding
operation. When a pre-impregnated fiber or prepreg is used, wetting is not performed.

Tensioning system is an important part of filament winding. This importance gets

critical when winding at high angles. Since tension changes the friction force between
fiber and the mandrel, it should be kept at a certain value during winding operation.
Fiber tension also affects the volumetric ratio of composite at a given point. Excessive
resin, due to a low tension, can result in decreased mechanical properties. Therefore,
tensioning systems should be capable of rewinding a certain value of fiber. This
condition occurs when fiber band reverses at the end of tube, while winding at low
angles.

Figure 2.1 – Schematic View of a Filament Winding Machine

Wetting can be done by two commonly used bathing type; drum bath and dip bath.
Drum bath provide less fiber damage than dip bath. This is especially important when
using carbon fibers. On the other hand, dip bath provides a better wetting action. If
fibers are not wetted in a desired way, air bubbles can be trapped between them and can

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cause voids in the composite part. Therefore, drum baths can be heated for a better
wetting action.

Lowering resin viscosity, reducing fiber speed, increasing fiber path on the drum are
other methods used for better wetting action. Dip baths are used with aramid or glass
fibers. If heated resin is to be used, dip baths are preferred since drum surface cools as
it leaves the resin bath. During the travel of fiber through a dip bath, non-rotating
surfaces are used for guidance. Non-rotating surfaces provide good wetting, and
prevents fiber built out due to broken fibers at rotating surfaces.

Figure 2.2 – Schematic View of a Drum Bath

Rotating mandrel can be a part of the produced composite part (such as in production
of a pressure vessel with a liner) or can be removed from composite part (such as a
composite tube). If it will be removed, a press should be used for removing. All
mandrels, which will be removed, should have low thermal expansions in order to
reduce residual stresses after curing action. Steel is generally used when producing
mandrels. If a tube is used as a mandrel, tube thickness should be uniform, in order to

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have a symmetric composite part. In addition, surface finish is an important point, since
an interface between the composite part and mandrel is generally not permitted.

Figure 2.3 – Schematic View of a Dip Bath

If a concave part is needed on the filament wound part, a female mold can be used. In
addition, excessive wet fiber can be used in order to fill concave parts. Metal parts can
be mounted on mandrel in order to guide winding action.

Winding angle is the angle between fiber and the line on surface of the mandrel, which
is parallel to mandrel axis. A maximum value, which is close to 90 degrees, can be
approximated. Very low winding angle values need some arrangements at the ends of
the mandrel, such as pins, etc.

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 Figure 2.4 – Fiber Orientation Angle
When designing and producing a filament wound tube, one has to consider many
possibilities and limitations. The first limitation will be the winding machine used. For
complex geometries, machines that are more complex should be employed. The
dimensions of the machine, the number of degrees of freedom, control unit used and
the pattern generation software directly affect the limits of winding action. A three or
four axis computer controlled filament winding machine will be practical for most
cases. Today, use of high-tech robotic winding machines even makes it possible to wind
T joints of pipes.

Second limitation will be the mandrel geometry that is used. Concave geometries are
generally not permitted. Sharp edges should be avoided in order not to cut fibers. End
edges should not restrict returns of winding. Pins or domes must be removable or
collapsible. Surface finish of the mandrel should meet the requirements.

Difficulty of winding action is a limitation on filament winding. Fibers can be wound

on the mandrel along different trajectories. Geodesic or semi-geodesic curves can be
used in order to wind geometry. Similar to works done on textile industry, there are
many applications on these geodesic pads and filament winding process. Deviation of
fiber from these geodesic pads increases the slippage and textile point of view gets more
importance. Ends of tube are the main critical point for these geodesic pads.

When the tube is subjected to a loading condition, all layers of fibers should be stressed
equally. This simply implies that, for each loading condition there exists an optimum
winding configuration. This makes the research and testing action necessary for
filament winding applications. These are difficult design items due to the complexity
of composite material behavior. Some assumptions can be done in order to simplify an
analysis. If woven structure is neglected, there exist three mutually perpendicular planes
in each lamina. Elastic properties are symmetric about these planes. These planes are
the cross-section, the fiber plane and a plane passes through axis of the cylinder. Using
this configuration, usually all design work on filament winding is performed.

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2.2 WINDING PATTERNS

In filament winding process, the winding tension can easily be controlled. Winding
tension, winding angle and/or resin content in each layer of reinforcement can be varied
until the desired thickness and strength of the composite are achieved. The properties
of the finished composite can be varied by the type of winding pattern selected. In
general, there are three basic filament winding patterns which are as follows.

2.2.1 HOOP WINDING

It is known as the girth or circumferential winding. In hoop winding, a high-angle

helical winding approaches an angle of 90_. Each full rotation of the mandrel advances
the band delivery by one full bandwidth as shown in Fig. 2.5

Fig. 2.5 Circumferential or hoop winding

2.2.2 HELICAL WINDING

In helical winding, the mandrel rotates at a constant speed while the fiber feed carriage
transverses back and forth at a speed regulated to generate the desired helical angles as
shown in Fig. 2.6.

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 Fig. 2.6 Helical winding

2.2.3 POLAR WINDING

In polar winding, the fiber passes tangentially to the polar opening at one end of the
chamber, reverses direction, and passes tangentially to the opposite side of the polar
opening at the other end. In other words, fibers are wrapped from pole to pole, as the
mandrel arm rotates about the longitudinal axis as shown in Fig. 2.7 It is used to wind
almost axial fibers on domed end type of pressure vessels.

Fig. 2.7 Polar winding

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 3. MATERIALS AND METHODS

3.1 MATERIALS
SR. NO. NAME OF NO. OF MATERIAL
COMPONENTS COMPONANTS USED
1. Mandrel 1 Wood
2. Lead Screw 1 Free Cutting Steel
3. Nut 1 Free Cutting Steel
4. Guide Bar 1 Mild Steel
5. Resin Bath Tub 1 Wood
6. Bearings 5 Chrome Steel
7. Motors 2 -
8. Belt 1 Rubber
9. Gears 2 Nylon
10. Frame 1 Wood
11. Pulleys 3 Nylon
12. DPDT Switch 1 -
13. Voltage Regulator 1 -

3.2 DESIGN CALCULATION

As we do not perform force analysis and motion analysis,

Let assume,

Total load on mandrel=1000 N

Total load on carriage=1000 N

These load value are very high compare to actual value because tension in string is only
around 100 N.

Hence our design procedure will be very safe from strength point of view.

Here we are performing design and selection procedure for following parts

1. Mandrel
2. Gears
3. Bearings
4. Pulleys
5. Leadscrew
6. Nut

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 3.2.1 DESIGN OF LEADSCREW

Design of leadscrew as power screw

Factor of safety=1.5

Material= mild steel

ϐ = 44 MPa
ζ = 24 MPa

𝐹
From ϐ=
𝐴

Where A=𝜋𝑟 2

4∗𝐹∗𝐹𝑂𝑆
d=√
𝜋 ∗ϐ

4∗1000∗1.5
d=√
𝜋 ∗44

d= 6.58 mm

Selecting next standard size,

Hence,

Diameter= 8 mm
Pitch= 1.25 mm

For single start thread,

Lead=pitch=1.25 mm

Now,
Torque developed

𝑙+µ∗𝜋∗𝑑
T= (𝐹 ∗ 𝑟) ∗ ( )
𝜋∗𝑑−µ∗𝑙

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 Assume coefficient of friction µ=0.25
Putting value in equation,

1.25+0.25∗𝜋∗8
T= (1000*0.008)∗ ( )
𝜋∗8−µ∗1.25

T=1.215 N.m=1215 N.mm

Checking for stresses

16∗𝑇
ζ=
𝜋∗𝑑3

16∗1215
ζ=
𝜋∗83

ζ =12.09 MPa

24
FOS =
12.09

FOS=1.98

Calculated FOS is greater than assumed FOS hence design is safe.

Power transmitting screw are generally with square or acme thread for self-locking
and high strength. But here in our application we provide adequate strength by very
high FOS.so we use V thread. However we feel that due to use of V tread accuracy
is decreased and causes vibration due to excessive backless error.

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 3.2.2 DESIGN OF NUT

Considering load shared equally by all thread of nut

Now for nut

𝜋
F= 4 * (𝐷𝑜2 -𝐷𝑖 2 )* (Pb *n)

Where,
n = number of thread
P = bearing capacity of nut
b

For brass nut Pb =12 Mpa

Do=8+1.25=9.25 mm
Di=8-1.25=6.75 mm

Substituting above value we get,

𝜋
1000= 4 * (9. 252 − 6.752 )* (12*n)

n = 2.65

Let take n=5 which is higher than calculated hence design is safe.

Now height of nut

H=l*n
H=1.25*5
H=6.25 mm

The nut threads are also subjected to crushing and shear. Considering crushing
failure we have

𝜋
F=n*( 4 ) (𝐷𝑜2 -𝐷𝑖 2 )* σc
Substituting value in above equation we get,
σc = 6.37 Mpa

Which is adequately safe and therefore crushing is not expected.

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 We select mild steel nut having height 40mm which give safer design than brass
nut.

3.2.3 SELECTION OF BEARING

Selection of bearing depend on shaft diameter, magnitude of radial and axial load.

Generally selection is carried out based on manufacture’s catalogue

Here we use SKF bearing catalogue

We select bearing for mandrel

Diameter of mandrel=30 mm
Radial load= 1000 N
Speed = 1000 rpm
Bearing life (expected) =1000 hrs (very worst condition)

60∗1000∗1000
L10= ( )
10^6
L10=60

Here load transmitted is very low and we do not require that level of accuracy so
we select sliding bearing made in china having bore of required shaft dimension.
Another benefit of Selection of china bearing is low cost.

3.2.4 SELECTION OF GEARS

We required gear only for power transmission not for reducing speed since we
provided voltage regulator which control speed with step less regulation. Hence we
select spur gear with speed ratio 1.

Due to assembly constraint we have following limitation,

Centre to centre distance=36 mm and we assume some standard data here such as
pressure angle, Addendum, Dedendum etc.

Which gives following dimension based on KHK gear calculator.

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 Normal module 1.44

Normal pressure 20° 0’ 0”

angle

Helix angle 0° 0’ 0”

Transverse module 1.44

Transverse pressure 20° 0’ 0”

angle
Small gear Large
gear

Number of teeth 25 25

Normal tooth profile 0 0

shift coefficient
Sum of Normal 0
tooth profile shift
coefficient
Transverse 20° 0’ 0”
contacting pressure
angle
Center distance 0
modification
coefficient

Centre distance 36

Pitch circle diameter 36 36

Contacting pitch 36 36
circle diameter

Addendum 1.44 1.44

Dedendum 1.8 1.8

Tooth height 3.24 3.24

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 Clearance 0.36 0.36

Base circle diameter 33.82893 33.82893

Tip diameter 38.88 38.88

Root diameter 32.4 32.4

Start of contact 34.26696 34.26696

diameter

Lead 0 0

Transverse contact 1.61165

ratio

Tooth thickness 2.26195 2.26195

perpendicular to
tooth
Transverse tooth 2.26195 2.26195
thickness
Transverse tip circle 1.03654 1.03654
tooth thickness
Chordal tooth 2.26046 2.26046
thickness

Chordal height 1.47552 1.47552

Span number of 3 3
teeth

Base tangent 11.13187 11.13187

Ideal pin (ball) 2.46677 2.46677

diameter
Pin (ball) diameter 2.46677 2.46677
used

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 Over pin 39.31046 39.31046
measurement
Spur • helical gear Calculation of profile shifted gear 2019/05/04
Allowable 844.97328 844.97328
circumferential
force (N)
Allowable 15.20952 15.20952
torque (N m)
Allowable power 1.59274 1.59274
(kW)

Normal module 1.44

Normal pressure 20° 0’ 0”

angle
Helix angle 0° 0’ 0”

Small gear Large gear

Number of teeth 25 25

Normal tooth 0 0
profile shift
coefficient
Sum of Normal 0
tooth profile
shift coefficient
Transverse 20° 0’ 0”
contacting
pressure angle
Center distance 0
modification
coefficient
Center distance 36

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 Pitch circle 36 36
diameter
Contacting pitch 36 36
circle diameter
Addendum 1.44 1.44

Dedendum 1.8 1.8

Tooth height 3.24 3.24

Tool tip 0.38

roundness radius
coefficient
Base circle 33.82893 33.82893
diameter
Tip diameter 38.88 38.88

Root diameter 32.4 32.4

Tooth width 11 11

Transverse 1.61165
contact ratio
Overlapping 0
contact ratio
Accuracy JIS 4 JIS 4

Tooth form Modifications Modifications

modification

Material S45C S45C

Heat treatment Normalized Normalized

Center hardness HB 200 HB 200

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Surface hardness HB 200 HB 200

Rotational 1000 1000

speed(rpm)
Peripheral speed 1.88482
(m/s)
Number of More or less
repetitions 100,000
Direction of load Both directions

Effective face 11 11
width
Tooth form 2.63361 2.63361
factor
Load distribution 0.62048
factor along gear
tooth
Helix angle 1
factor
Life factor 1.2 1.2

Size factor 1

Dynamic load 1.2 1.2

factor
Overload 1.25
coefficient
Safety ratio 1.2

Allowable tooth
root bending 130.75533 130.75533
stress( MPa )

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Spur • helical gear Calculation of bending strength [JGMA401-01]

1 KHK GCSW

From above calculation allowable load is around 840 N which is very high compare to
actual load. So to save cost, reduce weight and noise we use MC nylon plastic gear of
same size.

3.2.5 SELECTION OF MOTORS

Here requirement of torque is very low and we need to regulate the speed of
rotation.so we select DC variable speed motor with following specification

Motor for mandrel: 24 V DC with 500 rpm

Motor for leadscrew: 12 V DC with 1000 rpm

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4. DEVELOPMENT OF FILAMENT WOUND TUBES/PIPES

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 5. APPLICATIONS

There are many reasons to use filament winding as a composite manufacturing method.
First, many part such as rocket motor cases or pressure vessels require reduced radius
at the end openings. For these applications, generally a metal, plastic or rubber liner is
used. Rubber liners require a dissolvable material in order to support the rubber liner.

Secondly, filament winding is an effective way to produce high strength tubes. This
situation holds especially when there exists an internal pressure. In addition, it is even
possible to wound endless tubes for pipelines, etc. Having no connection points, endless
tubes are more economical and reliable. Winding angles can also be arranged in order
to optimize the design for several usage purposes.

It is possible to use filament winding for reinforcement. Thick pressure vessels, rocket
motor cases are all examples of this kind of applications. Filament winding can even be
used to reinforce concrete columns.

Following are some area where filament winding used extensively

1. High Pressure Air Tank used paint ball, emergency care

2. Fuel tank used hydrogen, CNG & LPG
3. High Pressure GRP Pipe
4. Pressure and storage Vessel
5. Coupling and joint fitting
6. Air craft and space
7. Industrial part
8. Military parts

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 6. CONCLUSION

We came to conclusion that development of actual machine is difficult than what we

thought and also came to know that while converting NX-model into real machine we
need to do too much compromise to consider assembly of parts and cost restriction. We
develop tubes from various material but not able to perform testing of produced parts
due to time constraint. Due to vibration of slider winding pattern is not uniform. We
also came to know that with increase in speed pitch of winding is increased Also at end
of each winding cycle change in diameter is not uniform. Through this project we got
real learning experience and understanding of the design procedure.

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 7. REFERANCES

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