WUT碳纤维缠绕成型技术

      碳纤维缠绕成型技术的核心是将浸渍树脂的碳纤维(或预浸碳纤维)按照预设路径(角度、密度)缠绕到芯模表面,经固化(加热或常温)后去除芯模,形成具有特定结构和性能的复合材料制品。其本质是通过纤维的定向排列,让材料强度沿受力方向最大化,同时利用树脂基体传递应力、保护纤维并赋予制品整体性。
      一、技术原理
      碳纤维缠绕成型技术的本质是“按应力分布规律设计纤维取向”:通过计算机控制缠绕轨迹,使碳纤维沿制品受载方向(如轴向、环向、旋向)定向排列,让纤维承担主要载荷,树脂基体则起到传递应力、保护纤维和密封的作用。这种 “定向增强” 特性,能最大限度发挥碳纤维的力学性能(比强度、比模量远高于金属材料),显著提升制品的结构效率。
      二、设备组成
      1.控制系统:是碳纤维缠绕机的 “大脑”,通过编程和控制算法,实现对芯模旋转速度、缠绕头移动速度、纤维张力等参数的精确控制,以保证碳纤维缠绕的精度和质量。
      2.张力控制:通过张力控制器对碳纤维丝束施加适当的张力,确保在缠绕过程中纤维丝束的张力均匀稳定,避免出现松弛或过紧的现象,影响产品质量。
      3.芯模系统:包括芯模及其支撑和驱动装置,芯模是碳纤维缠绕的基体,其形状和尺寸决定了最终产品的外形,支撑和驱动装置则保证芯模能够稳定旋转,实现碳纤维的缠绕。
      4.纱架系统:用于存放和输送碳纤维丝束,通常包含多个纱锭,可根据需要同时提供多股碳纤维丝。一些先进的纱架系统还具备自动换纱、张力控制和断纱检测等功能。
      5.绕头系统:是碳纤维缠绕机的关键部件,负责将碳纤维丝束准确地缠绕到芯模上。它通常包括导丝嘴、张力控制器、排线器等装置,能够实现纤维丝的张力控制、位置调整和精确排线。
      6.辅助系统:包括加热固化系统、冷却系统、脱模装置等。加热固化系统用于对缠绕后的碳纤维制品进行固化处理,提高其强度和性能;冷却系统则在固化过程中或之后对制品进行冷却,防止过热变形;脱模装置用于将固化后的碳纤维制品从芯模上顺利脱下。
      三、技术优势
      1.材料利用率高:纤维定向排布,几乎无废料(利用率可达 90% 以上,远高于模压、切削工艺);
      2.制品性能优异:纤维体积含量高(通常 50%-70%),轴向 / 环向强度可按需设计,比强度是钢的 5-10 倍,且耐腐蚀性、抗疲劳性优异;
      3.适合批量生产:自动化程度高(数控缠绕机可精准重复轨迹),适合标准化制品(如管道、气瓶)的批量制造;
      4.轻量化显著:相比金属制品,减重 30%-60%,尤其适合对重量敏感的领域。

WUT Carbon Fiber Filament Winding Technology‌

Carbon fiber filament winding technology involves impregnating carbon fibers (or prepreg carbon fibers) with resin and winding them onto a mandrel surface along predefined paths (angle, density). After curing (heated or ambient temperature), the mandrel is removed to form composite products with specific structures and properties. Its core essence lies in aligning fibers directionally to maximize material strength along stress-bearing directions, while the resin matrix transfers stress, protects fibers, and ensures structural integrity.
I. Technical Principle‌
The essence of the carbon fiber winding technology is to "design the fiber orientation according to the stress distribution law": control the winding trajectory by the computer, so that the carbon fibers are directionally arranged along the load-bearing direction of the product (such as axial direction, circumferential direction and rotational direction), so that the fibers bear the main load, and the resin matrix plays a role in transferring the stress, protecting the fibers and sealing. This "directional reinforcement" property can maximize the mechanical properties of carbon fiber (the specific strength and specific modulus are much higher than those of metal materials) and significantly improve the structural efficiency of products.
II. Equipment Components‌
‌‌Control System‌: It is the "brain" of the carbon fiber winding machine. Through programming and control algorithms, it realizes the accurate control of the core die rotation speed, winding head moving speed, fiber tension and other parameters, so as to ensure the accuracy and quality of carbon fiber winding. 
‌Tension Control‌: Apply appropriate tension to the carbon fiber tow through the tension controller to ensure that the tension of the fiber tow is uniform and stable during winding, avoid looseness or over-tightness and affect the product quality. 
‌Mandrel System‌: Including the core mold and its supporting and driving device. The core mold is the matrix of carbon fiber winding, and its shape and size determine the shape of the final product. The supporting and driving device ensures that the core mold can rotate stably to achieve carbon fiber winding. 
‌Creel System‌: Holds and feeds carbon fiber tows, often with multiple spools. Advanced versions feature automatic yarn change, tension control, and break detection. 
‌Winding Head‌: The ‌core component‌, comprising guide eyelets, tensioners, and traversers. It positions fibers accurately, controls tension, and ensures precise layering. 
‌Auxiliary Systems‌: Heating/curing systems, cooling units, and demolding devices. Heating solidifies the resin; cooling prevents deformation; demolding separates cured products from the mandrel. 
III. Advantages
‌1.High Material Utilization‌: Directional fiber placement minimizes waste (>90% efficiency, surpassing molding/machining). 
2.Superior Performance‌: High fiber volume fraction (typically 50–70%), customizable axial/hoop strength. Specific strength is ‌5–10× higher than steel‌, with excellent corrosion/fatigue resistance. 
‌3.Mass Production Suitability‌: Automation (via CNC) enables precise repeatability, ideal for standardized products (e.g., pipes, tanks). 
‌4.Lightweighting‌: Reduces weight by 30–60% vs. metals, critical in weight-sensitive applications.