Les réservoirs en matériaux composites représentent un moyen pourle stockage de l’hydrogène à des pressions de service très élevées. En dépit desnombreux avantages que présentent les réservoirs en composites, le stockage soushaute pression conduit à utiliser de fortes épaisseurs de composites, et lecomportement de ce type de structure reste mal maitrisé. Le procédé d’enroulementfilamentaire induit des variabilités et défauts qui impactent le comportement de lastructure et en particulier le comportement des fonds. De ce fait, il est nécessaired'apprécier ces variabilités dans la modélisation du comportement des réservoirscomposites épais.Ce travail de thèse présente une approche permettant de modéliser le comportementmécanique des réservoirs en prenant en compte les spécificités dues au procédé deréalisation. A ce titre, nos recherches concernent aussi bien l'analyse de structuresque l'aspect simulation numérique. / Les réservoirs en matériaux composites représentent un moyen pourle stockage de l’hydrogène à des pressions de service très élevées. En dépit desnombreux avantages que présentent les réservoirs en composites, le stockage soushaute pression conduit à utiliser de fortes épaisseurs de composites, et lecomportement de ce type de structure reste mal maitrisé. Le procédé d’enroulementfilamentaire induit des variabilités et défauts qui impactent le comportement de lastructure et en particulier le comportement des fonds. De ce fait, il est nécessaired'apprécier ces variabilités dans la modélisation du comportement des réservoirscomposites épais.Ce travail de thèse présente une approche permettant de modéliser le comportementmécanique des réservoirs en prenant en compte les spécificités dues au procédé deréalisation. A ce titre, nos recherches concernent aussi bien l'analyse de structuresque l'aspect simulation numérique.

The aim of this study was to investigate the effects of resin and fiber on the abrasion, impact and internal pressure resistances of fiber reinforced plastic composite pipes produced by continuous filament winding method. For this study, pipe samples were produced with different combinations of resin type, fiber type, fiber amount and fiber length. All the samples were tested in accordance with the related ISO (International Organization for Standardization), DIN (German Standardization Institution) and BSI (British Standards Institution) standards. Three types of resins were used as ortophthalic, isophthalic and vinylester / two types of fibers were used as E-glass and ECR-glass and one type of GLASSFLAKES was used as C-glass. It was observed that the type of resin did not have any significant effect on burst pressure. However, the vinylester resin had a considerable positive effect on the abrasion and impact resistances. Moreover, it was observed that the type of fiber did not have any significant effect on impact and internal pressure resistances, but the use of C-glass GLASSFLAKES resulted in a positive effect on the abrasion resistance. Additionally, it was found that the increase in the amount of glass fiber resulted in increase of burst pressure, impact and abrasion resistances. Finally, it was observed that the length of glass fiber did not have any significant effect on abrasion resistance, but the decrease in fiber length resulted in a higher internal pressure and impact resistances.

The aim of this study is to determine the mechanical characteristics of the filament wound composite tubes working under internal pressure loads, generating data for further investigation with a view of estimating the remaining life cycle of the tubes during service. Data is generated experimentally by measuring the mechanical behavior like strains in hoop direction, maximum hoop stresses that are formed during internal pressure loading. Results have been used to identify and generate the necessary data to be adopted in the design applications. In order to determine these parameters, internal pressure tests are done on the filament wound composite tube specimens according to ASTM D 1599-99 standard. The test tubes are manufactured by wet filament winding method, employing two different fiber types, two different fiber tension settings and five different winding angle configurations. The internal pressure test results of these specimens are studied in order to determine the mechanical characteristics, and the effects of the production variables on the behavior of the tubes. Pressure tests revealed that the carbon fiber reinforced composite tubes exhibited a better burst performance compared to the glass fiber reinforced tubes, and the maximum burst performance is achieved at a winding angle configuration of [&plusmn / 54&deg / ]3[90&deg / ]1. In addition, the tension setting is found not to have a significant effect on the burst performance. The burst pressure data and the final failure modes are compared with the results of the ASME Boiler and Pressure Vessel Code laminate analysis, and it was observed that there is a good agreement between the laminate analysis results and the experimental data. The stress &ndash / strain behavior in hoop direction are also studied and hoop elastic constants are determined for the tubes.

O semieixo automotivo é um componente usualmente metálico pelo qual o torque é transmitido do diferencial para as rodas do veículo. Diferentemente dos semieixos convencionais, os fabricados em materiais compósitos possuem algumas variáveis de projeto que devem ser levadas em consideração, como a orientação das fibras, a sequência de empilhamento, a espessura e o número de camadas. Neste trabalho, cilindros compósitos para aplicação em semieixos de transmissão foram processados por enrolamento filamentar com o objetivo de substituir peças em aço convencional por compósito laminado em fibra de carbono com matriz epóxi. Para tal, os parâmetros da aplicação do semieixo em compósito, como frequência natural, torque critico de flambagem e capacidade de transmissão de torque foram considerados. Foi realizado um ensaio preliminar de torção e foram selecionados três laminados: [±22/±45], [±89/±45] e [±45]2. Cilindros de carbono/epóxi foram fabricados pelo processo de enrolamento filamentar e ensaios de compressão radial e longitudinal dos cilindros foram realizados. Análises mecânicas foram realizadas por meio de abordagens analíticas e numéricas, sendo que a última foi baseada no método dos elementos finitos. Os resultados analíticos foram comparados com os numéricos e experimentais, apresentando uma boa correlação entre eles. O cilindro com o laminado [±45]2 apresentou o melhor desempenho de resistência sob torção. Para torque critico de flambagem, assim como em compressão radial e longitudinal, o laminado [±45]2 apresentou um desempenho satisfatório para a aplicação, apesar de não ser o melhor desempenho dentre os laminados. Conclui-se que o laminado [±45]2 é o que apresenta melhor desempenho, em geral e que a redução de massa do semieixo desenvolvido em compósito utilizando este laminado, em relação ao de aço é de 47%. / The automotive half shaft is usually a metallic-based component in which the torque is transmitted from the differential to the wheels. Unlike conventional half shafts, in composite half shafts there are several parameters to be improved, namely fiber orientation, stacking sequence, thickness and number of layers. In this study, composite cylinders for application in half shafts have been processed by filament winding in order to replace conventional steel parts by laminated composites with carbon fiber reinforced epoxy composites. For that, it must satisfy several parameters of the composite half shaft, such as critical speed, critical buckling torque and load carrying ability. A preliminary torsional test has been performed and three laminates were selected: [±22/±45], [±89/±45] and [±45]2. Carbon/epoxy cylinders were manufactured by filament winding process and radial and longitudinal compression tests were performed. Mechanical analysis has been accomplished by using analytical and numerical approaches, since the last one is based on the finite element method. Analytical results were compared with the numerical and experimental ones, presenting a good correlation between them. The cylinder [±45]2 has the best performance under torsional loading. For critical buckling torque, as well as radial and longitudinal compression, the laminate [±45]2 presented a satisfactory performance for the application, but not the best performance within the laminates. The main conclusion is that the laminate [± 45]2 has the best performance and the weight reduction of the composite half shaft developed using this laminate is of 47%, when compared to a steel-based shaft.

Made available in DSpace on 2014-10-09T12:25:54Z (GMT). No. of bitstreams: 0 / Made available in DSpace on 2014-10-09T14:00:39Z (GMT). No. of bitstreams: 0 / Dissertacao (Mestrado) / IPEN/D / Instituto de Pesquisas Energeticas e Nucleares - IPEN/CNEN-SP

O semieixo automotivo é um componente usualmente metálico pelo qual o torque é transmitido do diferencial para as rodas do veículo. Diferentemente dos semieixos convencionais, os fabricados em materiais compósitos possuem algumas variáveis de projeto que devem ser levadas em consideração, como a orientação das fibras, a sequência de empilhamento, a espessura e o número de camadas. Neste trabalho, cilindros compósitos para aplicação em semieixos de transmissão foram processados por enrolamento filamentar com o objetivo de substituir peças em aço convencional por compósito laminado em fibra de carbono com matriz epóxi. Para tal, os parâmetros da aplicação do semieixo em compósito, como frequência natural, torque critico de flambagem e capacidade de transmissão de torque foram considerados. Foi realizado um ensaio preliminar de torção e foram selecionados três laminados: [±22/±45], [±89/±45] e [±45]2. Cilindros de carbono/epóxi foram fabricados pelo processo de enrolamento filamentar e ensaios de compressão radial e longitudinal dos cilindros foram realizados. Análises mecânicas foram realizadas por meio de abordagens analíticas e numéricas, sendo que a última foi baseada no método dos elementos finitos. Os resultados analíticos foram comparados com os numéricos e experimentais, apresentando uma boa correlação entre eles. O cilindro com o laminado [±45]2 apresentou o melhor desempenho de resistência sob torção. Para torque critico de flambagem, assim como em compressão radial e longitudinal, o laminado [±45]2 apresentou um desempenho satisfatório para a aplicação, apesar de não ser o melhor desempenho dentre os laminados. Conclui-se que o laminado [±45]2 é o que apresenta melhor desempenho, em geral e que a redução de massa do semieixo desenvolvido em compósito utilizando este laminado, em relação ao de aço é de 47%. / The automotive half shaft is usually a metallic-based component in which the torque is transmitted from the differential to the wheels. Unlike conventional half shafts, in composite half shafts there are several parameters to be improved, namely fiber orientation, stacking sequence, thickness and number of layers. In this study, composite cylinders for application in half shafts have been processed by filament winding in order to replace conventional steel parts by laminated composites with carbon fiber reinforced epoxy composites. For that, it must satisfy several parameters of the composite half shaft, such as critical speed, critical buckling torque and load carrying ability. A preliminary torsional test has been performed and three laminates were selected: [±22/±45], [±89/±45] and [±45]2. Carbon/epoxy cylinders were manufactured by filament winding process and radial and longitudinal compression tests were performed. Mechanical analysis has been accomplished by using analytical and numerical approaches, since the last one is based on the finite element method. Analytical results were compared with the numerical and experimental ones, presenting a good correlation between them. The cylinder [±45]2 has the best performance under torsional loading. For critical buckling torque, as well as radial and longitudinal compression, the laminate [±45]2 presented a satisfactory performance for the application, but not the best performance within the laminates. The main conclusion is that the laminate [± 45]2 has the best performance and the weight reduction of the composite half shaft developed using this laminate is of 47%, when compared to a steel-based shaft.

Made available in DSpace on 2014-10-09T12:25:54Z (GMT). No. of bitstreams: 0 / Made available in DSpace on 2014-10-09T14:00:39Z (GMT). No. of bitstreams: 0 / Neste trabalho avaliou-se experimentalmente a influência da onfiguração de bobinagem no comportamento mecânico de cilindros de compósito polimérico com bobinagem simétrica e assimétrica. Para tanto, foram fabricados pelo processo de bobinamento filamentar (filament winding) dois grupos de cilindros com extremidades abertas, que apresentaram alteração no posicionamento das camadas em relação ao plano médio, caracterizando laminados simétrico e assimétrico. No compósito deste estudo, utilizou-se uma matriz com sistema tricomponente com resina epoxídica e reforço de fibra de carbono. Para avaliação da resistência mecânica, os cilindros foram submetidos a ensaio hidrostático que consistiu da pressurização interna em dispositivo apropriado mediante a utilização de um fluido até que ocorresse o colapso. Adicionalmente, as deformações e os modos de falha dos dois grupos de cilindros foram analisados e comparados. A utilização de um programa de cálculo de elementos finitos permitiu concluir que esta ferramenta, muito usada em projeto, não consegue identificar tensões na orientação da fibra em cada uma das camadas do compósito, bem como tensões de cisalhamento interlaminares que surgem nos cilindros com configuração assimétrica. Os resultados dos ensaios mostraram que as configurações de bobinagem exercem influência no comportamento mecânico dos cilindros de material compósito, favorecendo a construção do tipo simétrica. / Dissertacao (Mestrado) / IPEN/D / Instituto de Pesquisas Energeticas e Nucleares - IPEN/CNEN-SP

Ce travail de thèse s’est déroulé dans le cadre du projet de nanolanceur à propulsion hybride PERSEUS du CNES. La performance de ce concept est influencée par l’allègement de la structure du lanceur. La voie de développement qui a été choisie est de supprimer le liner du réservoir composite cryogénique. Elle repose sur trois exigences fonctionnelles : la compatibilité du matériau composite avec l’oxygène liquide (LOX), l’étanchéité du réservoir, et la résistance aux sollicitations thermomécaniques.L’étude de la compatibilité LOX des matériaux composites met en évidence l’importance du transfert de chaleur au sein du composite et plus précisément de la conductivité thermique des fibres. Ce résultat théorique est conforté par l’expérimentation.Le verrou scientifique principal du travail de thèse concerne l'influence de l’endommagement du composite sur la perméabilité de ce dernier. La conception de dispositifs expérimentaux a permis de déterminer l’évolution des endommagements (fissuration transverse, micro-délaminage, ouverture de fissure) et celle de la perméabilité. Un modèle complet de prévision de la perméabilité d’une paroi composite sollicitée thermo-mécaniquement est proposé. Il s’articule autour d’un modèle d’endommagement à l’échelle du pli, d’un modèle de prédiction de l'ouverture des fissures, et d’un modèle d’écoulement en milieu poreux. La pertinence du modèle développé est testée à travers la réalisation d’un démonstrateur technologique sans liner et d’une campagne d’essais d’endommagement et de mesure de perméabilité. / This thesis deals with hybrid propulsion launcher systems studied by the CNES (Centre National d'Etudes Spatiales). The performance of the launcher implies its lightening and in this work, the use of a cryogenic composite linerless tank is evaluated. Three functional requirements must be satisfied: the compatibility between the composite material and the liquid oxygen (LOX), the tank gas-tightness and the strength under pressure.The LOX compatibility of composite materials implies high thermal conductivity of the composite, and consequently of the fiber reinforcement. This theoretical result is confirmed by experiments.The main scientific challenge concerns the damage influence on the composite permeability. Specific experimental devices allow determining the damage evolution (transverse cracking, delamination, opening crack) and the composite permeability. A predictive composite permeability model is applied to a composite wall under thermomechanical load: this model includes a ply-scale damage model, a predictive opening crack model and a model of flow through porous media. The relevance of the model is validated through the realization of a linerless prototype tank and the associated tests which correlate damage and permeability.

The filament-winding process produces quality consistent composite parts for many industries. Filament winding allows for consistent quality parts by automating the winding process. A recent development of filament winding is the Lotus process. The Lotus process reverses conventional filament winding by leaving the mandrel stationary and winding composite fiber around the mandrel. The automated Lotus filament-winding machine is controlled by four-axis control manipulating the Lotus ring around a fixed mandrel. This allows Lotus filament winding to wind parts that do not have a linear axis. Lotus filament winding is in its early stages of development. As a second step in the development of Lotus filament winding a method of automatic part-to-machine manipulation has been developed. Parts wound on the new automatic-manipulated Lotus machine have comparable quality and appearance to those made by conventional winding.

In den letzten 20 Jahren näherte sich der einst nur für die Luft- und Raumfahrt entwickelte kohlenstofffaserverstärkter Kunststoff (CFK) mehr und mehr der industriellen Umsetzung in anderen Bereichen an. Die CFK-Halbzeuge und -Bauteile sind nun auch preislich in der Lage, unter Anwendung angepasster Fertigungsverfahren breiter eingesetzt zu werden. Der Fokus dieser Arbeit richtet sich exemplarisch auf die kosten- und energieeffiziente Herstellung von schnell laufenden CFK-Verbundwalzen und soll aufzeigen, dass Kostenersparnisse über Leane Fertigungsmethoden auch in der FKV-Industrie von großem Vorteil sind. Somit liefert diese Dissertationsschrift einen beispielgebenden Beitrag für den Durchbruch von Faserverbund-werkstoffen im industriellen Bereich. Darüber hinaus werden durch Prozessoptimierung Alternativen aufgezeigt, qualitativ hochwertigere und gleichsam kosteneffiziente Bauteile herzustellen.