An Interlacing-Aware Thickness-Prediction Method for Filament-Wound Shells with Multi-Tangent-Point Patterns
摘要
Filament-wound composite shells exhibit thickness nonuniformity because helical tows interlace and overlap on the mandrel surface, creating localized crossover regions that affect the thickness and stiffness distribution, and consequently influence failure behavior and load-carrying capacity. Conventional thickness-prediction methods typically ignore the effect of tangent-point number, which controls the crossover density and can therefore cause non-negligible underprediction for multi-tangent-point winding patterns. This work develops an interlacing-aware analytical thickness-prediction framework. First, a reduced local analytical model is introduced to quantify the additional thickness in representative circumferential and longitudinal interlacing/overlap regions. Second, the areal distribution of these regions is linked to the tangent-point number to construct a shell-scale thickness-correction coefficient, which is embedded into conventional cylindrical- and dome-thickness formulations to obtain an interlacing-corrected thickness distribution. The approach is validated against published measurements and our winding experiments for shells with different geometries and tangent-point numbers: the prediction error for local interlacing regions is below 6%, and the mean cylindrical-thickness error is below 2%. For dome sections, the proposed correction improves agreement with measurements compared with the conventional cubic-spline method, especially when the tangent-point number is large. The method provides a practical basis for geometric modeling and process-parameter design of filament-wound composite shells.