Reinforced carbon fiber combined winding layer pattern design of cone-column integrated structure

To address the issues of unsatisfactory thickness distribution in carbon fiber-reinforced winding for cone-cylinder integrated C/C composite preforms and fiber suspension tendency in the negative Gaussian surface transition zone, a combined winding layer pattern design method is proposed. Through force analysis of fibers on the core mold surface, a mathematical model for non-geodesic stable winding of the cone-cylinder integrated structure was derived. Based on this model and combined with the approximate circumcircle theory of the transition zone, the influence mechanism of winding layer thickness on the ultimate winding angle was investigated. Subsequently, the stable winding pattern parameter table of the cone-column integrated structure under different initial conditions satisfying the n-tangent point winding pattern law was obtained. The thickness of the winding layer with different distribution references under different initial conditions in the winding pattern table was simulated and analyzed. The feasibility of optimizing the thickness of the winding layer by different combination methods was explored. The optimal combination of the winding pattern was visually simulated in MATLAB. Experimental results of robotic dry fiber winding indicate no fiber suspension, slippage, or overlapping. Thickness measurement experiments show a maximum thickness error of 0.03 mm, with both winding accuracy and thickness optimization results meeting design requirements. This work verifies the feasibility and accuracy of the proposed combined winding layer pattern design method.