DPP B2(c)

Kolej Kemahiran Tinggi MARA

Masjid Tanah, Melaka

JOB SHEET
DIPLOMA IN POLYMER COMPOSITES
COURSE & CLASS
PROCESSING TECHNOLOGY
SESSION SEMESTER 3
DQP30072 PRESS &
CODE & SUBJECT SHEET NO JS1
FILAMENT WINDING
NO OF STUDENTS WEEK
DURATION VENUE WORKSHOP

LECTURER ROHAIZUAN BIN ROSILLI

FILAMENT WINDING : MACHINE OPERATION AND

TOPIC CONTROL

1.1 Filament winding techniques;

a. Introduction to winding operation and controls
b. Applicable materials
c. Winding angle and fibre orientation
SUB-TOPIC
d. Winding software
e. Types of mandrel
f. Curing process
g. Process advantages and limitations

After completing the subject, the students should be able to

LEARNING
OUTCOME 1. Describe the fundamental aspects of specialised fabrication
techniques commonly employed in composites industry
2. Demonstrate the ability to select and safely use the
processing equipment and tools required for each moulding
technique.
3. Practice and operate filament winding technique and
procedure

Tools/Equipment required:
TOOLS /
EQUIPMENTS / 1. Computerised 4-axes Filament Winding Machine

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MATERIALS : 2. CADWIND Software

DRAWING AND Refer to Filament Winding Operating Manual & CADWIND

DATA : Software Application Manual

Below are instructions to abide for this practical session;

1. Adhere to the safety practices in workshop, handling of
chemicals and usage of personal protective equipment
(PPE)
2. Students are required to follow the steps as described in the
INSTRUCTION :
procedure
3. This is an individual practical exercise for students to acquire
the relevant skills
4. Student are required to send in their individual report at the
end of the practical

PROCEDURE
These are the practical steps to abide during the practical activity:
1. Students should read through the steps described before attempting the practical
activity
2. Plan the work to be carried out in list of priorty
3. Students are required to record their findings in the appropriate appendix and
results column

STEP KEY POINT

Filament Winding Start-up and Operation i. Setup Sequence

Mandrel Assembly:
1. Select the mandrel to be used
2. Adjust the position of the tailstock for mounting of the
desired mandrel
3. Loosen chuck and mount mandrel between tailstock
and machine chuck
4. Tighten the chuck and the tailstock

Fiber Creel Assembly: i. Setup Sequence

1. Check the fiber creel to ensure that the right fiber
bobbins are mounted on the horizontal bobbin holder
2. When required, carefully mount the desired fiber

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STEP KEY POINT

bobbins onto the horizontal bobbin holder i.e glass
roving, carbon rovings etc.
3. Pull the fiber to the fiber guide and through the resin
bath.

Resin Bath Assembly: i. Setup Sequence

1. Assemble all the components of the resin bath i.e drum
roller, doctor blade,springs etc
2. Mount the resin bath assembly on the carriage

Machine Start – up: i. Setup Sequence

1. Switch on the main power
2. Switch on the the CONTROL panel
3. Switch on the computer by pressing the POWER ON
button at the machine controller
4. Switch on the filament winding machine by pressing the
MACHINE START button at the machine controller.
5. Connect the machine and the computer by pressing the
MACHINE ENABLE button at the machine controller.
6. After the computer and the machine is connected,
reposition the carriage at the home position by pressing
the HOME button at the machine controller

Manual Mode of Operation:

1. To manually operate the machine:-
a. To rotate the mandrel, set the mandrel speed using i. Understand the
the knob and push the mandrel joystick either sequence in
clockwise or anticlockwise. operation of Filament
Winding machine
b. Set the machine speed knob to enable the carriage
movement ii. Understand the
function of the
c. To position the carriage horizontally, push carriage
buttons, swicthes,
joystick to move it left or right.
knobs
d. To position the carriage vertically, push carriage
joystick frontward or backwards.
e. To position the winding eye, push the winding eye
joystick either clockwise or anticlockwise.
Note:
In emergency situation , the EMERGENCY STOP
button is located at:-
a. Machine Controller

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STEP KEY POINT

b. Machine Carriage
c. EMERGENCY STOP string at below the
horizontal bed.

Software Control Application i. Understand the

sequence in filament
1. Start the controller software by clicking twice at the icon
winding machine
OR click at the icon and ENTER.
operation
2. From the software mainframe, observe the MENU BAR
ii. Understand the
at the upper side of window mainframe.
function for winding
3. To load a pattern, follow the steps below proces observations.
a. Choose PATTERN..
b. Choose the generated pattern files from the
directories
Example : KKTM 001.dat
Note:
The files was generated and established from the
CADWIND software.
c. Confirm the files by pressing LOAD.
4. At the BUFFER CONTROL sub-windows,
a. Check the buffering number of the loaded file.
Proceed to Step 5 if the buffering number is correct.
b. If the loaded file does not appear at the buffering
number, check the buffering no of the loaded file by
pressing the BUFFER DIRECTORY button. Choose
the buffering number with the loaded file and confirm
by pressing the DONE button.
5. At the ALL TENSION SET sub-windows, set the tension
value to 0.2 lbs.
6. From the FOUR AXES INFO sub-windows, the following
parameters can be observed during the process.
a. Low limit
b. Position
c. Hi-Limit
d. Velocity
7. At the WINDER sub-windows,
a. To start the process, click at the START button. The
loaded file will automatically start the process with
the generated data.

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STEP KEY POINT

b. To hold the process, click at the HOLD button
c. To quit the process, click at the QUIT button.
d. To abort the process, click at the ABORT button.
8. At the MESSAGES sub-window, all the activites of the
machine will be shown online with respond of the
machine activities.
Example :
a. HOMING: the carriage reposition it self to the
original position
b. ERROR:
c. COMPLETE : Processing of the loaded file
completed

Shut-down procedure: i. Proper steps for

machine and
9. Press the QUIT button to ensure all process have
computer shut down.
been stop
10. Close the software control application.
11. Press the STOP button at the machine control panel
to stop the connection between the computer and the
machine.
12. Shut down the computer.
13. Press the OFF button at the control panel.
14. Switch off the main power.

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RESULT :

Notes :
The result shall consists all the keypoints stated above.

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QUESTION/DISCUSSION :

1. Using a simple diagram, name all axis for the machine used in this task.

2. Describe the filament winding process by using a simple flow chart.

3. Name the types of mandrel that can be apply in filament winding process.

4. Using a simple flowchart, describe the software control application from loading
the winding pattern until end of the process.

5. From your opinion, which is more relevant when producing composite pipe using;
a. RTM
b. Filament winding
Give your reason?

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CONCLUSION :

REFERENCE :

Checked by :

Signature :

Name :

Designation :

Date :

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