Fibre Tension-Induced Stresses in Filament-Wound Composites

Fibre tension is an important process parameter during filament winding. It strongly affects the void content and fibre volume fraction, which in turn determine the mechanical performance of the part. Fibre tension also contributes to the residual stresses that develop in the filament-wound material. This study focuses on how the fibre tension shapes the stress distribution in filament-wound composites. To this end, a numerical predictive model was developed. Experimental validation was conducted using a force sensor, and good agreement was observed between the model predictions and the experimental measurements. These findings provide deeper insight into the role of fibre tension in filament winding and offer practical guidance for optimising the process to enhance the performance of composite pressure vessels.