Optimization and experimental validation of reinforcing fibers winding pattern for carbon/carbon composite crucible preform

In order to address the problem of transition slip between the cylindrical segment and the ellipsoidal head segment of the carbon/carbon composite crucible preform with asymmetrical structure during the winding process, a winding pattern combining geodesic and non-geodesic is presented innovatively. Firstly, the formulae for the winding angle and the winding central rotation angle of the crucible cylindrical segment and the ellipsoidal head segment are established, and the fourth-order Runge-Kutta numerical method is employed for parametrical design. The two-tangent point winding path is determined by analyzing the effect of the cylindrical segment’s winding pitch, different ellipsoidal head segment heights, and slip coefficient on the winding angle. Secondly, the needle disk winding method is proposed to address the slight winding angle at the open end of the cylinder, making it easier to hang the yarn. Finally, the experiment on dry yarn winding of 3k carbon fiber (linear density: 198 g/km) is carried out. The results indicate that the relative error rate between the actual winding angle and the theoretical design angle differs by no more than 1.66%, demonstrating that carbon fibers can be stably and uniformly wound onto the surface of the carbon/carbon composite crucible preform. Compared to the traditional manual winding method, the winding pattern enhances winding efficiency, ensures carbon fibers’ uniformity and structural stability, and provides a new technological approach to producing high-performance composite materials.