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I ended up replacing the last “12mm” cylindrical section and replacing it with a modified version. This was done because we\u00a0realised that because the carbon fiber layup at the tip is going to be thicker than at the other end, we need to compensate for this with a narrower Mandrel – else we will NOT get the cone shape we are after. The Nose Cone would have been concave.<\/p>\n
The Laydown of Carbon Fiber<\/h2>\n
Working out the mathematics for laying down the Carbon Fiber has been a challenge. The Carbon Fiber needs to follow straight lines (geodesics) to ensure minimal slippage of Carbon Fiber to produce the best Nose Cone possible.<\/p>\n
There is more to the conical section of the Nose Cone, there is also the Cylindrical part. The Carbon Fiber from the Cylindrical part needs to “marry up” with the Carbon Fiber of the Cone part – no horribly bunching up. i.e. we need to continuous (well-formed) surface to wind around and for the CF Angle (with respect to the mandrel axis) to be the same at the interface.<\/p>\n
Initially, we tried:-<\/p>\n
- \n
- 0 degrees<\/li>\n
- 90 degrees<\/li>\n
- 180 degrees<\/li>\n
- 270 degrees<\/li>\n
- 360 degrees (back to the beginning)<\/li>\n<\/ul>\n
On the 5th pass, we move the Advancement angle amount. Then I thought it would be good to try and reduce the bunching of Carbon Fiber at the tip by having some adjacent CF. By having adjacent, we effectively double the width of the Carbon Fiber.<\/p>\n
- \n
- 0 degrees – 160mm from tip<\/li>\n
- 0 degrees – 165mm from tip<\/li>\n
- 90 degrees – 160mm from tip<\/li>\n
- 90 degrees – 165mm from tip<\/li>\n
- 180 degrees\u00a0– 160mm from tip<\/li>\n
- 180 degrees\u00a0– 165mm from tip<\/li>\n
- 270 degrees\u00a0– 160mm from tip<\/li>\n
- 270 degrees\u00a0– 165mm from tip<\/li>\n
- <<ADVANCE TWO x advancement amounts>><\/li>\n
- 360 degrees (back to the beginning)<\/li>\n<\/ul>\n
In 2-D it looks like: –<\/p>\n
![\"Sample](\"http:\/\/leederville.net\/rocket\/wp-content\/uploads\/CF_Pattern_2d.png\")
<\/a>Sample of how CF TOW passes are done in 2D. Obviously there would be more.<\/figcaption><\/figure>\n In the end, decided to not have adjacent CF laydowns and instead space them around the whole Nose Cone. This seems to produce a more even layup.<\/p>\n
It was calculated that we needed 45.1 passes to cover the Cone. We decided to go for 48. This is a nice number and the additional passes ensure coverage.<\/p>\n
We use a function to help “spread” the laydowns around the nose cone, so it wasn’t one next to the previous one.<\/p>\n
So it was<\/p>\n
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