Composite prepreg tape winding technology has proven to be an effective method for manufacturing revolving body composite structures in aerospace field. Process parameters including heating temperature, tape tension and roller pressure have an important impact on the winding products’ mechanical property such as tensile strength. The aim of this study is to investigate the influence mechanism and optimization analysis of parameters for the composite prepreg tape winding process. Firstly, the sensitivity analysis for single parameter had be employed to reveal the influence mechanism of each winding parameter change on tensile strength. Secondly, iso-surfaces analysis for parameter range had be applied to describe the distribution law of parameter with continuous distribution characteristics. Then the coupling analysis for process parameters was carried out employing response surface methodology. The analysis results showed that tape tension has the most significant effect on the winding products’ tensile strength. And the outstanding parameter combination with the heating temperature of 72 °C, tape tension of 307 N and roller pressure of 1263 N was provided by response surface design software via desirability function method. The validation experiments showed that the optimal parameter combination has a positive guiding significance for improving the quality of winding products.

The existing methods for blade polishing mainly focus on robot polishing and manual grinding. Due to the difficulty in high-precision control of the polishing force, the blade surface precision is very low in robot polishing, in particular, quality of the inlet and exhaust edges can not satisfy the processing requirements. Manual grinding has low efficiency, high labor intensity and unstable processing quality, moreover, the polished surface is vulnerable to burn, and the surface precision and integrity are difficult to ensure. In order to further improve the profile accuracy and surface quality, a pneumatic flexible polishing force-exerting mechanism is designed and a dual-mode switching composite adaptive control(DSCAC) strategy is proposed, which combines Bang-Bang control and model reference adaptive control based on fuzzy neural network(MRACFNN) together. By the mode decision-making mechanism, Bang-Bang control is used to track the control command signal quickly when the actual polishing force is far away from the target value, and MRACFNN is utilized in smaller error ranges to improve the system robustness and control precision. Based on the mathematical model of the force-exerting mechanism, simulation analysis is implemented on DSCAC. Simulation results show that the output polishing force can better track the given signal. Finally, the blade polishing experiments are carried out on the designed polishing equipment. Experimental results show that DSCAC can effectively mitigate the influence of gas compressibility, valve dead-time effect, valve nonlinear flow, cylinder friction, measurement noise and other interference on the control precision of polishing force, which has high control precision, strong robustness, strong anti-interference ability and other advantages compared with MRACFNN. The proposed research achieves high-precision control of the polishing force, effectively improves the blade machining precision and surface consistency, and significantly reduces the surface roughness.

As a significant way to manufacture revolving body composite, the composite prepreg tape winding technology is widely applied to the domain of aerospace motor manufacture. Processing parameters, including heating temperature, tape tension, roller pressure, and winding velocity, have considerable effects on the void content and tensile strength of winding products. This paper was devoted to studying the influence of process parameters on the performances of winding products including both void content and tensile strength and trying to provide the optimal parameters combination for the objectives of lower void content and higher tensile strength. In the experiments, tensile strength and void content were selected as the mechanical property and physical performance of winding products to be tested, respectively. An integrated approach by uniting the Grey relational analysis, backpropagation neural network, and bat algorithm was presented to search the optimal technology parameters for composite tape winding process. Then, the composite tape winding process model was provided by backpropagation neural network utilizing the results of Grey relational analysis. According to the bat algorithm, the optimal parameter combination was heating temperature with 73.8 °C, tape tension with 291.2 N, roller pressure with 1804.1 N, and winding velocity with 9.1 rpm. The value of tensile strength increased from 1215.31 to 1329.62 MPa. Meanwhile, the value of void content decreased from 0.15 to 0.137%. At last, the developed method was verified to be useful for optimizing the composite tape winding process.

The composite tape winding process, which utilizes a tape winding machine and prepreg tapes, provides a promising way to improve the quality of composite products. Nevertheless, the process parameters of composite tape winding have crucial effects on the tensile strength and void content, which are closely related to the performances of the winding products. In this article, two different object values of winding products, including mechanical performance (tensile strength) and a physical property (void content), were respectively calculated. Thereafter, the paper presents an integrated methodology by combining multi-parameter relative sensitivity analysis and single-parameter sensitivity analysis to obtain the optimal intervals of the composite tape winding process. First, the global multi-parameter sensitivity analysis method was applied to investigate the sensitivity of each parameter in the tape winding processing. Then, the local single-parameter sensitivity analysis method was employed to calculate the sensitivity of a single parameter within the corresponding range. Finally, the stability and instability ranges of each parameter were distinguished. Meanwhile, the authors optimized the process parameter ranges and provided comprehensive optimized intervals of the winding parameters. The verification test validated that the optimized intervals of the process parameters were reliable and stable for winding products manufacturing.