Proceedings of the Institution of Mechanical

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Engineering Science
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Predicting winding stresses for wound coils of non-linear orthotropic material

F R de Hoog, W Y D Yuen, M Cozijnsen and H-N Huynh
Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 2004 218:
27
DOI: 10.1243/095440604322786929

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 27

Predicting winding stresses for wound coils of

non-linear orthotropic material

F R de Hoog1, W Y D Yuen2* , M Cozijnsen2 and H-N Huynh1

1
CSIR O M athematical and Information Science, Canberra, Australian Capital Territory, Australia
2
BHP Steel R esearch Laboratories, Port K embla, N ew South Wales, Australia

Abstract: In another work, the authors presented an analysis of stresses in wound coils under the
assumption that the coil could be modelled as an orthotropic linear material. In this paper the authors
extend the theory to the case where the constitutive relations of the coil material are non-linear. The
approach adopted for both the linear and non-linear theory differs radically from that usually
reported in this
eld of research. Instead of the traditional ‘forward solution’ of calculating stresses
for a given winding policy, an ‘inverse solution’ is obtained in which the winding stresses required to
achieve speci
ed stress distributions in a coil are calculated. Stress distributions required to avoid
coiling problems can often be speci
ed. This method can therefore offer considerable advantages in
industrial applications, since winding stresses required to achieve a speci
ed stress distribution in a
coil can be calculated directly. The non-linear solutions are compared to those for the linear case for
different winding stresses and coil properties. An example of the effect of modifying the stress
distribution in a coil on the winding stress is given to illustrate the advantage of this method.

Keywords: winding stresses, winding, coil collapse, coiling, non-linear material

NOTATION Ro outer radius of the completed coil

…R ¡ R c †=h0 number of wraps in the coil
E azimuthal modulus of coiled material Sm strain energy in the mandrel
Ec effective modulus of the core (former tg gap thickness
and mandrel) ts sheet thickness
Eg modulus of the gap u radial displacement ˆ u…R , r†
qf
f …sr , sy † ˆ stress–strain relation b non-dimensional parameter (plane
qsy
qF …1 ¡ n2 †E c
F…er , ey † ˆ stress–strain relation strain) ˆ
qey E ‡ n…1 ‡ n†E c
g~ …p† term in the simpli
ed stress–strain er radial strain ˆ qu=qr
relationship er ˆ g…sr , sy † stress–strain relation
qf ey azimuthal strain ˆ …r ‡ u ¡ r†=r
g…sr , sy † ˆ stress–strain relation ey ˆ f …sr , sy †
qsr stress–strain relation
qF r radius of the …r ¡ R c†=h0 wrap if it were
G…er , ey † ˆ stress–strain relation unconstrained
qer
h0 thickness of unconstrained wra p s
^r target radial stress
p^ target inter-wrap pressure sw …R † winding stress
r radial coordinate s
^y target azimuthal stress
r‡u radius of the …r ¡ R c †=h0 wrap f…sr , sy † strain energy density
…r ¡ R c†=h0 wrap number, R c 4 r 4 R F…er , ey † strain energy density
R outer radius of the coil during winding n Poisson ratio of the coiled material
Rc radius of the core (former and mandrel)

T he M S was received on 15 A ugust 2002 and was accepted after revision
for publication on 16 S eptember 2003.
* Corresponding author: BHP S teel R esearch L aboratories, PO Box
202, Port Kembla, N S W 2505, A ustralia.
1 INTRODUCTION
This paper details the extension of another work by
the authors on stresses in wound coils {1}, which

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28 F R de HOOG , W Y D YU EN, M COZIJN SEN AN D H -N HUYN H
investigated winding policies to achieve a target inter-
wrap stress distribution under the assumption that the
coil could be modelled as a linear orthotropic material.
Speci
cally, it extends this work to the case where the
constitutive relation is non-linear. The new model also
includes non-linearities due to large displacements,
which are important for ‘soft’ materials such as paper
and plastics. H owever, as the primary motivation for
this study was to develop winding policies for metal coils
where these effects are not important, the focus will be
on the case when displacements are small. F or the same
reason, the model development focuses on the case
where the material is assumed to be in plane strain. The
analysis is essentially the same for plane stress.
As described in reference {1}, wound coils or rolls
store essentially at strip compactly without folding or
cutting and typically strip is wound and unwound a
number of times before its end use. The variety of
material that is wound into coils or rolls is very extensive
and includes magnetic tape, paper, cellophane, plastics,
fabric and metals such as aluminium and steel.
G enerally, coils are wound on to a core which typically
consists of a mandrel and former, as shown in F ig. 1,
which illustrates centre winding. Often, the mandrel is
removed after the coil is wound (as shown in F ig. 2) and
unwinding takes place on another mandrel. H owever,
there are a number of other ways that coils or rolls can
be wound, including surface winding, where the coil is
nipped by an exterior roll which is driven, or a
combination of centre and surface winding. A good
overview of the various winding methodologies may be
found in R oisum {2}.
Stresses wound into a coil provide its structural
integrity via the frictional forces between the wraps. F or
a coil with inadequate inter-wrap pressure, the wraps
may slip or telescope (causing surface scuf
ng) or the
coil may slump and collapse. On the other hand, large
internal stresses can cause increased creep and stress
relaxation phenomenon, collapse at the bore, stress
wrinkling and rupture of the material in the coil.
In reference {1}, the material was modelled as a linear
orthotropic material with small displacements. The
Fig. 1 Schematic of centre winding
Proc. Instn M ech. Engrs Vol. 218 Part C: J. M echanical Engineering Science
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main result was the derivation of a winding policy that
ensures a target inter-wrap pressure distribution at some
speci
ed time in a coil’s history, such as when the
mandrel is removed. Essentially, it complements the
theory developed by Altmann {3}, who derived simple
analytic formulae for the stress distribution for a given
winding policy. Thus, Altmann’s results can be thought
of as solving a ‘forward’ problem while the results in
reference {1} solve the ‘backward’ problem.
Although the solution derived under the assumption
of a linear stress–strain constitutive relation gives stress
distributions that are qualitatively correct (particularly
for materials that are not too ‘soft’, such as metal strip),
experiments with coiled material have demonstrated
marked deviation from linearity. Indeed, experiments
show clear evidence of hysteresis so that even the
assumption of an elastic material is strictly incorrect.
N evertheless, models that incorporate a non-linear
elastic stress–strain relationship do appear to mimic the
measured inter-wrap pressure quite well for the ‘forward’
problem. This has motivated the present work, which
addresses the ‘backward’ problem for such materials. As
mentioned in reference {1}, this problem appears to have
received relatively little explicit attention in the literature,
although the closely related problem of determining
appropriate winding policies has been addressed pre-
viously in H udzia et al. {4} and Cozijnsen and Yuen {5}.
It should be borne in mind that various extensions to
the theory of forward ‘coil winding’ have been proposed
to account for:
(a) relaxation effects, which are important in the
storage of magnetic tape {6–8};
(b) non-linear material properties {9, 10};
(c) large deformations, which are important for ‘soft’
materials such as paper and plastics {11, 12};
(d) air entrapment, which is important in high-speed
coiling {13, 14};
(e) centrifugal forces, which are important in high-
speed coiling {15–17}; and
(f ) three-dimensional effects {18–20}.
Clearly, there is also scope for extending the theory for
the inverse problem developed in this paper to include
some of the additional extensions listed above.
M uch of the work in the literature on coil winding is,
in the authors’ view, somewhat unsatisfactory in the
sense that it is based on discrete models (this is logical
since the wrap has a
nite thickness) and takes the form
of pseudo computer algorithms. As a consequence, the
models are often quite dif
cult to assess, particularly for
the case of
nite displacement where there is a need to
keep track of second-order terms. Almost always, the
discretization used in practice does not correspond to
the physical dimension (i.e. the wrap thickness), which
means that the results are meaningless unless the
nite
models converge to a continuous model in the limit
when the wrap thickness goes to zero. The authors
C13102 # IMechE 2004
 PR EDICTING WINDING STRESSES F OR WOUND COILS OF NON -LINEAR ORTH OTR OPIC M ATER IAL
Fig. 2 Schematic of the completed coil removed from the mandrel
believe that it is preferable to start with a continuous
model. H ence the coil material has been modelled as an
elastic continuum in plane strain using an energy-based
approach, which has the advantage that the develop-
ment of equations for large displacements is relatively
straightforward. H owever, the case of small displace-
ments is focused here as the authors’ primary interest is
in coils of relatively ‘hard’ materials such as metal strip.
Substantial work has been done in determining stress
distributions in coils. Of equal importance, but receiving
little attention, is the effect of residual stresses on coil
collapse, particularly coil slump and tight-bore collapse.
Coil slump can be attributed to inter-wrap movement
resulting from inadequate frictional forces between
wraps. Tight-bore collapse is caused by excessive
compressive stresses near the bore, which lead to
buckling of the inner wraps once the mandrel is
removed. Industrial applications require knowledge of
appropriate winding tensions required for the coiling of
strip (see, for example, references {4}and {5}). By relating
residual stresses to the tight-bore collapse phenomenon,
it has been possible to determine optimum/appropriate
coiling tension pro
les to alleviate coil collapse pro-
blems. This work involved calculating stress distribu-
tions for various winding stress pro
les and checking the
residual stresses against the coil collapse criterion.
The approach in this paper differs radically from
others. Instead of determining the stress distributions
for a given coiling tension pro
le, the coiling tension
required to give a desired stress distribution in the coil is
calculated. This approach has the advantage of being
able to specify stress distributions required to avoid
collapse problems and determining the appropriate
coiling tension to achieve this directly. N ote, however,
that the inter-wrap pressure for a given tangential stress
is not arbitrary, but has to satisfy the equilibrium
equation for stresses.
C13102 # IM echE 2004
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29
2 FUNDAM ENTAL RELATIONSHIPS
Because winding of the coils is under tension (pre-
stressed), the de
nition of strains requires some care.
The current approach is to consider a
xed domain
R c 4 r 4 R 4 R 0 , where R c is the undeformed radius of
the core (the former and/or mandrel) and the radial
coordinate r de
nes a particular wrap (see F igs 1 and 2).
Speci
cally, r denotes the ‰…r ¡ R c †=h0 Šth wrap, where h0
is the wrap thickness in the unstressed state. {N ote,
however, that r is not the radial position in the physical
coil, which is deformed. In fact, the radius of the
‰…r ¡ R c †=h0 Šth wrap is r ‡ u…r, R †.} Similarly, the
current coil consists of …R ¡ R c †=h0 wraps while the
completed coil consists of …R o ¡ R c †=h0 wraps.
With the assumption of plane strain, axial symmetry
and the existence of a strain energy density function F, it
follows (see, for example, Washizu, p. 580 {21}) that
qF
sr ˆ …1 ‡ er †sr ˆ : G…er , ey † …1†
qer
qF
sy ˆ …1 ‡ er †sy ˆ : F…er , ey † …2†
qey
where sr and sy are the stresses in the undeformed
coordinate system (known as
rst Piola–K irchhoff stress
tensors) and sr and sy are the stresses in the deformed
coordinate system (known as second Piola–K irchhoff
stress tensors). N ote that
qG qF
ˆ …3†
qey qer
which, for linear stress–strain relationships, constrains
the radial and axial Poisson ratios, i.e. the radial and
axial Poisson ratios are not independent elastic con-
stants.
Proc. Instn M ech. Engrs Vol. 218 Part C: J. M echanical Engineering Science
30 F R de HOOG , W Y D YU EN, M COZIJN SEN AN D H -N HUYN H

Equation (1) can be inverted and the strains can be gives

written in terms of the stresses as µ ¶
q qF qF
0ˆ¡ r…r† ‡
er ˆ g …s r , s y † …4† qr qer qey
µ
´¶
ey ˆ f …s r , s y † …5† q qu…R, r† r ‡ u…R , r† ¡ r…r†
ˆ¡ r…r†G ,
qr qr r…r†

´
and these relationships must satisfy qu…R , r† r ‡ u…R , r† ¡ r…r†
‡F , …13†
qr r…r†
qg qf
ˆ …6† F rom the de
nitions of G and F given by equations (1)
qsy qsr
and (2) respectively,
In fact, if the strain energy density is written in terms of q
the stresses ¡ ‰r…r†sr …R , r†Š ‡ sy …R , r† ˆ 0 …14†
qr

f…sr , sy † : F…g…sr , sy †, f …sr , sy †† …7† Equation (14) can be viewed as either a second-order
equation for u (technically a partial differential equa-
then tion, but really an ordinary differential equation for

xed R ) or as an equilibrium equation that gives a
qf constraint on the stresses. In addition, boundary terms
er ˆ …8† from the variation yield
qsr
qf At r ˆ R c :
ey ˆ …9†
qsy 0
2pr…r†sr …R , r† ˆ S m …r…r†f …sr …R , r†, sy …R, r††
As discussed in another paper {1}, the azimuthal strain, ¡ …r ¡ r…r††† …15†
ey , and radial strain, er , are related to the radial
displacement of a particular wrap, u, by {where equations (5) and (10) have been used to
substitute for u…R , r†} and
r ‡ u ¡ r…r† At r ˆ R :
ey ˆ …10†
r…r†
sr …R , r† ˆ 0 …16†
qu
er ˆ …11†
qr On the outer radius R , the azimuthal stress, sy …R , r†, is
speci
ed, i.e.
where r…r† is the radial location of the wrap if it were not
constrained by wraps that had been wound into the coil At r ˆ R :
previously.
sy …R , r† ˆ sw …R † …17†

where sw …R † is the winding stress at radius R . In some

instances, it is convenient to rewrite the boundary
condition (15) by noting that sr …R, R c† ! 0 and
3 NON-LINEAR FORMULATION u…R , R c † ! 0 as R ! R ‡
c . Thus, by combining equations
(5) and (10) at r ˆ R c,
3.1 Forward problem
R c ¡ r…R c† ˆ r…R c †f …0, sw …R c †† …18†
The strain energy in the coil and mandrel is
from which
…R
S …R † ˆ 2p r…r†F…er …R , r†, ey …R, r†† dr ‡ S m ‰u…R , R c †Š At r ˆ R c :
Rc
…R
´ 0
2pr…r†sr …R , r† ˆ S m …r…r†f …sr …R , r†, sy …R, r††
qu…R , r† r ‡ u…R , r† ¡ r…r†
ˆ 2p r…r†F , ¡ r…r†f …0, sw …R c ††† …19†
Rc qr r…r†
6dr ‡ S m …u…R , R c †† …12†
U sing the de
nitions of er and ey given by equations (10)
and (11),
where S m is the strain energy in the mandrel due to
compression by the coil. At equilibrium this energy is a q d
‰r…r†ey …R , r†Š ¡ er …R , r† ˆ ‰r…r† ¡ rŠ …20†
minimum. Thus, taking the variation with respect to u qr dr

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 PR EDICTING WINDING STRESSES F OR WOUND COILS OF NON -LINEAR ORTH OTR OPIC M ATER IAL 31

from which it follows that and

q sy …R , r† ˆ sw …R † …29†
‰r…r†f …sr …R , r†, sy …R , r††Š ¡ g…sr …R , r†, sy …r, R ††
qr
d At r ˆ R c :
ˆ ‰r…r† ¡ rŠ …21†
dr 0
2prsr …R , r† ˆ S m …r‰ f …sr …R , r†, sy …R, r††
The above gives a system of two
rst-order differ- ¡ f …0, sw …R c ††Š† …30†
ential equations, equations (14) and (21), and three
boundary conditions, equations (16), (17) and (19), to in terms of the stresses and, from equations (22) to (25),
determine the unknowns sr …R , r†, sy …R , r† and r…r†. Two µ
´¶
q qu…R , r† r ‡ u…R , r† ¡ r…r†
boundary conditions are used for the solution of the ¡ rG ,
qr qr r
differential equation, while the extra boundary condi-
´
tion can be used to determine r…r†. qu…R , r† r ‡ u…R , r† ¡ r…r†
‡F , ˆ0 …31†
The problem may also be formulated in terms of the qr r
displacement u…r, R †. Speci
cally {by substituting equa-
tions (1) and (2) and (10) and (11)}, subject to the boundary conditions
µ
´¶ At r ˆ R :
q qu…R , r† r ‡ u…R , r† ¡ r…r†
¡ r …r†G ,
´
qr qr r…r† qu…R , r† r ‡ u…R , r† ¡ r…r†

´ G , ˆ0 …32†
qu…R, r† r ‡ u…R , r† ¡ r…r† qr r
‡F , ˆ0 …22†
qr r…r†
and
subject to the boundary conditions
´
qu…R , r† r ‡ u…R , r† ¡ r…r†
F , ˆ sw …R† …33†
At r ˆ R : qr r

´
qu…R, r† r ‡ u…R , r† ¡ r…r† At r ˆ R c :
G , ˆ0 …23†
qr r…r†
´
qu…R , r† r ‡ u…R , r† ¡ r…r†
2prG ,
and qr r

´ 0
qu…R, r† r ‡ u…R , r† ¡ r…r† ˆ Sm …u…R, R c†† …34†
F , ˆ s w …R † …24†
qr r…r†
in terms of the displacement.
At r ˆ R c :

´
qu…R , r† r ‡ u…R , r† ¡ r…r†
2pr…r†G ,
qr r…r†
0
ˆ Sm …u …R , R c †† …25† 3.3 Constitutive equations—forward problem

U nder the plane strain condition and assuming that

displacements are small, the strain energy of the
mandrel, S m , and the radial and azimuthal strains, er
3.2 Small displacements—forward problem and ey , are given by

´2
In this case, by neglecting second-order terms and from u
equations (14), (21), (16), (17) and (19), S m …u† ˆ pR 2c E c …35†
Rc
q n…1 ‡ n†sy …R , r†
¡ ‰rsr …R, r†Š ‡ sy …R , r† ˆ 0 …26† er ˆ ¡ g~…p…R , r†† ¡ …36†
qr E
q
‰rf …sr …R, r†, sy …R , r††Š ¡ g…sr …R, r†, sy …R , r††
qr n…1 ‡ n†p…R , r† …1 ¡ n2 †sy …R , r†
ey ˆ ‡ …37†
d E E
ˆ ‰r…r† ¡ rŠ …27†
dr
where the radial stress, sr …R , r† has been replaced by the
subject to the boundary conditions inter-wrap pressure, p…R , r†:
At r ˆ R : p…R , r† ˆ ¡ s r …R , r† …38†
sr …R , r† ˆ 0 …28† E is the Young modulus of the coil material and n is a

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32 F R de HOOG , W Y D YU EN, M COZIJN SEN AN D H -N HUYN H

Poisson ratio. These are the most common assumptions (45) to (48) with respect to R ) to obtain
made in modelling of stresses in wound coils.  µ ¶¼
q q qp…R , r†
F rom equations (26) and (38), ¡ r r
qr qr qR
q E q~ g…p…R , r†† qp…R, r†
‰rp…R , r†Š ‡ sy …R , r† ˆ 0 …39† ‡ ˆ0 …49†
qr 1 ¡ n2 qp qR
and from combining equations (27), (4), (5), (39), (36) subject to the boundary conditions
and (37),
At r ˆ R :
q E
…rsy …R , r†† ‡ g~…p…R , r†† qp…R , r† sw …R †
qr 1 ¡ n2 ˆ …50†
E d qR R
ˆ ‰r…r† ¡ rŠ …40†
1 ¡ n2 dr At r ˆ R c :
µ ¶
subject to the boundary conditions qp…R , r† q qp…R , r†
¡b r ˆ0 …51†
At r ˆ R : qR qr qR

p…R, r† ˆ 0 …41† This form of equations represents the continuum limit

for the standard incremental formulation where ‘wraps’
and of thickness dR are added sequentially to the coil. The
solution to this system of equations represents the
sy …R , r† ˆ sw …R † …42† traditional ‘forward non-linear solution’ in which the
stresses in the coil are calculated from a speci
ed
At r ˆ R c : winding stress pro
le.
p…R, r† ‡ b‰sy …R , r† ¡ sw …R c †Š ˆ 0 …43†

where 3.4 Inverse problem

…1 ¡ n2 †E
c U p to this point, only the forward problem has been
bˆ …44†
E ‡ n…1 ‡ n†E c considered and the inverse problem is now examined.
Consider a target inter-wrap pressure p^…r† {or equiva-
H ere equation (43) has been obtained from equations lently the radial stress s^ r …r† ˆ ¡ p^…r†} for the coil after
(28), (29) and (38) and by using equations (5), (10) and winding is completed. The case when the mandrel has
(35) in equation (30). been removed will be focused, although the target inter-
F urther, sy can be eliminated {using equation (39)}to wrap pressure for the coil on the mandrel can equally be
obtain examined. The crucial thing is that only the boundary
 ¼ conditions change and that the equilibrium position r of
q q E
¡ r ‰rp…R , r†Š ‡ g~…p…R , r†† an unconstrained wrap is unchanged. As discussed
qr qr 1 ¡ n2
earlier, the residual stresses in the coil must satisfy {see
E d equations (14) and (21)}
ˆ ‰r…r† ¡ rŠ …45†
1 ¡ n2 dr
d
¡ ‰r…r†^
s r … r† Š ‡ s
^ y … r† ˆ 0 …52†
subject to the boundary conditions dr
d
At r ˆ R : ‰r…r†f …s
^ r …r†, s
^ y … r† † Š ¡ g … s
^ r …r†, s
^ y …r††
dr
p…R, r† ˆ 0 …46† d
ˆ ‰r…r† ¡ rŠ …53†
dr
and
and from equation (18)
q
‰rp…R , r†Š ˆ ¡ sw …R† …47† Rc
qr r…R c † ˆ …54†
1 ‡ f …0, sw …R c ††
At r ˆ R c :
which is an algebraic differential equation from which,
 ¼
q ^ y …r† and r…r† can be determined if the
in principle, s
p…R, r† ¡ b ‰rp…R , r†Š ‡ sw …R c † ˆ0 …48† winding stress sw …R c † at the mandrel is given. As for the
qr
linear case discussed in de H oog et al. {1}, the winding
and r can be eliminated (by differentiating equations stress at the mandrel is arbitrary. Once the target hoop

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 PR EDICTING WINDING STRESSES F OR WOUND COILS OF NON -LINEAR ORTH OTR OPIC M ATER IAL 33

stress s
^ y …r† and equilibrium position r…r† are known, the As for the forward problem, using equations (4), (5),
stresses during winding can be calculated from equa- (36) and (37) in equation (57) gives
tions (14) and (21), subject to the boundary conditions
q E
given by equations (16) and (19). The required winding ‰rsy …R , r†Š ‡ g~…p…R , r††
stress is simply sw …R † ˆ sy …R , R † {see equation (17)}. qr  1 ¡ n2 ¼
q E
¡ sy …R , r†Š ‡
‰r^ g~…p^…R, r†† ˆ 0 …60†
qr 1 ¡ n2
3.5 Small displacements—inverse problem where g~ is given by equation (58).
Equations (59) and (60), with the boundary condi-
U nder the assumption of small displacements, the
tions given by equations (41) and (43), can be solved for
inverse problem uncouples substantially. F rom equa-
sy …R, r† {and p…R , r†}. The required winding stress is then
tions (52) and (53),
given by sw …R † ˆ sy …R , R †. This system of equations
d contains the arbitrary constant sw …R c †, the winding
¡ ‰r^
s r … r† Š ‡ s
^ y … r† ˆ 0 …55† stress at the core, as a term in the boundary condition.
dr
d d
‰rf …s
^ r …r†, s
^ y … r† † Š ¡ g … s ^ y …r†† ˆ ‰r…r† ¡ rŠ
^r …r†, s
dr dr
…56† 4 RESULTS AND APPLICATIONS

from which explicit expressions for s

^y …r† and r…r† can be
4.1 Comparison between the forward and inverse
obtained. By equating equation (27) with (56),
solutions
q
‰rf …sr …R, r†, sy …R , r††Š ¡ g…sr …R , r†, sy …R, r†† The following comparison has been used to validate the
qr above theory. The residual stresses are calculated for a
d
ˆ ‰rf …s ^r …r†, s
^ y …r††Š ¡ g…s
^ r …r†, s
^ y … r† † …57† speci
ed winding stress pro
le for the ‘non-linear
dr forward model’ of section 3.3 and as described in
reference {5}. U sing the residual stresses (after mandrel
removal) as target stresses, the winding stress pro
le
3.6 Constitutive relations—inverse problem required to produce these stresses is then calculated
from the ‘inverse solution’ described in section 3.6 and
The constitutive relationships for the mandrel and coil
compared to the speci
ed winding stress. F igure 3 shows
material properties used are the same as for the forward
the results for two different types of winding stress
problem and given by equations (35) to (37) {with the
pro
les: (a) constant winding stress and (b) high winding
radial stress sr …R , r† replaced by the inter-wrap pressure
stress at the bore of the coil followed by a sharp drop to
p…R , r† of equation (38)}. The form of g~…p† in equation
a constant nominal winding stress throughout the rest of
(36) used here is given by
the coil. The latter pro
le is typically used for thin-gauge
µ
´¶ coil in order to prevent/alleviate coil collapse problems.
…1 ¡ n2 †p t g p
g~… p† ˆ ‡ 1 ¡ exp ¡ …58† Table 1 lists the material constants used for the
E ts Eg
calculations. As can be seen from F ig. 3, the calculated
where E is the Young modulus of the coil material, t s is winding stress pro
les agree very well with the speci
ed
the strip thickness, E g is the gap modulus and t g is the ones.
gap thickness (at zero pressure) between the metal
sheets. In particular, …E g†¡1 is a measure of the
compressibility of the coil; the larger this value the 4.2 Comparison between the non-linear and linear
more compressible (i.e. ‘soft’) is the coil. The above ‘forward solution’
constitutive relationship for the coil material has been
developed for metal strip and is discussed by Cozijnsen Stress distributions were calculated for winding stress
and Yuen {5} and Wadsley and Edwards {22}. pro
les typically used for thin-gauge metal strip using
The winding stress is calculated by solving equations the non-linear ‘forward’ model. These were compared to
(26), (55) and (57), subject to the boundary conditions the corresponding linear ‘forward solutions’. F igures 4
given by equations (28) and (30). F or the constitutive and 5 show the results for different winding stresses as
relations of the coil material, the system of equations to well as coils with different values of the elastic modulus
be solved can be written by combining equations (26) of the gaps between the wraps, E g. The other material
and (55): constants are given in Table 1.
 ¼ The differences between the linear and non-linear
q d
‰rp…R , r†Š ‡ sy …R , r† ¡ ‰r^
p … r† Š ‡ s
^ y …r† ˆ 0 …59† models are largest for high winding stresses and fairly
qr dr ‘soft’ coils, i.e. coils with a low value of E g. The non-

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34 F R de HOOG , W Y D YU EN, M COZIJN SEN AN D H -N HUYN H

Fig. 3 Comparison of speci
ed and calculated winding stresses for two different winding tension pro
les

linearity arises from the pressure dependence of the
function g~ in the radial stress–strain relationship
{equation (36)}. H igh winding stresses result in high
inter-wrap pressures while ‘soft’ coils have low values
for E g. Both result in large values of p/E g in the
exponential term of g~ {equation (58)}.
4.3 Comparison between the non-linear and linear
‘inverse solution’
Calculations for the inverse model, i.e. calculation of
the winding stress required to achieve speci
ed stress
distributions in the coil, are now compared to the
linearized model (valid for small inter-wrap pressures).
F or the linear case, g~…p† can be approximated by
t gp
g~…p†& …61†
t sEg
These linear calculations are equivalent to the ‘inverse
solution’ for the linear model described in reference {1}.
F or this comparison the non-linear inter-wrap pressure
and hoop stress distributions after mandrel removal of
F igs 4 and 5 were used as target stresses for both the
non-linear and linear inverse model. The results are
given in F igs 6 and 7. Again the largest differences
between the non-linear and linear solutions occur for
high winding stresses and fairly ‘soft’ coils (i.e. with a
low value of E g). As expected, the non-linear model
predicts a lower winding stress as the coil material
becomes ‘harder’ as the inter-wrap pressure increases.

Table 1 M aterial constants used in the calculations (Poisson’s

ratio has been set equal to zero for these calculations; 4.4 Effect of target stresses on the winding stress pro
le
hence the results are valid for both plane strain and
plane stress) The inverse model has the advantage of being able to
predict the winding stress required to achieve desired
Radius of the bore Rc 250 mm
Outer radius of the coil Ro 750 mm stress distributions in coils. Once limits on residual
Elastic modulus of the mandrel Ec 100 GPa stresses required to alleviate potential problems in coils
Elastic modulus of the coil in the tangential direction E 200 GPa during and after coiling have been determined, the
Poisson’s ratio of the coiled material n 0
required winding stress pro
les can be determined

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 PR EDICTING WINDING STRESSES F OR WOUND COILS OF NON -LINEAR ORTH OTR OPIC M ATER IAL 35

Fig. 4 Comparison of the inter-wrap pressure and hoop stress distribution for the non-linear and linear
‘forward solutions’ for low and high nominal winding stresses (sw/s0 as for F ig. 3b, E g ˆ 10 M Pa,
t g ˆ 2 mm)

Fig. 5 Comparison of the inter-wrap pressure and hoop stress distribution for the non-linear and linear
‘forward solutions’. Case (a) is for a coil with low compressibility, i.e. high value of E g. Case (b) is for
a coil with a low value of E g. Both cases have the same winding stress pro
le sw as for F ig. 3b and
t g ˆ 0.5 mm

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36 F R de HOOG , W Y D YU EN, M COZIJN SEN AN D H -N HUYN H

Fig. 6 Comparison of the winding stress using the non-linear and linear inverse models for (a) a low nominal
winding stress and (b) a high nominal winding stress. The non-linear interwrap pressure distribution
after mandrel removal of F ig. 4 was used as the target residual stress pro
le for both linear and non-
linear solutions (E g ˆ 10 M Pa and t g ˆ 2 mm)

Fig. 7 Comparison of the winding stress using the non-linear and linear inverse models. Case (a) is for a coil
with low compressibility, i.e. a high value of E g. Case (b) is for a coil with a low value of E g. Both cases
have the non-linear interwrap pressure distribution after mandrel removal of F ig. 5 as the target
residual stress pro
le and t g ˆ 0.5 mm

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 PR EDICTING WINDING STRESSES F OR WOUND COILS OF NON -LINEAR ORTH OTR OPIC M ATER IAL 37

Fig. 8 Effect of the target hoop stress distribution on the required winding stress pro
le

directly. The preferred stress distributions vary depend-
ing on the particular coiling operation and type of coil.
In order to alleviate tight-bore collapse problems, it is
usually desirable to keep the compressive stresses near
the bore after mandrel removal to a minimum, especially
for thin strip. Excessive radial pressure at the bore
during coiling should be avoided in order to prevent
possible partial collapse of the mandrel segments {23}.
On the other hand, inter-wrap pressure distributions in
the coil during and after coiling need to be suf
ciently
high to prevent inter-wrap slippage. Examples of wind-
ing stresses required to achieve modi
ed tangential
(hoop) stress distributions are given in F ig. 8. F igure 8a
shows the original residual hoop stress in a coil for a
winding stress pro
le typical for thin gauge coils (the
winding stress pro
le of F ig. 3b). H igh compressive
stresses near the bore can lead to possible problems with
coil collapse. H ence the original hoop stress distribution
is now modi
ed so as to move the minimum stress
further into the body of the coil, as illustrated by the
modi
ed pro
les A and B. N ote, however, that the inter-
wrap pressure, p, corresponding to the modi
ed hoop
stress distributions, has to be redetermined so as to
satisfy the equilibrium equation for stresses {equation
(52)}, as well as the boundary conditions, before the
required winding stress pro
les can be calculated. The
calculated winding stress pro
les to achieve these
modi
ed hoop stress distributions are shown in F ig. 8b.
5 CONCLUSION
This paper presents a novel approach of analysing
stresses in coils, modelled as an orthotropic material, for
the case where the constitutive relations are non-linear.
Instead of calculating stresses for a given winding
policy, an ‘inverse solution’ is obtained in which the
winding stresses required to achieve speci
ed stress
distributions are calculated. R esults for this non-linear
model are compared to previous work for the linear
case. The inverse solution has the advantage of being
able to determine the winding policies required to
achieve the desired stress distributions in the coil
directly. To illustrate this, examples of winding stresses
for modi
ed stress distributions in the coil are given.

C13102 # IM echE 2004 Proc. Instn M ech. Engrs Vol. 218 Part C: J. M echanical Engineering Science
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38 F R de HOOG , W Y D YU EN, M COZIJN SEN AN D H -N HUYN H
ACKNOWLED GEMENTS
The authors wish to thank the management of CSIR O
and BH P Steel R esearch Laboratories for permission to
publish the material contained in this paper.
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