Process for manufacturing flanged tubular members from fiber composites

A method for manufacturing a fiber reinforced composite structural member, said structural member including a tubular portion having predetermined inner and outer configurations and having opposite ends, and a pair of planar flanges extending radially outwardly from said tubular portion at said opposite ends, said method comprising:

• a. applying a winding to a core assembly, said core assembly comprising a core element having an axis and including a central portion having opposite ends, said central portion having a configuration which is substantially complimentary to said inner configuration of said tubular portion, said core assembly further comprising a pair of spreader elements which extend outwardly from said core element adjacent said opposite ends of said central portion thereof, said winding comprising a plurality of fiber strands in an uncured curable matrix, said fibers crossing one another in angular relation to said axis, said winding being applied to both said central portion and said spreader elements and being conically widened outwardly by said spreader elements to provide conical regions in said winding adjacent opposite ends of said central portion;
• b. applying a forming tool to the portion of said winding on said central portion, said forming tool having a tubular inner surface which is substantially complimentary to said tubular portion outer configuration, said tubular inner surface terminating in opposite ends, said forming tool also including a pair of planar end faces which extend radially outwardly relative to said tubular inner surface, said tubular inner surface merging into said end faces through rounded transition edges;
• c. applying outward pressure to said fibers along said transition edges utilizing an elastically expandable pressure medium in order to retain said fibers in uniformly distributed orientation along said transition edges;
• d. thereafter assembling the fibers and matrix in said conical regions to form flange composites which are applied to said end faces, said fibers being uniformly distributed in said flange composites;
• and
• e. curing said matrix.