This paper presents a process model for simulating the manufacturing process of prepreg filament wound composite tubes developed based on the finite element analysis. The model relates the process variables, such as degree of cure, viscosity, material property and temperature etc., to the parameters characterizing (residual stresses, warpage deformation) the composite tube and the mandrel. From the simulating results, several important trends in both the data and model are observed (1) Low temperature will go with low reaction rate and the reaction starts under low temperature will later compared with high temperature; (2) The results using CHILE model after demolding will smaller than the one using linear elasticity which assumes a stress-free prior to cool-down. After the mandrel (mold) is removed, some residual stresses, especially hoop stress will be released. (3) Remarkable stress concentration appeared in the transition zone between the boss and cylinder. In order to prevent the structural failure due to interlaminar shear or delamination, both the outer surface of the cylinder and the inner of the boss should have the same ply orientation angle.
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