Sources of residual stresses in composite materials and methods of their re
ductions are discussed and analyzed rigorously for one dimensional micro-me
chanical model and numerically for axisymmetric filament wound composite tu
be model using finite element analysis (FEA). The incorporation of mechanic
al preload to the Fabrication process is discussed and two designs of an ex
pandable mandrel are proposed. Two processes, conventional and with preload
, are numerically simulated for residual stresses.