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Product Name: CADWIND
Product Description
Process simulation software for filament winding technology:-
Fiber orientation is the decisive factor in the strength of fiber-reinforced
plastics (composites). From the various production methods, filament winding
technology offers a high degree of automation. It also offers the best
possibilities for defined impregnation, positioning, and orientation of the
fibers in the composite material.
Filament wound components are produced by a filament winding machine where
resin-impregnated fibers or fabric tapes pass through a feed-eye and are wound
on a rotating mandrel. In this way the laminate is formed on the mandrel. The
co-ordination of the 2 to 6 computer-controlled machine axes of motion, creating
different filament winding angles in the laminate, is difficult.
However, due to the physical limitations, not all laminates can be achieved. In
designing filament wound components it is first necessary to determine which of
the winding angles with the best load bearing capacity can be achieved. Then the
machine has to be programmed for the production. For this step, which is often
decisive for efficiency, and thus the commercial success of the product, CADWIND
has proven to be an indispensable process simulation system - for every
application throughout the world.
CADWIND calculates, from the given strength requirements, the fiber lay-up on
the mandrel and generates automatically the part program for any winding
machine. It is guaranteed that the laminate structure will be reproduced on the
filament winding machine exactly as calculated by CADWIND.
Features
Lighter and better
In aerospace applications every gram counts. The use of filament winding
technology is indispensable.
Fresh and waste water tanks in aircraft (e.g. Airbus A330) or hydraulic tanks
for the control of rocket engines (e.g. Ariane 5) are typical components
manufactured using filament winding.
Here, CADWIND makes it possible to obtain the optimum design for these highly
stressed components. By taking into account the friction between the fibers and
the mandrel, CADWIND can also calculate the fiber paths that do not lie on the
geodesic path (i.e. the shortest distance between two points on a curved
surface). For example, this allows the optimization of the fiber lay-up on the
pole caps of the pressure vessel. Also the manufacture of pressure vessels with
different pole cap geometries no longer poses any problems.
Due to the multiple optimization possibilities of CADWIND the decisive weight
reductions can be obtained.
Safety is paramount and thus quality is the essential requirement. However,
quality control of composite components is difficult. This makes monitoring of
the production process even more important. For this, CADWIND ensures accurate
fiber positioning, smooth machine movements, defined impregnation of the fibers
and uniform fiber tension.
Shorter production times
In pressure bottles (e.g. for respiratory equipment) high pressure allows
greater autonomy. Furthermore, a low weight is important. Both these properties
are obtained with filament winding technology.
The laminate structure consists mainly of two different layers: a helical
winding with a low winding angle for accommodating longitudinal forces and an
outer circumferential winding for resisting circumferential forces.
Since these components are mass produced, one important factor is minimizing the
production times.
For this, CADWIND provides two advantages. First, CADWIND can combine the
different layers so that the complete manufacture is possible without machine
stops. Second, CADWIND calculates the part program with the shortest production
time using the maximum velocities and accelerations of the winding machine.
Quality for every meter
In pipe manufacturing, high quality is essential for every meter. Especially
with highly aggressive or toxic fluids or gasses a small defect can lead to a
catastrophe. Glass fiber-reinforced plastics provide safe protection from
corrosion with high strength. Because ofthe high degree of automation, filament
winding technology has become the major production method.
However, in the manufacture of the pipe fittings, like elbows or tees, manual
wrapping of the mandrel with tapes is still common.
With CADWIND, these complex components can also be automatically produced. It is
now just as simple to calculate the desired laminate structure for elbows or
tees as it is for straight pipes.
The component construction is optimized through precise fiber positioning. Up to
30% of the material and 70% of the production time can be saved. The mechanical
reproducibility and the complete control of the production process by CADWIND
ensures that there are no defects
Custom fiber orientation
In sports, everybody wants to achieve new records. Therefore the sporting goods
industry needs more and more composite materials. Filament winding technology
allows the production of components with specific properties.
An example is masts for sailboards. The mast is the decisive component in
controlling the airfoil properties of the sail and converting wind energy to
propulsion.
CADWIND can take into account the friction between the fiber and the mandrel.
Therefore it can calculate non-geodesic winding paths. This allows the winding
angle to be varied in different regions of the part. Different rigidity values
in different sections of the mast can be obtained. Additional automatically
integrated circumferential windings can accommodate the forces exerted by the
wishbone boom.
CADWIND makes it possible to examine different variants of the laminate
structure and to simulate the deformation due to stresses by a linked FEM
program. To a great extent this avoids the expensive production and testing of
prototypes.
Optimum use of the material
In mechanical engineering, the commercial success of a product depends on
rational process engineering. Often the productivity can be improved by higher
production speeds, which naturally increases the demands made of the machine
mechanical system. Filament winding technology also provides solutions here.
Light rollers made of carbon fiber-reinforced plastics have gained acceptance
for machines in the film and paper industries. The higherrigidity of the
material - compared to steel or aluminium - enables a higher number of
revolutions due to the lower bending of the roller. In addition, the smaller
mass moment of inertia of these components provides better acceleration and
deceleration characteristics.
In the manufacture of these rollers it is important to make optimum use of the
expensive material. With CADWIND, the quantity of material needed and the
component weight can be precisely determined in the development phase.
With CADWIND, the user also controls the fiber positioning in the turning zone.
For example, the winding direction can be reversed on the cylindrical mandrel
section or over the shaft shoulder. Since the turning zones can become integral
parts of the specific component, material losses by removal of surplus material
in these zones are avoided. Depending on the requirements, the connecting
elements can also be optimally integrated
Innovative concepts
In motor racing the best is never good enough. This is a prime example for the
use of composite materials. In modern racing cars, chassis panels as well as the
primary structure of the frame consist of fiber-reinforced materials. Filament
winding is used in the manufacture of rods, pressure vessels, and drive shafts
where superior mechanical properties are required along with low weight.
The example of a drive shaft, that transfers up to 1,000 hp, shows clearly that
these components have little in common with those used in mass produced cars.
CADWIND allows the optimum design of the drive shaft by concepts using the
maximum potential of the material. Variable winding angle in the laminate gives
the best resistance to the stresses on the component: a low winding angle for
resistance to bending forces (mainly in the middle of the shaft), 45° for
transfer of the torque and circumferential windings at the component ends for
integration of the power input elements.
Specifications
Mandrel Generator
automatic creation of 3D mandrel models
interface for input of mandrel models from CAD systems
Laminate Calculation
calculating for axissymmetric and non-axissymmetric mandrel geometries
calculating of the standard patterns - circumferential winding, helical winding
and polar winding
calculating of any geodesic and non-geodesic windings
combining of several layers
variation of the winding angle
color codes for indicating winding angle deviation, geodesic behavior and
laminate thickness
numerical display of fiber consumption and component weight
storing of the laminate structure as an interface for FEM programs
Postprocessing
calculation of the part programs for any winding machine with 2 to 6 axes
optimization of the part program for regular, smooth running of the machine
speed optimization (reducing production time, winding with constant pay-out
speed or with constant mandrel speed)
display of the production time
display of displacement-time, speed-time, and acceleration-time diagrams of the
machine movements
Handling
modern, user-friendly window interface
metric system or English system
German, English or French as dialog language
Hardware
Windows 95/98/ME/NT/2000/XP
600 MHz Intel Pentium III processor or equivalent
128 MB RAM
Service
extensive advice for the entire filament winding sector
installation and training
continuous update and hot-line service through software maintenance
Advantages
saving time in the construction phase, at programming the filament winding
machine and at component modifications
machine time reduction by avoidance of trial and error tests in the development
phase
elimination of material losses in winding tests
shorter production times
material savings through optimized use of materials
higher quality standards
greater flexibility in changing manufacture or winding parameters
maximum use of material potentials
Versions and modules
CADWIND is the most powerful software tool for winding fibre reinforced
plastics. With CADWIND you can calculate the winding pattern and the fibre
lay-up on the mandrel and generate the part program for the winding machine.
The working principle
The mandrel has to be described as three-dimensional model for the later
calculation. CADWIND can generate such models automatically for every important
mandrel geometry. You only have to enter the basic dimensions like length,
diameter and shape of the turning zone. Furthermore, it is possible to define
any geometry manually or to import them from other CAD systems via the DXF
interface.
The winding pattern and the fibre lay-up on the mandrel are calculated and
displayed in three dimensions after entering the wanted winding parameters (e.g.
winding angle, pattern number). The resulting values such as laminate thickness,
fibre consumption or laminate weight are displayed numerically. In addition a
colour scale indicates the deviation of the winding angle from the desired
value, the geodesic behaviour, the possibility of fibre bridging and the
laminate thickness for every point of the laminate. The thickness and the fibre
orientation of the laminate structure can be saved on disk. This file can be
used as input to FEA programs.
The postprocessor computes the control data for the winding machine from the
calculated winding path and the machine characteristics (2 to 6 axes). After
that you can produce the part directly.
The basic versions
CADWIND lite
CADWIND lite offers you the usual standard winding patterns together with
CADWIND´s extremely powerful postprocessor (including Module 3). This allows you
to control any winding machine with one single, user-friendly system.
The calculation possibilities of CADWIND lite are:
circumferential winding on cylinders
helical winding on cylinders and vessels (geodesic)
polar winding on vessels
CADWIND lite includes Module 3. Module 2 can be added as an option.
CADWIND vessel
CADWIND vessel allows you to treat cylinders and vessels as well. However,
besides the above mentioned standard patterns you can wind non-geodesically.
This gives you a much bigger choice of possible laminate structures. For
instance you can wind vessels with different pole openings. Furthermore CADWIND
vessel can import mandrel models from CAD systems via the DXF interface.
CADWIND vessel can have Module 2, 3, UNI, FEA and S as options.
CADWIND pro
CADWIND pro is the basic version that gives you access to the widest range of
manufacturing possibilities. You can treat all axisymmetric mandrel geometries
without restrictions. You can use the standard patterns of CADWIND lite as well
as all non-geodesic fibre paths.
One important aspect of the non-geodesic winding path calculation should be
mentioned here. The winding angle can be defined differently in the various
sections of the mandrel surface. For example this allows you to wind a shaft
with a winding angle of 30° in the middle and 45° at the ends.
CADWIND pro also offers you the most flexible extension possibilities. It can be
extended with all Modules (1A, 1, 2, 3, T, OP, UNI, FEA, S).
CADWIND high-end
CADWIND high-end, consisting of CADWIND pro and Modules 1, 2 and 3, represents a
price reduced package for the all axisymmetric and non-axisymmetric (Module 1:
e.g. pipe elbows, wing profiles) mandrel geometries. Besides the possibilities
of the extended postprocessor (Module 3) you can combine several different
layers (Module 2).
CADWIND high-end can be extended with Modules T, OP, UNI, FEA and S.
The modules
Module 1A
Module 1A enables you to wind parts with rectangular and elliptical
cross-sections. Module 1A is included in Module 1.Module 1
Module 1 allows you to treat any non-axisymmetric mandrel geometries. Module 1
includes Module 1A.
Module 2
With Module 2 you can combine several different layers. It calculates the
transition between the different layers (e.g. helical to circumferential). So
you can wind the different layers without machine stops.
Module 3
Without Module 3 the postprocessor generates the control data in a machine
independent format with the axis positions in absolute values and without a time
scale.
Module 3 contains the following additional functions:
The control data can be calculated directly as a part program. You can define
the output format by yourself so that the programs run on any machine
controller.
The control data are optimised according to the axis velocities of the machine.
For example this allows you to wind with constant pay-out speed or constant
mandrel speed.
The accelerations of the winding machine are taken into consideration. This
leads to a smoother running machine.
The displacement-time, velocity-time and acceleration-time diagram of the
machine motion can be displayed. This gives you a better control over the
complete winding process.
The time needed for the winding is displayed. This allows you to minimise the
winding time and to produce parts faster and at a lower cost.
Module 3 can calculate part programs for tumble winding machines to optimize
manufacturing of elbows and T-parts.
Module T
Module T calculates winding paths on T-parts automatically (also for tapes).
Module OP
Module OP opens the interfaces of the postprocessor. You can store the winding
path during its calculation on the hard disk and edit it. A modified winding
path or an externally generated winding path can be converted to a part program
by the postprocessor. Furthermore, Module OP can translate the control data from
the machine independent format in absolute values (also if they have been edited
or externally generated) into a part program.
Module OP requires Module 3.
Module UNI
Module UNI allows you to manufacture uniply windings. All rovings with a
positive winding angle will be wound before placing the fibers in negative
direction. Thus there are no intersections between the fibers of one layer.
Module FEA
Module FEA compiles the laminate data of all layers and the mandrel geometry to
a data package which can be used directly by finite element analysis programs.
Module FEA generates data for any FEA program (NISA, NASTRAN, COSMOS, ANSYS,
...).
Module S
Module S is CADWIND's new service module. Module S can exchange project and
diagnose files with MATERIAL's engineers directly via the internet. This gives
you instant assistance and extensive advise on your current project as well as
for the entire filament winding sector. Users of Module S can also use the
engineering helpdesk via telephone, fax or e-mail. Module S includes a regular
software update service.
Handling
CADWIND NG runs under Windows 95/98/2000/NT. You can switch between the Metric
system (millimeter, meter, kilogram, ...) or English units (inch, foot, pounds,
...) at any time. You can choose between English, French or German as dialog
language.
Service
By using CADWIND you can take advantage of more than 10 years world-wide
experience of MATERIAL´s engineers. This includes the extensive advise for the
entire filament winding sector.
The software maintenance service provides the latest updates as well as hot-line
support.
The functions of CADWIND are guaranteed. If the system should not work according
to its specification you will receive your money back.
Summary
Products
Composite Star
Cadwind
Features
Specifications
Version & modules
Order
Engineering Services
Mandrel geometry lite vessel pro
high-end
cylinder
vessel
any axisymmetric geometry
elliptical cross-section module 1A
rectangular cross-section module 1A
any non-axisymmetric geometry (excl. T-parts) module 1
T-part module T
Calculation of the laminate lite vessel pro
high-end
circumferential winding
helical winding
polar winding
non-geodesic (including variable winding angle)
combination module 2 module 2 module 2
T-part module T
consideration of the thickness of the fiber built-up
uniply winding module UNI module UNI module UNI
Postprocessing lite vessel pro
high-end
control data in absolute values
calculation of the part program for any machine • module 3 module 3
optimisation of the velocities • module 3 module 3
consideration of the accelerations • module 3 module 3
graphical display of the machine motion • module 3 module 3
winding time • module 3 module 3
calculation for tumble winder module 3 module 3
external winding path module OP module OP
translator absolute control data -> part program module OP module OP
Interfaces lite vessel pro
high-end
import DXF data from CAD systems • • •
export data for any finite element analysis program module FEA module FEA module
FEA
Service lite vessel pro
high-end
instant diagnose and assistance via the internet module S module S module S
engineering helpdesk via e-mail, phone or fax module S module S module S
update service module S module S module S
Company Details
MATERIAL's software system CADWIND has been the industry's standard for filament winding technology for more then 10 years. In 2000 MATERIAL started development of Composite Star, a database and design software which will be released in spring... more
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