User Manual

Copyright by MATERIAL SPRL. All rights reserved.

This manual, as well as the software described in it, is furnished under license and may be
used or copied only in accordance with the terms of such license. The content of this
manual is furnished for informational use only, is subject to change without notice, and
should not be construed as a commitment by MATERIAL SPRL. MATERIAL assumes no
responsibility or liability for any errors or inaccuracies that may appear in this manual.

Except as permitted by such license, no part of this publication may be reproduced, edited,
stored in a retrieval system or transmitted, in any form or by any means, electronic,
mechanical, recording or otherwise, without the prior written permission of MATERIAL
SPRL.

CADWIND®, iWind® and COMPOSITE STAR® are registered trademarks.

MATERIAL SPRL
11 rue des Chartreux, 1000 Brussels, Belgium
www.material.be, info@material.be

revison 20112701

CADWIND User Manual © MATERIAL SPRL 2

Contents

Contents............................................................................................................................... 3
1 Installation ................................................................................................................... 12
1.1 Single user license installation .............................................................................. 12
1.2 Floating license installation.................................................................................... 14
1.2.1 Installation on the server ................................................................................. 14
1.2.2 Installation on the client computers ................................................................. 14
1.3 Installing an update ............................................................................................... 14
1.4 Hardware .............................................................................................................. 15
2 Versions ...................................................................................................................... 16
3 Support & Assistance .................................................................................................. 19
4 The User Interface (Screen Layout) ............................................................................ 20
4.1 The menu bar ........................................................................................................ 20
4.2 The graphics display ............................................................................................. 21
4.2.1 Display Options............................................................................................... 21
4.2.2 Color Scale Options ........................................................................................ 22
4.2.3 Animation Controls ......................................................................................... 23
4.2.4 Animation Speed ............................................................................................ 24
4.2.5 View Orientation ............................................................................................. 25
4.2.6 Mandrel Display .............................................................................................. 25
4.2.7 Roving Display ................................................................................................ 26
4.2.8 Zooming in/out ................................................................................................ 26
4.2.9 Panning (moving the view across the screen) ................................................. 27
4.2.10 View Reorientation ...................................................................................... 27
4.2.11 Dialogue windows........................................................................................ 27
5 Options Menu .............................................................................................................. 29
5.1 Units ...................................................................................................................... 29
5.2 Language .............................................................................................................. 29
6 Projects ....................................................................................................................... 30
6.1 About project files .................................................................................................. 30
6.2 Project file contents ............................................................................................... 30

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 6.3 How to save a project ............................................................................................ 30
6.4 Options when saving a project .............................................................................. 30
6.4.1 Use external files ............................................................................................ 31
6.4.2 Include the files in the Project file .................................................................... 33
6.5 How to load a project............................................................................................. 33
7 Getting Started: Demonstration of CADWIND usage ................................................... 34
7.1 Step 1 – Creating the mandrel ............................................................................... 35
7.2 Step 2 – Winding over the mandrel ....................................................................... 37
7.3 Step 3 – Making the part program and simulation ................................................. 40
7.4 Step 4 - Analysing the machine motion ................................................................. 43
8 Mandrel models .......................................................................................................... 44
8.1 Generating mandrels automatically ....................................................................... 44
8.1.1 Circular Cross-Section .................................................................................... 44
8.1.2 Rectangular Cross-Section Mandrels .............................................................. 48
8.1.3 Elliptical Cross-Section Mandrels .................................................................... 49
8.1.4 Elbows ............................................................................................................ 51
8.1.5 Cones ............................................................................................................. 52
8.1.6 T-Shaped Mandrels ........................................................................................ 54
8.2 Frames and meshing of automatically generated mandrels ................................... 55
8.2.1 Numbers of Frames ........................................................................................ 57
8.2.2 Number of Points ............................................................................................ 58
8.2.3 T mandrel meshes .......................................................................................... 58
8.3 Saving and loading mandrel generation parameters ............................................. 59
8.4 Generating mandrel models manually ................................................................... 60
8.4.1 Mandrel Coordinate System ........................................................................... 60
8.4.2 Division of the mandrel into frames and points ................................................ 61
8.4.3 The Mandrel Contour format (for axisymmetric mandrels) .............................. 62
8.4.4 The Mandrel Surface format (for non-axisymmetric mandrels) ........................ 63
8.4.5 Creating mandrels using external CAD software ............................................. 66
8.4.6 DXF ➯ Contour... ........................................................................................... 66
8.4.7 DXF ➯ Surface... with CADWIND EXPERT or HIGH-END ............................. 70
8.5 The T-mandrel format ............................................................................................ 73
9 View Menu .................................................................................................................. 74

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 9.1 New mandrel views ............................................................................................... 74
9.2 View results ........................................................................................................... 74
9.3 Clear winding patterns ........................................................................................... 77
9.4 Show only last pattern ........................................................................................... 77
10 Winding over the mandrel with iWind ........................................................................ 79
10.1 Introduction to iWind .......................................................................................... 79
10.2 iWind overview ................................................................................................... 80
10.2.1 Overview of the different sections ................................................................ 80
10.2.2 Changing the parameters ............................................................................ 82
10.2.3 The Calculate button ................................................................................... 83
10.2.4 The Live button ............................................................................................ 84
10.2.5 Progress bar and cancel button ................................................................... 85
10.2.6 Time required for calculation ....................................................................... 86
10.3 iWind - Winding parameters ............................................................................... 86
10.3.1 Start frame................................................................................................... 86
10.3.2 Start position ............................................................................................... 87
10.3.3 Start winding direction ................................................................................. 87
10.3.4 Turning zones .............................................................................................. 88
10.3.5 Winding angle .............................................................................................. 89
10.3.6 Constant winding angle ............................................................................... 90
10.3.7 Variable winding angle ................................................................................ 90
10.3.8 Set range ..................................................................................................... 91
10.3.9 Friction factor – non-geodesic winding......................................................... 92
10.3.10 Friction factor parameter.............................................................................. 93
10.3.11 Actual friction factor used ............................................................................ 94
10.3.12 Variable friction factor .................................................................................. 95
10.3.13 Total bandwidth ........................................................................................... 95
10.3.14 Calculate first cycle only .............................................................................. 97
10.3.15 Calculate patterns........................................................................................ 98
10.3.16 Coverage range - Number of cycles range .................................................. 98
10.4 iWind - Material parameters ............................................................................. 102
10.4.1 Overview of material parameters ............................................................... 102
10.4.2 TEX value or Yield (single roving) .............................................................. 103

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 10.4.3 Bandwidth (single roving) .......................................................................... 103
10.4.4 Fiber density .............................................................................................. 103
10.4.5 Fiber volume fraction and Fiber mass fraction ........................................... 103
10.4.6 Matrix density ............................................................................................ 104
10.4.7 Resulting ply thickness .............................................................................. 104
10.5 iWind - Results Table ....................................................................................... 105
10.5.1 Grouping columns ..................................................................................... 106
10.5.2 Un-grouping columns ................................................................................ 107
10.5.3 Sorting the results...................................................................................... 108
10.5.4 Filtering the patterns .................................................................................. 109
10.5.5 Cycles ....................................................................................................... 110
10.5.6 Coverage ................................................................................................... 111
10.5.7 Pattern Number ......................................................................................... 112
10.5.8 Skip ........................................................................................................... 113
10.5.9 +/- .............................................................................................................. 113
10.5.10 % of friction limit ........................................................................................ 114
10.5.11 Winding length ........................................................................................... 115
10.5.12 Path length ................................................................................................ 116
10.5.13 Weight ....................................................................................................... 117
10.5.14 Thickness .................................................................................................. 117
10.6 Save laminate data (for the export to FEA software) ........................................ 117
10.6.1 Save laminate data as .LAM file ................................................................ 118
10.6.2 Save laminate data as .iLAM file ................................................................ 119
10.7 Load/Save iWind parameters ........................................................................... 119
10.8 iWind compared with CADWIND’s classical non-geodesic winding .................. 120
10.9 Update mandrel / Reset / Save update ............................................................ 122
10.9.1 The Update mandrel feature ...................................................................... 122
10.9.2 How to use the Update mandrel feature .................................................... 122
10.9.3 Updating non-axisymmetric mandrels ........................................................ 123
10.9.4 Limitations of the Update mandrel feature ................................................. 123
10.9.5 Circumferential winding over an updated mandrel ..................................... 123
10.9.6 Reset ......................................................................................................... 123
10.9.7 Save update... ........................................................................................... 124

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11 Winding over the mandrel with the classical algorithms .......................................... 125
11.1 The material parameters .................................................................................. 125
11.2 The division of the mandrel into zones ............................................................. 127
11.3 Circumferential (hoop) winding ......................................................................... 128
11.3.1 Position ..................................................................................................... 129
11.3.2 Degree of coverage ................................................................................... 131
11.3.3 Dwell ......................................................................................................... 132
11.4 Helical winding ................................................................................................. 133
11.4.1 Pole openings on vessel mandrels ............................................................ 134
11.4.2 Starting angle ............................................................................................ 135
11.4.3 Starting frame ............................................................................................ 135
11.4.4 Degree of covering / Number of cycles ...................................................... 135
11.4.5 Pattern number and skip index .................................................................. 136
11.4.6 Closing of winding pattern options ............................................................. 139
11.4.7 Pattern recommendations .......................................................................... 140
11.4.8 Dwell in helical winding .............................................................................. 142
11.4.9 Number of layers ....................................................................................... 143
11.5 Non-geodesic winding ...................................................................................... 143
11.5.1 Geodesic versus non-geodesic winding..................................................... 143
11.5.2 Non-geodesic winding ............................................................................... 145
11.5.3 Winding angle ............................................................................................ 146
11.5.4 Friction factor ............................................................................................. 146
11.5.5 Variable friction factor and variable winding angle ..................................... 146
11.5.6 Set range ................................................................................................... 148
11.5.7 Constant thickness .................................................................................... 149
11.5.8 Pattern number .......................................................................................... 150
11.5.9 Degree of covering / Number of cycles ...................................................... 150
11.5.10 Dwell Front and Dwell Back ....................................................................... 150
11.5.11 Number of layers ....................................................................................... 150
11.5.12 Turning zone front and Turning zone back ................................................ 150
11.5.13 Starting frame ............................................................................................ 150
11.5.14 Starting position ......................................................................................... 150
11.6 Polar winding ................................................................................................... 151

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 11.6.1 Application and limitations of Polar winding ............................................... 151
11.6.2 How to use Polar winding .......................................................................... 151
11.6.3 Band centring on poles .............................................................................. 152
11.6.4 Polar winding options ................................................................................ 152
11.7 Combination (transitional) winding ................................................................... 152
11.7.1 How to use Combination winding ............................................................... 153
11.7.2 Starting angle ............................................................................................ 154
11.7.3 Starting frame ............................................................................................ 154
11.7.4 Starting position ......................................................................................... 154
11.7.5 Ending angle ............................................................................................. 155
11.7.6 Ending frame ............................................................................................. 155
11.7.7 Friction factor ............................................................................................. 155
11.7.8 How the Combination winding algorithm works .......................................... 155
11.7.9 Optimising the combination winding by adjusting the friction factor ............ 156
11.8 T-winding ......................................................................................................... 157
11.8.1 Possible T-winding patterns ....................................................................... 158
11.8.2 Creating the T winding sequence .............................................................. 158
11.8.3 Syntax for the T Sequence file ................................................................... 159
11.9 Update mandrel / Reset / Save update ............................................................ 160
11.9.1 The Update mandrel feature ...................................................................... 160
11.9.2 How to use the Update mandrel feature .................................................... 161
11.9.3 Updating non-axisymmetric mandrels ........................................................ 162
11.9.4 Limitations of the Update mandrel feature ................................................. 162
11.9.5 Circumferential winding over an updated mandrel ..................................... 162
11.9.6 Reset ......................................................................................................... 162
11.9.7 Save update... ........................................................................................... 163
11.10 Winding options ............................................................................................... 163
11.10.1 Pattern display on axisymmetric geometries .............................................. 164
11.10.2 Save laminate data .................................................................................... 164
11.10.3 Save winding path ..................................................................................... 165
11.11 Load / Save winding parameters ...................................................................... 167
12 Postprocessing ....................................................................................................... 168
12.1 Calculation of the control data for the part program .......................................... 168

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 12.1.1 Calculation mode ....................................................................................... 169
12.1.2 Velocity calculation .................................................................................... 174
12.1.3 Minimal distance ........................................................................................ 175
12.1.4 Pay-out speed ........................................................................................... 175
12.1.5 Filter value ................................................................................................. 175
12.1.6 Positioning Length ..................................................................................... 176
12.1.7 Axes to Calculate....................................................................................... 177
12.1.8 Yaw mode ................................................................................................. 177
12.1.9 Save as ..................................................................................................... 178
12.2 Postprocessing parameters: Part program tab ................................................. 179
12.2.1 Program number........................................................................................ 180
12.2.2 Gear & Spindle .......................................................................................... 180
12.2.3 Heating, Tension, Compaction................................................................... 180
12.2.4 Mandrel ID, Fiber ID, Resin ID ................................................................... 180
12.3 Postprocessing parameters: Source tab........................................................... 181
12.4 Postprocessing parameters: Tumbler tab ......................................................... 181
12.5 Postprocessing parameters: Begin tab ............................................................. 183
12.6 Postprocessing parameters: Mandrel rotation tab ............................................ 183
12.7 CCDF-> Part program... ................................................................................... 184
12.8 Translate Baer TCS-84... ................................................................................. 185
12.9 Display... .......................................................................................................... 185
12.9.1 What can be graphed on the Y-axis ........................................................... 186
12.9.2 The scale of the Y axis .............................................................................. 186
12.9.3 What can be graphed on the X axis ........................................................... 187
12.9.4 Zooming and panning the graph ................................................................ 188
12.10 Load... and Save... ........................................................................................... 189
12.11 Notes on part programs which contain sub-programs ...................................... 189
13 Machine .................................................................................................................. 191
13.1 Parameters... ................................................................................................... 191
13.1.1 Reference tab ............................................................................................ 191
13.1.2 Dimensions tab .......................................................................................... 193
13.1.3 Velocities tab ............................................................................................. 196
13.1.4 Accelerations tab ....................................................................................... 197

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 13.1.5 Processing time tab ................................................................................... 198
13.1.6 Resolutions tab .......................................................................................... 198
13.1.7 Axes tab .................................................................................................... 201
13.1.8 Format tab ................................................................................................. 201
13.2 Definition Files ................................................................................................. 202
13.2.1 Defining different sections of the part program .......................................... 202
13.2.2 Variables for Loops, Sub-programs and block numbers ............................ 204
13.2.3 Markers ..................................................................................................... 205
13.2.4 Machine Position Variables ....................................................................... 205
13.2.5 Time and feed-rate variables ..................................................................... 208
13.2.6 Calculation of feedrate (in increments per minute) ..................................... 208
13.2.7 Number of digits after the decimal point (of a variable) .............................. 209
13.2.8 Absolute versus relative programming ....................................................... 209
13.2.9 Special characters ..................................................................................... 210
13.3 Load... and Save... ........................................................................................... 210
14 Export for Finite Element Analysis (FEA) ................................................................ 211
14.1 Overview .......................................................................................................... 211
14.2 Output formats ................................................................................................. 212
14.2.1 The HDF5 Composite Data format ............................................................ 212
14.2.2 Other formats ............................................................................................ 213
14.2.3 Format summary ....................................................................................... 213
15 Printing from CADWIND ......................................................................................... 214
15.1 Printing graphics .............................................................................................. 214
15.2 Printing reports................................................................................................. 214
16 The text editor (Tools menu) ................................................................................... 215
17 Help menu .............................................................................................................. 216
17.1 Help reports ..................................................................................................... 216
17.2 About... ............................................................................................................ 216
18 Function summary .................................................................................................. 217
18.1 File ................................................................................................................... 217
18.2 View ................................................................................................................. 217
18.3 iWind ................................................................................................................ 218
18.4 Winding ............................................................................................................ 218

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 18.5 Postprocessing ................................................................................................ 219
18.6 Machine ........................................................................................................... 219
18.7 Tools ................................................................................................................ 220
18.8 Window ............................................................................................................ 220
18.9 Options ............................................................................................................ 220
18.10 Help ................................................................................................................. 220
19 CADWIND file types and their extensions ............................................................... 221

CADWIND User Manual © MATERIAL SPRL 11

1 Installation

1.1 Single user license installation

1. Using Windows Explorer, create a new folder in the location where you want
CADWIND program files to be stored on your harddisk (e.g. D:\CADWIND\). You
need full read and write access to this folder.
Note: You can use the folder C:\Program Files (x86)\CADWIND\ but you need full
administrator rights to copy files to this location.

2. Login on https://www.material.be/sign-in with the username and password you

received from MATERIAL.

3. Download the file CADWIND_V10_***.ZIP. Unzip it and extract all files into the folder
created in step 1.

4. Create a folder named CADWIND in your documents folder (C:\Users\<User

name>\Documents\CADWIND). Copy the example folders DEF EXAMPLES and
MDR EXAMPLES into this folder.

5. Run CodeMeterRuntime.exe. This will install the driver software for the CodeMeter
dongle.

6. Connect the CodeMeter dongle to an USB port of the computer.

7. This step is only necessary if you have been instructed to do so by MATERIAL via
email.

If the license information on the CodeMeter dongle needs to be updated and you
received a license update file (e.g. “MATERIAL_2-2021872_190301_124200
.WibuCmRaU”), either as download from https://www.material.be/sign-in or by email,
simply double click on this file. This will update the license information on the dongle.

8. Now you should be able to run CADWIND. Simply double click on the file
CADWIND_V10_***.EXE.

Recommendations:

• Use a display with a resolution of 1920 x 1080 or more.

• In Windows in the Display settings set the scaling to 100%.

CADWIND User Manual © MATERIAL SPRL 12

 • If your computer has several graphic cards make sure that CADWIND runs on the
most powerful graphic card. For example, notebooks often have two graphic cards:
an integrated more energy efficient graphic system and a dedicated more powerful
graphic card. Look in the settings of the dedicated graphic card (like NVIDIA or
RADEON settings) and assign CADWIND in particular or software using the OpenGL
graphics standard in general to work on this card.

Warnings from Windows or anti-virus software:

Due to the protection mechanisms used by the CodeMeter dongle, it is possible that
Windows or anti-virus software incorrectly detect a risk and issues a warning message
when you start CADWIND. Please ignore these messages.

Here is an example from Windows Defender:

Note: CADWIND uses the following folders:

folder description
C:\Users\<User name>\Documents\CADWIND the standard working folder

C:\Users\<User name>\AppData\Roaming\CADWIND location of the file

CADWIND.CON which stores
the last session settings
C:\Users\<User name>\AppData\Local\Temp\CADWIND used for temporary files

CADWIND User Manual © MATERIAL SPRL 13

1.2 Floating license installation
If you purchased the floating license option for CADWIND you can connect CADWIND's
CodeMeter software protection dongle to a computer which acts as a server. You can then
run CADWIND on all client computers which have a permanent network connection to the
server until all licenses stored on the dongle are used up.

To install the CodeMeter dongle in a network please proceed as follows:

1.2.1 Installation on the server

IMPORTANT: The following steps have to be executed with full administrator rights.

1. On the server computer follow all steps for the single user installation in section 1.1.

2. Start the CodeMeter Control Center: In the Windows Start Menu / All Programs /
CodeMeter open the "CodeMeter Control Center".

3. In the CodeMeter Control Center window click on the "WebAdmin" button in the
lower right corner. This will open your internet browser and give access to the
administration tools of the dongle.

4. In the CodeMeter WebAdmin go to the "Configuration / Server / Server access"

page. Enable the "Network Server" option and click the "Apply" button.

5. Restart the CodeMeter Control Center: In the CodeMeter Control Center window go
to the "Process" menu and click on "Restart CodeMeter Service".

1.2.2 Installation on the client computers

On each client computer:

1. Make sure that the client computer has a permanent network access to the server.

2. Follow steps 1. to. 5 and step 8. for the single user installation in section 1.1.

1.3 Installing an update

If you are updating from version 9 or earlier you have to make a complete new installation
and follow all steps in section 1.1 or 1.2.

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If you are installing a minor update for version 10 you can simply download the new
CADWIND_V10_***.ZIP file, extract the new CADWIND_V10_***.EXE file and replace the
old existing EXE file with the new one.

1.4 Hardware
CADWIND requires the following hardware for its installation:

Minimum system:
• Windows 7, 8.1 or 10
• at least 8 GB of RAM
• OpenGL capable graphic card
• one free USB 2.0 port for the CodeMeter dongle

Recommended system:
• Windows 10
• QuadCore CPU or better (CADWIND’s iWind pattern search algorithm uses parallel
processing on all CPU cores)
• 16 GB RAM or better
• dedicated OpenGL capable graphic card (NVIDIA or RADEON)
• screen resolution 1920 x 1080 or more

CADWIND User Manual © MATERIAL SPRL 15

2 Versions

Please check which CADWIND version and build number you are using. Some program
functions described in this manual can only be executed with the appropriate version and
build.

There are four versions of CADWIND V9: ESSENTIAL, STANDARD, EXPERT and HIGH-
END. Any of these packages can be extended with the DESIGN PACK option. The
following table lists the capabilities of the different packages.

ESSENTIAL

STANDARD

HIGH-END
EXPERT
Feature Description

Axisymmetric parts

Cylinder or tube with circular cross-section ✔ ✔ ✔ ✔

Vessel, bottle or cone ✔ ✔ ✔

Any axisymmetric part ✔ ✔

Non-axisymmetric parts

Tube with rectangular, elliptical or any other cross-section ✔ ✔

Elbow with circular, rectangular, elliptical or any other cross- ✔

section

T-part (eg. a pipe branch) with a circular cross-section ✔

Any non-axisymmetric geometry ✔

Mandrel model generator

Cylinder or tube with a circular cross-section ✔ ✔ ✔ ✔

Pressure vessel, bottle, cone ✔ ✔ ✔

Tube with rectangular or elliptical cross-section ✔ ✔

Elbow with circular, rectangular or elliptical cross-section ✔

T-part (eg. a pipe branch) with a circular cross-section ✔

CADWIND User Manual © MATERIAL SPRL 16

 ESSENTIAL

STANDARD

HIGH-END
EXPERT
Feature Description

Mandrel model import and export

Import axisymmetric mandrels via Autocad standard .DXF file ✔ ✔ ✔ ✔

Import non-axisymmetric mandrels via Autocad standard .DXF ✔

file

Export via CADWIND contour or surface data file (ASCII ✔ ✔ ✔ ✔

standard text)

Laminate calculations
Physical modelling and friction modelling ✔ ✔ ✔ ✔

Geodesic and non-geodesic winding ✔ ✔ ✔ ✔

Variable winding angle ✔ ✔ ✔ ✔

Variable friction definition ✔ ✔ ✔ ✔

Color scale indication of the: ✔ ✔ ✔ ✔

winding angle, laminate thickness, geodesic behaviour and
fiber bridging
Analytical circumferential (hoop) winding ✔ ✔ ✔ ✔

Analytical helical winding ✔ ✔ ✔ ✔

Analytical polar winding ✔ ✔ ✔

Modelling of thickness build-up on mandrel ✔ ✔ ✔

Layer linking (“transition” or “combination” winding) ✔ ✔ ✔

Calculation of the machine motion

Consideration of the machine’s maximum velocities and ✔ ✔ ✔ ✔
accelerations
Optimization for minimum production time ✔ ✔ ✔ ✔

Calculation of programs with constant mandrel speed ✔ ✔ ✔ ✔

Calculation of programs with constant pay-out speed ✔ ✔ ✔ ✔

Calculation of the winding time and fiber consumption ✔ ✔ ✔ ✔

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 ESSENTIAL

STANDARD

HIGH-END
EXPERT
Feature Description

Display of displacement-time, speed-time and acceleration-time ✔ ✔ ✔ ✔

graphs
The ability to create part programs from imported or modified ✔ ✔
fiber paths

Calculation of the part program for the winding machine

Machine with 2 to 6 axes ✔ ✔ ✔ ✔

Robots ✔ ✔ ✔ ✔

Specialised or custom-built winding machines ✔ ✔ ✔ ✔

Output for any machine control system ✔ ✔ ✔ ✔

Output in user defined format ✔ ✔ ✔ ✔

Output in CADWIND’s controller independent format ✔ ✔ ✔ ✔

Special part program commands for automation ✔ ✔ ✔ ✔

Control data editing ✔ ✔

Translation of existing program from CADWIND’s format to any ✔ ✔

format

Machine simulation
Real-time 3D rendered visualisation of the moving machine ✔ ✔ ✔ ✔

Graphical visualisation of the machine dynamics ✔ ✔ ✔ ✔

Collision control ✔ ✔ ✔ ✔

Numerical display of the machine positions at given times in the ✔ ✔ ✔ ✔

program

Laminate Design and Analysis

Export laminate data to any FEA program Requires

DESIGN PACK
COMPOSITE STAR (Laminate Analysis Software) included

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3 Support & Assistance

Should you encounter problems with CADWIND, please email MATERIAL with your
enquiry:

Email: info@material.be
Internet: www.material.be

It would be helpful if you can save the CADWIND project via “File” menu ► Save Project,
include the mandrel model file and part program definition file and add a short message
describing your problem and email the project file with your enquiry. The project file
contains all the winding parameters, machine parameters, mandrel model, etc that you
have been using so that an engineer at MATERIAL can replicate your problem and give you
the best advice on how to fix your problem.

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4 The User Interface (Screen Layout)

The user interface of CADWIND corresponds to the Microsoft Windows standard. So, any
user already familiar with Windows should have no difficulty navigating through
CADWIND’s menus, short-cut buttons and dialogue windows.

4.1 The menu bar

Most of CADWIND’s functions can be accessed by moving a mouse or other pointing
device over the menu bar items on the upper edge of the screen, and clicking the left button
once.

For example, Figure 4.1 shows the File menu opened, following a left-button click.

Figure 4.1: The menu bar with file menu open

Menu items with three points (...) will open a dialogue window for entering parameters (eg.
“Load Project...”). Menu items with an arrow (►) will open a sub menu (eg. “Create Mandrel
►“). All other menu items will execute their function immediately when clicked (eg. “Exit”).

CADWIND User Manual © MATERIAL SPRL 20

4.2 The graphics display
The graphics window (see Figure 4.2) contains a toolbar with selection boxes and buttons.
They allow the change of view orientation, zoom factor and they allow the switching on/off
and control of several graphics features.

Details are given in the paragraphs below.

Figure 4.2: The graphics window

4.2.1 Display Options

At the top-left of the graphics window, there are a series of toggle buttons. Click each one
to turn on or turn off the following features:

Co Coordinate system display

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 Di Dimensional reference (shows the distance from the coordinate system origin
(ie. X=Y=Z=0.0) to the point indicated, in order to indicate the scale of the
displayed mandrel winding)

MM Mandrel Marker. Red and blue longitudinal line markers on the mandrel surface
at 90° increments.

FN Frame Numbering of the mandrel

FP Frame Positions (ie. distance along the Y axis from the coordinates’ origin to
each frame)

PN Point Numbering. The numbering of the points which divide the frames.

Ve Facet normal Vectors. For every faceted division of the mandrel, this displays a
vector line projected perpendicular to that facet. This can help indicate the
shape of the mandrel and identify any bad geometry on the mandrel surface
(useful for mandrels imported to CADWIND).

Ma Machine axes. Displays the movable axes of the winding machine, as defined in
the Machine Parameters.

Fl Workshop Floor. This shows the floor of the workshop under the working area
of the particular machine (defined by the carriage and cross-carriage range of
motion in the machine parameters). This is useful for visualising the range of
motion of the machine, and also for checking that big mandrels are not going to
touch the floor when in the machine.

ND Numerical Display. This displays numerical data about the position of the fiber
(after the mandrel has been wound on, but before the machine simulation has
started) or the position of the machine (during the machine motion simulation).

4.2.2 Color Scale Options

The color scale appears on the bottom edge of the screen when turned on. It gives
colorised information about the laminate properties. The exact color of the roving at each
point in the winding corresponds with a thickness value, as shown on the scale.

CS Color Scale on / off

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Clicking in the drop-down box beside the CS button gives the following options:

Laminate thickness: Displays the estimated thickness of the layer at every point. It
is calculated at the centre of the roving, and is based on the
material properties (bandwidth, fiber volume fraction, etc) as
well as the winding (number of overlaps of plies, etc) at each
point on the mandrel surface.

Winding angle: Similar to the laminate thickness, but the winding angle is
displayed. 0° corresponds to longitudinal oriented fibers (ie.
parallel with the axis of rotation). 90° is for circumferential
(hoop-wound) fibers.

Winding angle The difference between the intended winding angle (as defined
deviation: in the Winding parameters) and the actual winding angle at
each particular point on the winding.

Geodesic behaviour: Indicates the degree to which friction is being relied upon to
prevent the roving from slipping sideways across the mandrel
surface. Roving areas shown as being on the “geodesic path”
do not rely on friction to prevent slippage (and hence should
never slip). Rovings which are at the “friction limit” rely on
having friction, as defined by the “friction factor” in the winding
parameters, to prevent slipping. Hence, if the friction factor
defined for these areas is higher than the maximum friction
factor (ie. coefficient of friction) in real life, the fibers will slip.
So, in effect this color scale indicates the areas where slipping
might occur.

4.2.3 Animation Controls

Both the winding (ie. before the machine simulation), and the machine simulation can be
animated using the DVD player style of animation control buttons shown in Figure 4.2.

SSB Single Step Backward: Moves the animation one frame backwards.

< Play the animation backwards

STP SToP: Pauses the animation.

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 > Play the animation forwards

SSF Single Step Forward: Moves the animation one frame forwards.

Loo Loop: Toggle button which causes the animation to start again at the beginning
immediately upon reaching the end. Hence, playing in a continuous loop.

4.2.4 Animation Speed

The first box (on the left) in the “Animation Speed” area shown in Figure 4.2 controls the
number of winding steps between one animation frame and the next frame (ie. the frame
display rate). This box is greyed-out and unusable when the machine motion simulation is
running.

“1“ means that every step in the winding is shown as an animation frame. Higher numbers
increase the speed of the animation proportionately (ie. “2“ is 2 steps per frame, so the
animation runs at 2x the speed, “4“ is 4 x the speed, etc). The value can be changed by
clicking on it, deleting the current value and typing a new value, or by clicking the up/down
arrows.

▲ Increase the frame display rate of the animation by 1

▼ Decrease the frame display rate of the animation by 1

The second box is used to control the speed of the machine motion animation during the
machine simulation. The number is a percentage of full speed. This box is greyed-out and
unusable if the machine motion simulation is not running.

“100“ means 100% machine speed. “200“ means 200%, and runs the simulation at twice
the speed as the machine would actual run (assuming the controller is set at 100%).

▲ Increase the machine motion simulation speed by 1%

▼ Decrease the machine motion simulation speed by 1%

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4.2.5 View Orientation

The “View Orientation” settings shown in Figure 4.2 control the way that the mandrel,
winding and simulation are displayed in the graphical window.

The drop-down box showing “Top”, “Front”, “Perspective”, etc. are predefined views and
when selected will reorient the mandrel view (in the display window). Left-click on the arrow
to the right of the drop-down box and then select the desired view by left-clicking again with
the mouse.

- Zoom out: Makes the mandrel smaller in the display window.

+ Zoom in: Makes the mandrel larger in the display window.

X Reset zoom: Resets the zoom factor to its default (ie. makes the mandrel fit
neatly inside the display window). Does not affect view orientation.

<- Reset view: Resets the view orientation and zoom to the default for the view
selected in the drop-down box left of this button.

4.2.6 Mandrel Display

The drop-down box labelled as “Mandrel Display“ in Figure 4.2 controls the way the
mandrel in the display window is rendered. The options are:

None: No mandrel displayed / invisible mandrel (rovings are still displayed).

Mesh: A mesh which traces the mandrel frames and joins points on adjacent
frames is shown as a series of white lines. This is analogous to a mesh in
a finite element surface model.

Facets: The mandrel is rendered as a series of facets (ie. flat faces).

Solid: The mandrel is rendered smoothly.

Solid+Mesh: The mandrel is rendered smoothly, with the mesh (see above) overlaid on
the top.

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4.2.7 Roving Display

The roving display area has two drop-down boxes. The first one (to the left) controls the
thickness of the roving displayed and has three options:

Roving: Displays the full roving bandwidth, having the width defined in the material
parameters (bandwidth = number of rovings x roving width).

Thin line: Displays a thin line representing the roving, located at the roving centre.

Thick line: Displays a thick line representing the roving, located at the roving centre.

The second drop-down box controls the display of the “Crawler”. The crawler is a shortened
version of the roving, showing the last few steps of winding only. It moves as the animation
progresses, appearing to “crawl” across the mandrel.

Full roving:

Short crawler:

Long crawler:

4.2.8 Zooming in/out

There are two possible methods for magnifying an area of the graphics display (ie. making
the mandrel view bigger or smaller):

• the mouse scroll wheel can be used to zoom in and out dynamically.
• left-click on the buttons - + described in the Section 4.2.5 to incrementally
zoom out or in.

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4.2.9 Panning (moving the view across the screen)

The mandrel view can be panned across the screen without changing the zoom or
orientation using the mouse, by doing the following:

1. Move the pointer anywhere inside the display window.

2. Click and hold the left mouse button.
3. Move the mouse pointer left, right, up or down and the mandrel should pan with it.

Note that it is possible to pan the mandrel completely outside of the display window, so that
it is no longer visible. If this happens, the best thing to do is click the view reset button <-
to restore the mandrel in the display window (see Section 4.2.5 for details).

4.2.10 View Reorientation

The view can be reoriented in one of three ways.

• Use the predefined view orientations. See Section 4.2.5 for details.
• Dynamically change the orientation with the mouse (or pointing device) by:
1. Move the pointer anywhere in the display window.
2. Click and hold the RIGHT mouse button.
3. Move the mouse left, right, up or down to rotate the view dynamically.
• Click on the view reset button <- to restore the orientation to its original view.

4.2.11 Dialogue windows

All parameters are entered via standard dialogue windows. They contain four different
elements:

• input fields for entering text.

• radio buttons to choose one out of several options.
• check boxes to switch on/off options.
• function buttons to execute a function directly.

These elements can be reached as follows:

• by pressing TAB or SHIFT-TAB on the keyboard to move from one field to the next.
• by pressing and holding ALT on the keyboard and then the underlined character.
• by clicking with the mouse in the field.

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The parameters in a dialogue window can be confirmed by pressing the OK button. You
can cancel with ESC or by pressing the Cancel button.

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5 Options Menu

CADWIND has a few general usage options which can changed according to the user’s
preferences. They can be reached by clicking:

“Options” menu ► “General Options...”

Figure 5.1: General options

Any changes made to the general options are automatically saved and will be the same
next time CADWIND is opened.

5.1 Units
The options for “Units” are:

Metric system: All dimensions will be in millimetres

English units: All dimensions will be in inches

5.2 Language
The “Language” option will change the language used for all labels on menu items,
dialogue windows, etc.

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6 Projects

6.1 About project files

The CADWIND project is a convenient way to save the user’s work, so that the user can
return to it later. It is a text file containing all the parameters entered into CADWIND. As it is
a text file, it can be viewed and edited using CADWIND’s text editor under the “Tools”
menu, or any other text editor (eg. Notepad).

There are other several ways to save CADWIND parameters too. For example, the mandrel
(.MDR) file stores the information about the mandrel geometry only (see Section 8), while
the iWind parameters file (.iWind) stores the winding parameters that were entered into the
iWind window (see Paragraph 10.7) and the post processing parameters (.PPP) file stores
only the post-processing parameters.

The user could save the mandrel, winding parameters, post-processing parameters in
separate files and re-load them all. However, it is often more convenient way to store all the
parameters in one file. CADWIND does this in the Project file.

6.2 Project file contents

The Project file contains all the parameters entered in CADWIND, at the time the Project file
was saved, including:

• the mandrel parameters and optionally, the mandrel geometry (frame data)
• all winding parameters for a single layer,
• all postprocessing parameters,
• all machine parameters,
• the definition file,
• various display options (window sizes and positions, etc).

6.3 How to save a project

To save a project, click the “File” menu, then “Save project…”

6.4 Options when saving a project

After clicking “Save project…”, the user will be asked to choose to either:

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 • “Use external files”, or
• “Include the files in the project file”

Figure 6.1: Save project options

If “Use external files” is chosen, then the definition file and the mandrel file (ie. frame data)
are not saved in the project file. Instead, the path and filename of these files is stored.

If “Include the files in the project file” is chosen, then the contents of the definition file and
the contents of the mandrel file are saved inside the project file.

6.4.1 Use external files

Note that if “Use external files” is chosen, CADWIND does not save the information in the
mandrel and definition files, and relies only on a stored links to these files, to retrieve the
information therein.

If either the mandrel file or definition file names or folder locations changes after the project
file has been saved, then the link will be broken and the project file will not load correctly.

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Figure 6.2: Project file’s link to a mandrel file

If CADWIND cannot find the file in the link when the project is loaded, it will give an error
message.

Figure 6.3: Mandrel file not found

This error might occur if the mandrel file or definition file have been either:
• moved,
• renamed,
• deleted,
• or if the Project file has been copied to a different computer where either of these
files are in different folders or have different names.

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6.4.2 Include the files in the Project file

If the “Include the files in the project file” option is selected, then the information contained
in the mandrel file and the definition file will be stored in the project file. This ensures that
there is no link to external files that can be broken and will avoid the potential error
message described in the previous paragraph. This makes the “Include the files in the
project file” option more robust and usually a better choice for new users. It is certainly a
better choice if the project file is to be copied to another computer or shared with another
user.

The disadvantage of this selection is that if any changes are made to the mandrel file or
definition files after the project is saved, those changes will not be present when the project
file is reloaded. So, some advanced users may prefer the “Use external files” option for this
reason.

6.5 How to load a project

Before a project can be loaded, the project first needs to be saved (see previous
paragraphs).

To load a project, click the “File” menu, then “Load project…”

Then, simply browse to the project file in the usual way. The file should have a .CWP file
extension.

Then click Browse .

If an error occurs, like “Error reading the project file”, it may be because a link to an external
file has been broken. See 6.4.1, above, for details of why this might occur.

If a link is broken in this way, it can be repaired by opening the project file in CADWIND’s
text editor (“Tools” menu -> “Editor…”) or Notepad, or any other text editor. After opening
the text file for editing:

1. locate the mandrel file link (near the top at approximately line number 19) or
definition file (near the bottom at approximately line number 357),

2. correct the path and file name,

3. then save the text file

4. try reloading the project with CADWIND (“File” menu -> “Load project…”).

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7 Getting Started: Demonstration of CADWIND
usage

An example is the best way to demonstrate the operation of CADWIND for new users. The
example on the following pages shows the winding of a pressure vessel with closed ends.

Figure 7.1: Example vessel winding

There are 3 basic steps required to create a winding simulation and part program.
Step 1 – Creating the mandrel
Step 2 – Winding over the mandrel
Step 3 – Simulating the machine movements and making the part program

There is an optional fourth step, to analyse the machine motion by graphs, and make sure it
is acceptable.

Step 4 – Graphing the machine motion

This chapter steps the reader through an example of the process, showing each step. It is
intended for new users to show them the work-flow; not as a detailed explanation.

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7.1 Step 1 – Creating the mandrel
CADWIND makes mandrel creation easy. Simply click the “File” menu and “Create mandrel”
and then “Circular cross-section…”

Figure 7.2: Circular cross-section mandrel menu

Enter the mandrel dimensions as parameters (as shown below), in the “Circular cross-
section” window that should appear. Choose “Ellipsoid” for the pole caps (domes).

Figure 7.3: Example mandrel parameters

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The meanings of the parameters are shown below:

Figure 7.4: Mandrel parameter definitions

When you click “Ok”, you are confirming the values you just entered. A window will appear
asking you to give a location and name under which to save the mandrel file.

Give the mandrel file a name and folder

Browse to the folder where you want to keep your CADWIND files for this example and type
in a name for the mandrel file. For example:

Example_Pressure_Vessel.MDR

The .MDR file extension is for CADWIND mandrel files.

Click “Save”.

At this point, a question window might appear on the screen as shown. It is a warning that
any winding parameters you may previously have been working with will be lost unless you
save them, in preparation for the new winding.

Figure 7.5: Resetting of winding parameters

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If you were not doing any important winding before starting this example, just click “No”.

Now the mandrel should appear on the screen as shown below.

Figure 7.6: 3D mandrel model

7.2 Step 2 – Winding over the mandrel

A common task for a pressure vessel is to design a winding layer which covers the dome
ends completely, leaving only the pole openings uncovered. CADWIND’s iWind feature
makes this easy.

To start the iWind feature, click the “iWind” menu, then “iWind”.

Keep the defaults for “Start frame”, “Turning zone front”, “Turning zone back from” and “Start
winding direction”. Enter the other parameters as shown.

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Figure 7.7: iWind parameters

Select “Live” calculation mode, so you can instantly see the windings on the screen.

Figure 7.8: Live mode

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Set the friction factor to the maximum limit for your type of winding (for example, 0.12 is a
safe limit for wet winding).

Now experiment with different winding angles by typing the angle in the “Winding Angle”
field, or sliding the slider.

After each winding experiment, check to see whether the poles are completely covered. It
will help to set up two windows, one showing the front pole and one showing the back. You
can do this by clicking the “View” menu and clicking “New mandrel view”. You can orient
each view using the drop-down box at the top-left of the screen.

Simply keep experimenting with winding parameters until you find the winding pattern you
like.

Figure 7.9: iWind window with Front and Back mandrel views

At the bottom of the iWind window, there is a list of different possible winding patterns. You
can experiment with these to find the degree of coverage, pattern number, friction limit, etc.
that you want. Just click on the pattern you want and it will appear on the screen. You can
scroll up/down using the scroll bar to the right.

You can also sort the patterns (ascending or descending order) according to any of the
parameters, by clicking the arrow ( )

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You can filter for particular parameters by clicking the filter icon ( ). For example, if you
want to see what 4 and 9 pattern numbers are available, you would sort as shown below:

Figure 7.10: Filtering patterns

7.3 Step 3 – Making the part program and simulation

Now that a layer is ready, the machine movements required to wind this layer can be
calculated.

1. Click “Postprocessing” menu ► “Parameters...”

A dialogue window should appear, ready for you to enter the parameters that CADWIND
needs to calculate the machine movements.

2. Enter the postprocessing parameters

Enter the postprocessing parameters, exactly as shown in Figure 7.11 below. Don’t worry if
you don’t understand all these parameters yet as they will be explained later in the manual.

CADWIND User Manual © MATERIAL SPRL 40

Figure 7.11: Example postprocessing parameters

3. Click on Browse

This will open a window where you can select a location and filename for the part program.
In this example, use the “CCDF” (CADWIND Control Data Format), which is non-machine
specific, select the folder for the CCDF file and give it a name with a .DAT extension.

eg. D:\Example_pressure_vessel.dat

4. Click on Control data

By clicking on Control data , you will:

• save the post-processing parameters entered (in memory only, not on the hard-disk),
• calculate the machine control data,
• save the control data into a part program and
• start the machine motion simulation.

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If this warning message appears on the screen: “File Example_pressure_vessel.dat already
exists. Overwrite?”, choose appropriate responses to continue (eg. click Yes ).

If this warning message appears on the screen: “Position out of range. Axis: Carriage” (or
similar), this means that the carriage has moved beyond the limits defined in the machine
parameters. Don’t worry about it now (although perhaps your machine parameters need to
be corrected later). Just click OK .

You should see the animated simulation in the display window, as shown in Figure 7.12.

Figure 7.12: Machine motion simulation

5. Practice panning, zooming and reorienting the view

You can pan, zoom and change the view orientation while the simulation is running to
closely inspect all aspects of the machine motion closely. You can also speed up, slow
down, pause the animation and change the appearance of the mandrel, roving and
machine. It is a good idea to practice doing all this at this point, to build proficiency using
CADWIND’s interface.

See Section 4.2 for details on how to do all the above.

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7.4 Step 4 - Analysing the machine motion
One good way to analyse the machine is simply to watch the animation carefully. By doing
this, you can see if there is likely to be any collision between machine and mandrel, or if
there are any undesirable machine movements (such as a motion that is to rapid or jerky).

Another way to analyse the machine motion is by using graphs. This section demonstrates
the use of the machine motion graphing tools.

1. Click on “Postprocessing” menu ► “Display...”

This will open a window which allows you to browse to the CADWIND Control Data Format
(CCDF) file created before, which should have a .DAT extension

eg. D:\Example_pressure_vessel.dat

2. Select the .DAT file you created earlier

3. Click on Open

4. A series of graphs should appear on the screen as shown in Figure 7.13:

Figure 7.13: Machine motion graphs of position versus time

You can graph many different aspects of the machine motion, such as positions, velocities
and accelerations of each axis or several axes all on the same graph. Experiment by
choosing different options from the options on the left of the window.

Any rapid machine movements or jerky accelerations should show up on these graphs,
allowing them to be identified before risking damage to the winding machine.

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8 Mandrel models

The first step in the CADWIND process is to create a computer model of the winding
mandrel.

CADWIND is able to create a range of common mandrel shapes quickly and easily using
the mandrel generator. More complicated mandrel shapes can be imported from a .DXF
(CAD file) or spreadsheet.

8.1 Generating mandrels automatically

The following section discusses the use of the mandrel generator to quickly make the most
commonly used mandrel shapes.

To open the mandrel generation options, click: “File” menu ► Create mandrel

The basic geometries that can be created are:

• Circular cross-section geometries such as pipes, tubes and pressure bottles
• Rectangular cross-sections (only with CADWIND EXPERT or HIGH-END) such as
rectangular tubes
• Elliptical cross-sections (only with CADWIND EXPERT or HIGH-END)
• Elbows (only with CADWIND HIGH-END) such as pipe bends
• Cones (only with CADWIND STANDARD, EXPERT or HIGH-END) and tapering
tubes
• T-Parts (only with CADWIND HIGH-END) such as pipe branches

Note that some options may not be available, depending on the CADWIND version you
have purchased. Contact MATERIAL if you wish to upgrade your version to allow for the
generation of more mandrel shapes.

The generation of the different mandrel geometries will be covered in detail in the following
sections.

8.1.1 Circular Cross-Section

Select:

“File” menu ► Create Mandrel ► Circular cross-section...

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Figure 8.1: Creating circular X-section mandrels

A window should appear, asking for the dimensions of the mandrel, as shown below.

Figure 8.2: Dialogue window for circular cross-section mandrels

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Parameters for Circular Cross-Section Mandrels

The dimensions in the ‘Circular cross section’ mandrel creation window are defined as
follows:

Figure 8.3: Dimensions of circular cross-section mandrel

The different pole cap styles are as follows:

Extension:
Fibers turn on the
surface and do not cover
the end

Stepped Shaft:
Fibers wrap over the
edge radius and flat
surface but may not
cover the pole

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 Ellipsoid:
Same as “Stepped
Shaft”, but with an
elliptical dome profile
that continues to the pole
opening. Fibers turn on
elliptical surface, but do
not cover the pole.

Parabolic:
Same as “Ellipsoid”, but
a parabolic dome profile
is used.

Cone:
Fibers will turn around
over the cone, but not
over the pole opening.

Sphere:
Same as “Ellipsoid” but
with a spherical shape. It
is not necessary to
define a dome length.

Figure 8.4: The different pole cap styles

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Number of frames: see Section 8.2.1

8.1.2 Rectangular Cross-Section Mandrels

The creation of rectangular cross-section mandrels is only possible with EXPERT or HIGH-
END.

Select: “File” menu ► Create Mandrel ► Rectangular cross-section...

A window should appear, asking for the dimensions of the mandrel, as shown below.

Figure 8.5: Parameters for mandrels with rectangular cross-sections

The definition of the parameters is as shown in Figure 8.6.

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Figure 8.6: Dimensions of a rectangular cross-section mandrel

The only two options for the pole caps are: Extension, or Stepped shaft. The parameters for
both styles are the same as for a circular cross-section mandrel (see Section 8.1.1 and
Figure 8.6 for details).

Number of frames: see Section 8.2.1

8.1.3 Elliptical Cross-Section Mandrels

Creating elliptical cross-section mandrels as described here is only possible with EXPERT
or HIGH-END.

Select: “File” menu ► Create Mandrel ► Elliptical cross-section...

A window should appear, asking for the dimensions of the mandrel, as shown in Figure 8.7.

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Figure 8.7: Dialogue window for mandrels with elliptical cross-section

The definition of the parameters is as shown in Figure 8.8 below:

Figure 8.8: Dimensions of an elliptical cross-section mandrel

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The only three options for the pole caps are: Extension, Stepped shaft or Ellipsoid. The
parameters for all styles are the same as for a circular cross-section mandrel (see Section
8.1.1 for details and the Figure 8.8 for Stepped Shaft and Extension).

Number of frames: see Section 8.2.1

8.1.4 Elbows

Creating elbow shaped mandrels as described here is only possible with CADWIND HIGH-
END.

Select: “File” menu ► Create Mandrel ► Elbow circular cross-section...

or, “File” menu ► Create Mandrel ► Elbow rectangular cross-section...
or, “File” menu ► Create Mandrel ► Elbow elliptical cross-section...

A window should appear, asking for the dimensions of the mandrel, as shown below.

Figure 8.9: Dialogue window for elbow mandrels (circular cross-section)

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The definition of these parameters is as shown in Figure 8.10.

Figure 8.10: Dimensions of a elbow shaped mandrel

The options for the pole caps (areas where the fiber will be turned) are:
• Extension
• Stepped shaft
• Ellipsoid
• Paraboloid
• Cone
• Sphere

These options are exactly the same as for a straight mandrel with circular cross-section.
See Section 8.1.1 for details on the different pole cap types.

Number of frames: see Section 8.2.1

8.1.5 Cones

Creating cone shaped mandrels as described here is only possible with CADWIND
STANDARD, EXPERT or HIGH-END.

Select: “File” menu ► Create Mandrel ► Cone...

A window should appear, asking for the dimensions of the mandrel, as shown in Figure
8.11.

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Figure 8.11: Dialogue window for cone mandrels

The definition of these parameters is as shown below.

Figure 8.12: Dimensions of a cone shaped mandrel

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The options for the pole caps (areas where the fiber will be turned) are:

• Extension
• Stepped shaft
• Ellipsoid
• Paraboloid
• Cone
• Sphere

These options are exactly the same as for a straight mandrel with circular cross-section.
See Section 8.1.1 for details on the different pole cap types.

Number of frames: see Section 8.2.1

8.1.6 T-Shaped Mandrels

Creating T shaped mandrels as described here is only possible with CADWIND HIGH-END.

Select: “File” menu ► Create Mandrel ► T...

A window should appear, asking for the dimensions of the mandrel, as shown below.

Figure 8.13: Dialogue window for T shaped mandrels

The definition of these parameters is shown below.

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Figure 8.14: Dimensions of a T shaped mandrel

8.2 Frames and meshing of automatically generated

mandrels
All CADWIND mandrels, except T mandrels are mathematically divided longitudinally into
frames and each frame is subdivided into points around its perimeter. Frames are spaced
longitudinally along the mandrel and define its shape. For an axisymmetric mandrel, the
frame can be completely defined by only two numbers: a diameter and a longitudinal
position (Y value). This information is stored for each frame of an axisymmetric mandrel, in
the mandrel (.MDR) file.

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Figure 8.15: Frame numbering on a pressure vessel mandrel

The first point on each frame of all CADWIND generated mandrels is on the X axis. The
numbering of points increases in the counter-clockwise direction, when viewed from the
front (ie. as though the viewer were at the headstock of the machine, or “Front” view in
CADWIND). Point numbering continues on subsequent frames. For example, if 40 was the
last point of frame 1 then 41 would be the first point of frame 2.

Figure 8.16: Point Numbering around Frame 1

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8.2.1 Numbers of Frames

Except for T mandrels you can define the frame divisions on the mandrel model with the
"Number of frames" section in the mandrel creation dialogue windows (see Figure 8.17).

There are two methods:

• individually spaced frames: You can enter different number of frames for the different
parts of the mandrel model (the centre section ie. the area between the pole caps,
the front pole cap, the back pole cap).
• equally spaced frames: You can enter the total number of frames for the whole
mandrel model. The frames are equally spaced over the mandrel model.

Figure 8.17: Definition of the frame divisions

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8.2.2 Number of Points

By default, there are always 40 points per frame on an automatically generated mandrel.
This can be easily changed by altering the mandrel file for circular cross-section mandrels
and cones (see Section 8.4.3 for details).

8.2.3 T mandrel meshes

As Figure 8.18 shows, the ‘T’ mandrel is very different from all other CADWIND mandrels
types. It is the only mandrel that has 3 pole openings, and so the point positioning making
up the mesh (which defines the shape) is quite different from other mandrels and more
complicated.

It is not possible to define a T-mandrel and import to CADWIND like it is for other mandrels,
so the user will never be required to define the mesh.

Figure 8.18: T-mandrel mesh

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8.3 Saving and loading mandrel generation parameters
The mandrel generation parameters can be saved and loaded by clicking the
Save parameter… and Load parameter… buttons. This function is available for all mandrel
generation types, except “T” mandrels.

The mandrel parameters are stored in a text file with a CWGen file extension. An example
is shown below.

Figure 8.19: Example of .CWGen file

These same parameters are also saved at the bottom of the mandrel (MDR) file itself (see
Section 8.4.3). However, the parameters at the bottom of the MDR file are not loaded by
CADWIND when the mandrel file is loaded via the “File” menu ► Load Mandrel, so they
can be considered as comments for the user’s reference.

To see the mandrel generation parameters from a previously defined mandrel, in the
mandrel generation window, a CWGen file or a MDR file which contains the mandrel
generation parameters must be loaded with the Load parameter… button.

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8.4 Generating mandrel models manually
CADWIND can create the most commonly used mandrel shapes automatically. However,
more complicated mandrel shapes must be created outside of CADWIND. There are two
ways to do this:

• Using a spreadsheet or text editor to create a text file that defines the mandrel
numerically and saving it with a .MDR file extension (eg. “Example mandrel.MDR”).

• Using CAD (Computer Aided Design) software to create a .DXF file (ie. an Autocad
Drawing eXchange Format file) and using CADWIND to convert this into a mandrel
(.MDR) file.

The following sections will address the method of making mandrel text files directly and will
discuss how to make them using CAD software.

CADWIND has three formats of mandrel file:

• the mandrel contour format for axisymmetric mandrels
• the mandrel surface format for any mandrel geometry (axisymmetric and non-
axisymmetric)
• the “T” format for T-shaped mandrels

8.4.1 Mandrel Coordinate System

To define a mandrel mathematically, first a right-handed coordinate system must be

defined. CADWIND’s mandrel coodinate system is defined as:

• The ‘Y’ axis is aligned with the spindle rotation axis on the machine (an offset is
possible for non-axisymmetric mandrels)
• The ‘Y’ axis positive direction runs from the headstock (where the chuck and spindle
motor are) towards the tailstock.
• The ‘Z’ axis is vertical and points upwards when the mandrel is at 0° rotation.
• The ‘X’ axis is horizontal when the mandrel is at 0° rotation.

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Figure 8.20: The mandrel coordinate system

8.4.2 Division of the mandrel into frames and points

Section 8.2 describes the division of the automatically generated mandrels into frames and
points. The only difference with manually created mandrels is that the user must decide:

• where the mandrel coordinate system should be,

• the number and positioning of frames and
• the number (and positioning for non-axisymmetric mandrels) of points.

Figure 8.21: Example of manually defined mandrel frame numbering & coordinates

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8.4.3 The Mandrel Contour format (for axisymmetric mandrels)

To create an axisymmetric mandrel outside of CADWIND, a text file needs to be written

using ASCII standard characters and loaded by selecting “File” menu ► Load mandrel...

The CADWIND text editor can be used to write, view or edit the mandrel file by selecting:
“Tools” menu ► Editor...

Or, the text file can be written using another editor (eg. Notepad), or a spreadsheet (eg.
Excel). Spreadsheets can be written to rapidly make mandrels of a shape that is of interest.

The mandrel contour format has the following structure:

Example of Line Syntax Explanation

CADWIND CONTOUR DATA FILE The first Line identifies the file type to
CADWIND. The file MUST start with this line,
written exactly as shown.
MM “MM” for values in millimetres or “IN” for
values in inches
28 The total number of frames (must be an
integer)
40 The number of points per frame (must be an
integer)
6 The front turning zone ends at Frame 6 (an
integer)
23 The back turning zone starts at Frame 23 (an
integer)
-230.00 80.00 Y coordinate Diameter of Frame 1
-200.00 181.00 Y coordinate Diameter of Frame 2
-140.00 281.00 Y coordinate Diameter of Frame 3
... etc. ...etc.
1240.00 320.00 Y coordinate Diameter of Frame 27
1280.00 150.00 Y coordinate Diameter of Frame 28

Created by CADWIND's mandrel Mandrel generation parameters, stored as

generator comments for the user’s reference by the
{Units} mandrel generator.
Units=metric
{Mandrel generator / Geometry}
This information is not used by CADWIND and
Geometry=Circular cross-section
not required by CADWIND when the mandrel
{Mandrel generator / Circular cross-
section} file is loaded via “File” menu ► Load
Diameter (mm)=100 mandrel....
… etc.

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Notes:
• The total number of frames must be between
4 (minimum) and 400 (maximum).
• The number of points per frame must be between
12 (minimum) and 600 (maximum).
• The front turning zone must be between
1 ≤ front turning zone ≤ (maximum number of frames - 1)
• The back turning zone must be between
front turning zone < back turning zone ≤ (maximum number of frames-1)
• If no value for units is specified (line 2), CADWIND assumes millimetres (MM)

8.4.4 The Mandrel Surface format (for non-axisymmetric mandrels)

The Mandrel Surface format can describe both axisymmetric and non-axisymmetric
mandrels. However, it is much simpler to use the Mandrel Contour format for axisymmetric
mandrels, so the Mandrel Surface format is usually used only for non-axisymmetric
mandrels.

To create an axisymmetric mandrel outside of CADWIND, a text file must be written in

ASCII standard characters and loaded into CADWIND by selecting “File” menu ► Load
mandrel...

The CADWIND text editor can be used to write the mandrel file by selecting:
“Tools” menu ► Editor...

Or, the text file can be written using another editor (eg. Notepad), or a spreadsheet (eg.
Excel). Spreadsheets can be written to rapidly make mandrels of a shape that is of interest.

The Mandrel surface format approximates each frame as a polygon. The X,Y,Z coordinates
of each polygon point are stored in the mandrel file.

Figure 8.22 shows an example for the point numbering of an elliptical shaped frame, with
18 points.

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Figure 8.22: Point numbering of an elliptical shaped frame

Mandrel Surface format files have the following structure:

Example of Line Syntax Explanation

CADWIND SURFACE DATA FILE The first Line identifies the file type to
CADWIND. The file MUST start with this line,
written exactly as shown.
MM “MM” for values in millimetres or “IN” for
values in inches
AXISYM: NO Indicates that the mandrel is not axisymmetric.
Alternative: “AXISYM: YES”
36 The total number of frames (must be an
integer)
40 The number of points per frame (must be an
integer)
7 The front turning zone ends at Frame 7 (an
integer)
17 The back turning zone starts at Frame 17 (an
integer)
0.00 -30.00 0.00 X, Y, Z coordinates of the start point
0.00 309.90 0.00 X, Y, Z coordinates of the end point
75.00 -30.00 0.00 X, Y, Z coordinates of point 1 on frame 1
74.08 -30.00 6.26 X, Y, Z coordinates of point 2 on frame 1
71.33 -30.00 12.36 X, Y, Z coordinates of point 3 on frame 1
...etc. ...etc.
74.08 -30.00 -6.26 X, Y, Z coordinates of point 40 on frame 1

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 Example of Line Syntax Explanation
(Optional spacer line between frames for
easier reading)
75.00 -25.00 0.00 X, Y, Z coordinates of point 1 on frame 2
74.08 -25.00 6.26 X, Y, Z coordinates of point 2 on frame 2
...etc. ...etc.
74.08 -25.00 -6.26 X, Y, Z coordinates of point 40 on frame 2
...etc. ...etc.
30.00 309.90 0.00 X, Y, Z coordinates of point 1 on frame 36
...etc. ...etc.
29.63 309.90 -4.69 X, Y, Z coordinates of point 40 on frame 36

Created by CADWIND's mandrel Mandrel generation parameters, stored as

generator comments for the User’s reference by the
mandrel generator.
{Units}
Units=metric
This information is not used by CADWIND and
{Mandrel generator / Geometry}
not required by CADWIND.
Geometry=Elliptical cross-section
{Mandrel generator / Elliptical cross-
section}
Axis A (mm)=150
Axis B (mm)=60
…etc.

Notes:
• The total number of frames must be between
4 (minimum) and 400 (maximum).
• The number of points per frame must be between
12 (minimum) and 600 (maximum).
• The front turning zone must be between
1 ≤ front turn zone ≤ (total frames - 1).
• The back turning zone must be in the range of:
front turning zone < back turning zone ≤ (total frames-1).
• If no value for units is specified (line 2), CADWIND assumes millimetres (MM).
• The points must be ordered in a counter-clockwise direction. See Figure 8.22.
• The points should be approximately equally spaced for best results. Try to avoid
large jumps in point spacing (ie. avoid having a short distance from points 1 to point
2, followed by a large distance from point 2 to point 3).
• For best results, edges (for example, on a rectangular section) should be rounded
with a radius defined by several points. Avoid sharp edges.

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 • The gradients of corresponding polygon lines should be approximately equal.
Otherwise twisting of the mandrel model is possible and problems may occur with
the winding (see Figure 8.23).

gradient a ≈ gradient b gradient c ≠ gradient d

⇒ correct mandrel ⇒ incorrect mandrel (twisted mandrel)
Figure 8.23: Correct and twisted mandrel model

8.4.5 Creating mandrels using external CAD software

The mandrel generator is limited to common shapes, and to create CADWIND mandrel files
manually for complex geometries can be time-consuming and difficult. Hence, CADWIND
has two methods of converting CAD data quickly into mandrel files. They are:

• "File" menu ► DXF ➯ Contour

• "File" menu ► DXF ➯ Surface

8.4.6 DXF ➯ Contour...

The DXF ➯ Contour feature takes an Autocad standard Drawing eXchange Format .DXF
file and creates a CADWIND Mandrel Contour format file. If you have CAD software that
can create DXF files, this is a fast way of making complicated axisymmetric mandrels.

Start by drawing the contour profile that you want in your CAD system. Figure 8.24 gives an
example of a contour drawn in pro/Engineer.

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Figure 8.24: Profile contour shape created in CAD software

The rules for CAD drawings

There are several rules that you must follow when drawing your profile, in order to
successfully convert it into a CADWIND mandrel.

• The CAD drawing must be 2 dimensional. It represents only the profile shape
(contour) of an axisymmetric mandrel.
• 3 dimensional solid or surface models will NOT convert successfully into mandrel
shapes.
• the CAD data must be in AutoCAD standard drawing exchange format (.DXF).
• the CAD data must only contain straight lines and circular arcs.
• Splines, bezier lines, polylines, etc must not be used and, if necessary, should be
approximated by straight lines and circular arcs.
• The coordinate system origin of the 2 dimensional CAD data corresponds to the
origin of the 3 dimensional mandrel coordinate system
• The distance from the X axis of the CAD drawing to the contour at any point,
represents the radius of the mandrel at that point. Therefore, the positioning of the
contour above the X-axis is critical to achieving a mandrel with the correct
dimensions (see Figure 8.25).
• The ending point of straight line or circular arc must align exactly with the starting
point of the next straight line or arc. This can be achieved easily in most CAD
systems by using the “Snap to object” (or similar) feature
• If the CAD drawing is in inches, then the CADWIND contour data file must be
opened with a text editor after it has been created, and the header changed from
“MM” to “IN”.
• CADWIND only accepts CAD data in millimetres or inches. Don’t use other units in
the CAD drawing such as feet, metres, etc.

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Figure 8.25: CAD data positioning

Hints for better quality CADWIND mandrels

Divide Long Straight Lines: CADWIND will automatically divide an arc into several frames in
order to accurately represent the arc’s shape. However it does not divide straight lines into
multiple frames. So, a long straight line will not have any frames subdividing it, which may
lead to a part program which does not run smoothly. To avoid this, divide long straight lines
into several short lines (see Figure 8.26). CADWIND then creates more mandrel frames
leads to a better quality part program.

Figure 8.26: Dividing long straight lines in CAD data

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Define the turning zones

If you have converted CAD data into a CADWIND mandrel, there is no information about
the location of turning zones on that mandrel. By default, CADWIND will set the front
turning zone at Frame 1 and the back turning zone to be one frame before the last frame.
This probably is not the best definition of the turning zones.

You can set the turning zones manually in the winding parameters later, but if you already
know where you want the fibers to turn, it is better to enter this information in the mandrel
file itself. That way, the turning zones will automatically be set correctly in the winding
parameters window, and there is less chance of forgetting to set them.

To set the parameters manually (after having converted the .DXF file to a mandrel file):
• First open the mandrel in the display window by selecting “File”menu ► Load
Mandrel...
• Turn on frame numbering by clicking FN on the display options toolbar.
• Find the frames where you want the fibers to turn at the front and the back, and
make a note of their frame numbers.
• Open the mandrel file in the text editor by selecting “Tools” menu ► Editor... and
browsing to the mandrel (.MDR) file and clicking Open .
• Change lines 6 and 7 to be the frames at the edge of the front and back turning
zones, respectively (see Figure 8.27).

Figure 8.27: Defining the turning zones manually

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The procedure for importing the CAD geometry into CADWIND as a mandrel:

1. Once the .DXF file has been created, it can be converted into a mandrel (.MDR) file
by selecting “File” menu ► DXF-> Contour...
2. In the window that appears, browse to the DXF file created by a CAD system. Select
it and click Open .
3. In the next window that appears, the mandrel file to be saved needs to be given a
folder location and filename. Browse to the folder where you want to store your
mandrel and give it a name with a .MDR file extension, then click Save .

If the process was successful, there will now be a new mandrel file saved in the chosen
folder.

4. Select: “File” menu ► Load mandrel...

5. Browse to the new mandrel file as usual, select it and click Open .

You should now see the mandrel in the display window. You can wind over this mandrel
and create part programs in the same way as for any other mandrel.

8.4.7 DXF ➯ Surface... with CADWIND EXPERT or HIGH-END

CADWIND EXPERT or HIGH-END users can convert 3D CAD geometry into non-
axisymmetric mandrels.

Figure 8.28: CAD drawing of a single frame

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Figure 8.29: CAD drawing of all frames (the mandrel surface is shown only for clarity, and
should not be included in the .DXF file)

Section 8.4.4 describes the mandrel surface format, and Section 8.2 explains that the
mandrel is divided into frames and the frames are divided into points. To define a 3
dimensional non-axisymmetric mandrel, therefore it is necessary to define the location of
every point on every frame. See Figure 8.28 and Figure 8.29.

If you use a CAD system to define the mandrel shape, you should draw all the frames as
polygons, using straight line segments. The locations where the line segments meet is
where the points on the frames will be.

The rules for creating surface mandrels in external CAD software:

Just like creating CAD drawings for axisymmetric mandrels, there are several rules that
must be followed to achieve a successful result.

• All frames must contain the same number of points, therefore all polygons must have
the same number of sides.

And, as already mentioned in Section 8.4.4:

• The total number of frames must be between

4 (minimum) and 400 (maximum).
• The number of points per frame must be between
12 (minimum) and 600 (maximum).

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 • The points must be sequenced in a counterclockwise direction, as shown in Figure
8.22.
• The points should be approximately equally spaced for best results. Try to avoid
large jumps in point spacing (ie. avoid having a short distance from points 1 to point
2, followed by a large distance from point 2 to point 3).
• All edges (for example, on a rectangular section) should be rounded with a radius.
• The gradients of corresponding polygon lines should be approximately equal.
Otherwise it is possible that the mandrel model is twisted and problems may occur
later when winding over it (see Figure 8.23).

The procedure for importing the CAD geometry into CADWIND as a mandrel:

6. Once the 3 dimensional .DXF file has been created, it can be converted into a
mandrel (.MDR) file by selecting “File” menu ► DXF-> Surface...
7. In the window that appears, browse to the DXF file created by a CAD system. Select
it and click Open .
8. In the next window that appears, the mandrel file to be saved needs to be given a
folder location and filename. Browse to the folder where you want to store your
mandrel and give it a name with a .MDR file extension, then click Save .

If the process was successful, there will now be a new mandrel file saved in the chosen
folder.

9. Select: “File” menu ► Load mandrel...

10. Browse to the new mandrel file as usual, select it and click Open .

You should now see the mandrel in the display window, similar to the example below. You
can wind over this mandrel and create part programs in the same way as for any other
mandrel.

Figure 8.30: CADWIND display of mandrel and winding, imported from CAD data

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8.5 The T-mandrel format
The T-mandrel format allows the definition of T-shaped mandrels only. Because of the
specific shape of T-mandrels, no points of either the contour or the surface are stored.
Instead CADWIND simply stores the characteristic dimensional values in the mandrel file.
Each time the T mandrel file is opened, CADWIND recalculates the surface geometry. See
Section 8.1.6 for details on the meaning of the dimensional values given below.

Example of Line Syntax Explanation

CADWIND T DATA FILE The first Line identifies the file type to
CADWIND. The file MUST start with this line,
written exactly as shown.
MM “MM” for values in millimetres or “IN” for
values in inches
100.00 Length A
100.00 Length B
100.00 Length C
300.00 Diameter A
300.00 Diameter C
100.00 Inside radius
0.00 Offset of main pipe central axis relative to
spindle rotation axis
POSITION: HORIZONTAL Position of mandrel in the chuck. Use
“HORIZONTAL” only as “VERTICAL” option is
no longer supported in CADWIND v9

It should not be necessary to edit a T-mandrel file externally, as CADWIND can be used to
make any changes in the T-mandrel definition window (“File” menu ► Create mandrel... ►
T...).

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9 View Menu

9.1 New mandrel views

The mandrel loaded into CADWIND can be shown at different orientations and zoom
factors in different windows at the same time. To do this, select: “View” menu ► New
mandrel view

Figure 9.1: Three different mandrel views in different windows

Section 4.2 explains how to change the view orientation, zoom factor, etc. Just click inside
the window to be changed first, then use the predefined view menus, zoom buttons or
mouse-controlled dynamic zoom, spin and pan features to orient each window view
differently.

9.2 View results

CADWIND calculates several useful parameters related to the winding, and displays them
in a results window, as shown in Figure 9.2.

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Figure 9.2: Results window

To display this window, select:

“View” menu ► Results...

The table over the page explains the calculated results:

Result Displayed Description

Mandrel file name The name and location of the currently loaded
mandrel file.
Calculation method The winding method chosen (eg. non-
geodesic, helical, polar, circumferential, etc).
Winding angle The range of winding angles (compared with
the axis of spindle rotation) in the centre
winding zone.
Degree of covering The range of degree of coverage (see Section
11.3.2 for definition) in the centre winding
zone.

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 Result Displayed Description
Laminate thickness The range of thickness, for the current layer
only, in the centre winding zone.
Number of cycles The value displayed is the total number of
cycles used to complete the current layer. This
is explained in Section 11.4.4.
Pattern number This is explained in Section 11.4.5.

Ending position This is the circumferential (angular) location of

the fiber at its last contact point with the
mandrel surface after one full cycle, given in °.
Fiber consumption The length of fiber used (not counting multiple
rovings), in metres or feet, for the current
layer.
Laminate weight The weight added to the mandrel by of the
current layer (taking into account the material
properties such as fiber fraction and density.
Winding length front Horizontal length of winding in front turning
zone. See Figure 9.3
Winding length central Horizontal length of winding in central zone.
See Figure 9.3.
Winding length back Horizontal length of winding in back turning
zone. See Figure 9.3
File name The file name of the part program created.
Production time The time needed for the machine to wind the
layer, at 100% speed.
Pay-out speed For part programs with a constant pay-out
speed only.
Program size Memory space used by the part program.

Notes:
• Results are not displayed for circumferential winding
• Note that T-shaped mandrel windings do not use cycles, pattern numbers etc. These
results, along with laminate thickness, winding angle, degree of covering and ending
position are not shown for T mandrels.

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Figure 9.3: The winding lengths shown in the results window

See Section 11.2 for the definition of the central winding zone, front and back turning
zones.

9.3 Clear winding patterns

To remove the display of all windings, so that the bare mandrel only is showing in the
display window, select “View” menu ► Clear winding patterns

9.4 Show only last pattern

CADWIND has the ability to show multiple windings on the same mandrel, overlaid one on
top of the other just like a real winding would. However, if you are trying to develop only one
winding pattern and are experimenting with different parameters, it might be undesirable to
see the previous winding attempts.

To show only the last winding pattern generated, and not the series of windings, select
“View” menu ► Show only last winding pattern

This is a toggle function. So, if there is a ✔ beside the “Show only last winding pattern”,
then the option stays activated until it is selected again and the ✔ disappears.

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Figure 9.4: The effect of “Show only last pattern” option

Important note:
The part program is generated for one layer at a time only. Therefore, there should be only
one pattern showing in the display window when the part program is generated. To avoid
errors in the part program, select “Show only last pattern” before creating a part program.

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10 Winding over the mandrel with iWind

10.1 Introduction to iWind

iWind is an entirely new way of simulating filament windings, unique to CADWIND V10. It is
designed to make it faster and easier for users to find their desired winding patterns and
improve their experience with CADWIND.

iWind is CADWIND V10’s main winding feature. It can be used in most situations. However,
the classical non-geodesic, helical, or polar winding algorithms have all been kept in V10
(see Section 11), so that V10 remains backwards compatible with previous CADWIND
versions, and so that experienced users can use CADWIND V10 in the way they are used
to, if they prefer. For a comparison of iWind with the classical non-geodesic algorithm see
Section 10.8.

iWind includes friction calculations, to make sure that the fibres will not slip in reality.

Figure 10.1: The iWind dialogue window

The best way to learn how to use iWind is to try it! By experimenting with the different
features, and the user will instantly see how the feature works and the effect on the
winding.

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10.2 iWind overview
10.2.1 Overview of the different sections

The upper part of the iWind window is the parameters section. All the parameters needed to
calculate the winding path are entered here.

Figure 10.2: Winding parameters section

The lower part of the iWind window is the results section. This is where iWind lists the
possible winding patterns that it has found.

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Figure 10.3: Results section

The material parameters used for thickness and weight calculations are located on a
separate tab, within the iWind window.

Figure 10.4: Material parameters section

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10.2.2 Changing the parameters

All numerical parameters in the iWind window can be changed in one of two ways.
1) Left click the mouse in the number field and enter a number using the keyboard, or
2) Left click and drag the slider using the mouse

Figure 10.5: Changing a parameter using the keyboard

Figure 10.6: Changing a parameter using the slider

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10.2.3 The Calculate button

Figure 10.7: Calculate button

Click “Calculate” to calculate the possible winding patterns and refresh the results table at
the bottom of the window.

If the “Live” button is checked, there is no need to click the “Calculate” button, as the results
will automatically be updated every time a change is made to any of the parameters or
options.

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10.2.4 The Live button

Figure 10.8: Live button

If the Live button is checked (✓), then the iWind calculations will automatically be made
every time a parameter is changed, the results table will be updated and the first result in
the table will be simulated on the screen.

To check or uncheck the Live button, left click it with the mouse.

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10.2.5 Progress bar and cancel button

Figure 10.9: Progress bar

Some time is required for iWind to complete its calculations. Many factors will affect the
amount of time needed (see Section 10.2.6), but it typically ranges from less than a second
to about 10 seconds.

The progress bar gives a visual indication of how much time has been used and how much
more time is required. The progress bar fills up with green, from left to right (shown above).
It will do this twice before the calculations are complete and the results are displayed.

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If the calculations are taking too long, the calculation can be cancelled by left-clicking the
cancel button (the X to the right of the progress bar).

Figure 10.10: Cancel button

10.2.6 Time required for calculation

The factors which affect the amount of time required for CADWIND to complete iWind
calculations are:

- Computer hardware. Faster CPU’s, more CPU cores and more available RAM
all reduce the calculation time.

- Depth of Pattern search. More depth requires more calculation time (but also
finds more patterns).

- Number of Frames. More frames on the mandrel increases calculation time.

- Number of points per frame. More points per frame increases calculation time.

- Bandwidth. A larger bandwidth reduces calculation time if “Calculate patterns”

option is selected (has no effect if “Calculate first cycle only” is selected).

- Calculate patterns / Calculate first cycle only. The “Calculate patterns” option
will usually require much more calculation time than the “Calculate first cycle
only” option.

10.3 iWind - Winding parameters

10.3.1 Start frame

This is the frame number on the mandrel where the winding will start and finish. See
Section 8.2 for an explanation of frames if unsure. The best place for the starting position
on a vessel is often where the cylindrical section meets the dome, at the front end. For a

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pipe or tube, the best place is the front edge of the central winding zone (see Section
10.3.4).

To determine the frame number from the graphical view of the mandrel, simply turn on
Frame numbering (click FN in the toolbar). If all frame numbers don’t appear, zoom in on
the starting position until the frame number does appear.

10.3.2 Start position

The Start position is the circumferential position at which the winding starts. It always lies
on the Start frame (see Section 10.3.1).

The Start position is the first point at which the fibre theoretically contacts the mandrel, at
the beginning of the first cycle.

The Start position is given as a percentage of the total distance around the Start frame. At
Start position zero (ie. 0%), it falls on the first point of the Start frame. If CADWIND was
used to generate the mandrel, this first point will usually coincide with the X axis.

Figure 10.11: Start position

10.3.3 Start winding direction

In iWind, the winding direction can be started either going forwards or backwards. Forwards
means that the fibre will begin the cycle travelling in the positive Y direction. Backwards will
start winding in the negative Y direction.

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Figure 10.12: Start winding direction

10.3.4 Turning zones

For all winding except circumferential (hoop) winding, it is necessary to turn the fibers at the
mandrel ends, so that they return to the centre and continue the winding. CADWIND uses
allocated turning-zones on the mandrel to control the positioning of the turns.

Hence, the mandrel is divided into the following winding zones.

• Front turning zone
• Centre winding zone
• Back turning zone

In the centre turning zone, it is not the intention to turn the fiber, so CADWIND ensure that
the fibers follow the set winding angle as closely as possible, within the set limits of friction.

Note that the higher the friction limit, the better CADWIND will be able to maintain the
desired winding angle(s). This applies only to complicated geometry; not to simple shapes
like pipes and cylindrical pressure vessels, where maintaining the winding angle is not an
issue.

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Figure 10.13: Winding zones and winding angle deviation

It is important to note that the location of centre winding zone and turning zones is arbitrary
and is the decision of the designer/engineer. It is not dependant on the mandrel shape.
Closed-end pressure vessels often have turning zones which lie on the domes while the
centre winding zone lies on the cylindrical section, however this is not a necessity.

10.3.5 Winding angle

The Winding Angle is the angle between the fibre direction and mandrel rotation axis. α1
and α2 are examples of the winding angle at two different locations on the mandrel below.

Figure 10.14: Winding angles

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10.3.6 Constant winding angle

Figure 10.15: Constant winding angle parameter

If the “Variable” button is not pressed, then the winding angle is the angle at the starting
frame. CADWIND will try and maintain this angle, (within the limits of the user-defined
friction factor) in the centre winding zone only (ie. between turning zones).

It may not always be possible to keep this angle constant if the mandrel diameter changes
rapidly, or if the mandrel is highly non-axisymmetric. For axisymmetric windings with
constant diameter, the winding angle will always be kept constant in the centre winding
zone.

For situations where the angle can not be kept constant, the higher the friction factor is, the
better able CADWIND will be to maintain the constant angle (but be careful, as too high a
friction factor may lead to fibre slipping).

Usually on a vessel, pipe or tube, the set value is the desired winding angle on the
cylindrical section, as the starting frame is located somewhere on the cylindrical surface.
For example, see α1 on the figure above.

10.3.7 Variable winding angle

It is possible to assign different winding angles for different parts of the mandrel by clicking
the “Variable” button.

Figure 10.16: Variable winding angle parameters

This opens a table of winding angles that can be altered for different areas on the mandrel.

The numbers entered are the desired winding angle from frame to frame, on the mandrel.

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So, in the above example:

• the desired winding angle between frames 10-11 would be 40°,

• when the filament passes frame 11, CADWIND will start to increase winding angle
using a friction factor of 0.18 (not visible in the figure), until it reaches 70°.
• CADWIND will continue with a 70° fiber angle until it passes frame 14,
• After frame 14, it will start reducing the winding angle again in the other direction with
a friction factor of 0.18 until it reaches 40°.

The screen-grab below shows the result of this winding. Note the much higher winding
angles in between frames 11-14, and the gradual changing winding angle. This gradual
changing of winding angle means that the angle you entered in the winding parameters
table is not necessarily the actual winding angle on the mandrel - it is just the target winding
angle, and the limits of friction will be respected in getting to the target winding angle so that
slippage will not occur.

Figure 10.17: Variable winding angle

10.3.8 Set range

With variable winding angle or friction factor selected, a new button appears to the right,
giving the option to “Set range” (see Figure in previous section). This is a faster way of
entering the same winding angle or friction factor across many frames, rather than entering
the same number for each frame individually.

To use this feature, first make sure that the “Variable” button is pressed (for winding angle
or friction factor). Then click "Set range". Enter the desired value for winding angle or
friction, the starting frame and the ending frame for this particular value in the window that
appears, then click "OK". The Set range window will disappear and the relevant cells in the
iWind table will be automatically filled-in.

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Figure 10.18: Set range

10.3.9 Friction factor – non-geodesic winding

Before the reader can understand the friction factor, they should have an understanding of
the meaning of non-geodesic and geodesic winding.

Helical winding is geodesic winding (with some necessary adjustment to close the winding
pattern), but iWind offers the ability to wind non-geodesically. This section explains the
difference between the two.

Figure 10.19: Geodesic path from Paris to New York

The word “geodesic” comes from “geodesy”, the science of measuring the size and shape
of the earth. Under the original meaning, the geodesic path was the shortest route between
any two places on the surface of the earth. It is simple to demonstrate this by stretching a
slippery string tightly across two points on a globe.

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In filament winding, a geodesic winding path means the shortest path across the surface of
a mandrel between two points. The geodesic path is the only path that a filament stretched
tightly between two points on a mandrel can take without relying on friction to stop slipping.

Figure 10.20: Geodesic & non-geodesic paths on a dome

So, iWind is a method of calculating a winding path that uses friction between the filament
and the mandrel to move away from the geodesic path.

The amount to which the filament can move away from the geodesic path depends on the
amount of friction between the filament and the mandrel. Very sticky filaments (eg. tow-
preg) on high-friction mandrels (eg. rubber) can take a path that is greatly different from the
geodesic path. However, very slippery filaments (eg. fiber lubricated with a low viscosity
liquid resin) on very smooth mandrels (eg. polished stainless steel) must follow a path that
is very similar to the geodesic path, or they will slip.

10.3.10 Friction factor parameter

This factor is actually the coefficient of friction between the filament and the mandrel
surface. In other words, it is a number that represents how slippery or how sticky the
filament is on that particular mandrel. iWind needs this number so that it knows how quickly
it can change the fiber angle without causing slipping.

iWind can also be used to achieve a geodesic winding simply by entering a friction factor of
zero. Beware however; with a friction factor of zero, iWind will follow the geodesic path
exactly, and this does not leave many possible winding patterns. If a friction factor of zero is

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entered, it is sometimes not possible for iWind to find a working pattern at all; so a small
friction factor (eg. 0.01) is recommended as a minimum.

The table below gives an approximate indication of typical friction factors for various
combinations of filament and mandrel materials. It may be used as a guide, but tests should
be conducted with any new mandrel / fiber / resin combination, to determine the real friction
factor.

Mandrel Surface Dry fiber Wet fiber Prepreg fiber

Smooth metal 0.18 0.15 0.35
Smooth plastic 0.20 0.17 0.32
Dry laminate 0.22 - -
Impregnated - 0.14 -
laminate
Prepreg laminate - - 0.37

If it is critical that the fiber does not slip, then a friction factor below those listed (above)
should be used to give some margin of safety.

10.3.11 Actual friction factor used

Note that iWind treats the friction factor entered as the maximum limit. It will show winding
patterns that use actual friction factors up to and including the limit value entered, but never
more than the value entered.

The percentage of the limit value is given with each winding pattern generated (see Figure
below). The lower the percentage of the limit friction, the closer the winding pattern is to the
geodesic path and the safer it is against slipping.

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Figure 10.21: Percentages of friction limit

10.3.12 Variable friction factor

It is possible to assign different friction factors for different parts of the mandrel by clicking
the “Variable” button.

This opens a table of friction factors that can be altered for different areas on the mandrel.

For setting a range of friction factors see Section 10.3.8.

10.3.13 Total bandwidth

iWind treats the total bandwidth as a variable parameter, allowing the user to make quick
changes to bandwidth and see the results instantly.

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Figure 10.22: Total bandwidth

In the material parameters tab, there is also a Bandwidth (single roving) field. Note that the
bandwidth in the material parameters is the width of one roving / tow only. The width in the
“Winding parameters” tab is for all rovings / tow combined.

Figure 10.23: Single roving bandwidth

The total bandwidth is related to the single roving bandwidth by the number of rovings:

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 𝑇𝑜𝑡𝑎𝑙_𝑏𝑎𝑛𝑑𝑤𝑖𝑑𝑡ℎ = 𝑆𝑖𝑛𝑔𝑙𝑒_𝑏𝑎𝑛𝑑𝑤𝑖𝑑𝑡ℎ × 𝑁𝑢𝑚𝑏𝑒𝑟_𝑜𝑓_𝑟𝑜𝑣𝑖𝑛𝑔𝑠

Note that the total bandwidth is not related to the single bandwidth in CADWIND directly –
so, it is up to the user to make sure that the total bandwidth is correct, with respect to the
single bandwidth and number of rovings, as in the equation above.

The single bandwidth is used for calculation of the layer thickness and weight only – it does
not affect the iWind simulation or part program directly, like the total bandwidth does.

10.3.14 Calculate first cycle only

There are two options for the calculation mode. The first cycle only can be calculated, or the
entire winding pattern, along with all the alternative patterns, can be calculated.

If “Calculate first cycle only” is selected, then CADWIND will calculate and display only one
cycle out of the pattern. The friction factor will be 100% of the parameter entered, in this
case. There will be no patterns displayed in the results section, and there is no effort made
to close the pattern (ie. the last point in the pattern probably will not be in an acceptable
position for any pattern).

It is much faster to calculate the first cycle only, compared with calculating the patterns. It is
very useful for determining the approximate values of parameters like the winding angle
and friction factor needed for the desired result (eg. closing a pole on a pressure tank).

Figure 10.24: Calculate first cycle only

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10.3.15 Calculate patterns

If “Calculate patterns” is selected, the entire winding pattern is simulated on the screen, and
all the alternative winding patterns are also calculated and tabulated in the results section.

Much more computation is needed to calculate the patterns than to calculate the first cycle
only, so the result will take longer to display.

Figure 10.25: Calculate patterns

There may be a significant difference in the winding path between the first cycle and the
complete pattern, particularly if a high friction factor is used. This is because the Calculate
first cycle option uses 100% of the input friction factor, whereas the Calculate patterns
option could use any friction factor up to the input value.

This is particularly noticeable if trying to find a pattern to close the domes on a pressure
tank – the Calculate first cycle option may pass exactly adjacent the desired pole opening
where the Calculate patterns option, with a lower friction factor, may give a pole opening
that is too small.

10.3.16 Coverage range - Number of cycles range

If “Calculate patterns” is selected, iWind searches for patterns within a certain coverage
range or range of cycles.

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The Coverage parameter tells CADWIND how close to wind adjacent bands on the start
frame. With 100% coverage, adjacent bands are laid side-by-side so that they just touch.
Coverage of <100% leaves gaps in between the bands and coverage of >100% has
overlaps.

Figure 10.26: iWind window with 50% coverage

The above iWind parameters would lead to the simulation shown below:

CADWIND User Manual © MATERIAL SPRL 99

Figure 10.27: Tube winding example with 50% coverage

It is also possible to specify the Number of cycles range desired instead of the Coverage.
The Coverage and Number of cycles are proportional.

One cycle is defined as one lap around the mandrel, back to the starting frame.

Figure 10.28: One cycle only

Most winding require many cycles to get the desired coverage of the mandrel.

For example, a filter-housing may require specific sized gaps in-between the bands (for the
fluid to flow through). The designer would calculate the number of cycles required to
achieve the required gap-width, and enter the values in the Number of cycles range
accordingly.

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To enter the acceptable range for number of cycles instead of coverage, click the circle next
to the “Number of cycles range”. Then enter the desired minimum and maximum number of
cycles in fields below.

Figure 10.29: Number of cycles

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10.4 iWind - Material parameters
10.4.1 Overview of material parameters

Figure 10.30: Material parameters

Material parameters are entered into iWind on a separate tab within the same window
(shown above).

The material parameters are only used for thickness and weight calculations and do not
affect the winding path or part program for the layer. Note that if the “Update mandrel”
feature is used, the material parameters will affect the dimensions of the updated mandrel,
and so may affect the following layer indirectly.

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10.4.2 TEX value or Yield (single roving)

This is the linear weight of one (dry) roving or tow in grams/km, or yield in yards/lb. The
manufacturer should supply this information in a datasheet, or you can weigh a roving and
divide by its length (or length divided by weight will give the yield in yards/lb).

10.4.3 Bandwidth (single roving)

This is the width of one roving or tow, on the surface of the mandrel. This value will only be
used for thickness and weight calculations and will not set the total bandwidth (which iWind
uses for calculating the patterns), so the user needs to make sure that the following
relationship is respected:

𝑇𝑜𝑡𝑎𝑙_𝑏𝑎𝑛𝑑𝑤𝑖𝑑𝑡ℎ = 𝑆𝑖𝑛𝑔𝑙𝑒_𝑏𝑎𝑛𝑑𝑤𝑖𝑑𝑡ℎ × 𝑁𝑢𝑚𝑏𝑒𝑟_𝑜𝑓_𝑟𝑜𝑣𝑖𝑛𝑔𝑠

See Section 10.3.13 for more details.

10.4.4 Fiber density

This is the density of the fiber material alone. The fiber manufacturer should supply this
information. Typical values are:

E-glass = 2.6 g/cm3 (1.50 oz/in3)

carbon = 1.8 g/cm3 (1.04 oz/in3)

10.4.5 Fiber volume fraction and Fiber mass fraction

This is the proportion of fibers in the composite, measured by volume or mass. Typical
values for volume content from filament winding vary from 35-65%, with wetter laminates
having a lower value. If unsure, it is possible to measure the mass of a length of roving dry
and the mass of the same length wet. Divide the dry weight by the wet weight to get the
Fiber mass content.

Example:

- 10m dry glass roving weighs 24g,

- 10m wet roving (from resin bath or other impregnation device) weighs 34g.

24
𝐹𝑖𝑏𝑒𝑟 𝑚𝑎𝑠𝑠 𝑐𝑜𝑛𝑡𝑒𝑛𝑡 = ∙ 100% = 70.6%
34

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10.4.6 Matrix density

This is the density of the resin alone. The resin manufacturer should supply this information.
A typical value is 1.2 g/cm3 (0.69 oz/in3), for epoxy or 1.1 g/cm3 (0.64 oz/in3) for polyester /
vinyl-ester.

10.4.7 Resulting ply thickness

This is a calculated result that is not related to the iWind simulation. It uses only the
parameters in the material parameters window. It assumes 100% coverage and a single ply
which covers the mandrel once only (where most winding patterns will cover the mandrel
twice). The real layer thickness and the ply thickness are approximately related as given
below:

𝐿𝑎𝑦𝑒𝑟_𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 ~ 2 × 𝑃𝑙𝑦_𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 × 𝐶𝑜𝑣𝑒𝑟𝑎𝑔𝑒

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10.5 iWind - Results Table
There are often many possible ways to wind the mandrel using the set of winding
parameters. iWind searches for the possible patterns which work, and provides the user
with the successful patterns in a table, located near the bottom of the window.

Figure 10.31: Results table

The table is a grid consisting of are several columns and rows. Each row represents a
successful pattern and each column represents a result related to that pattern, such as
Coverage or Pattern number.

Each column can be grouped, or filtered, and the table can be sorted according to the
results in any of the columns.

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10.5.1 Grouping columns

Each column can be grouped together, to make it fast and easy to see the patterns that
meet certain criteria when there are a lot of patterns in the table. To group a column, drag it
by the header into the grey area above the results table, as shown below. To drag, position
the mouse over the desired header, click and hold the left mouse button whilst over the
header, move the mouse up to the grey area (labelled “Drag a column header here to group
by that column”) and release the button.

Figure 10.32: Grouping by one column

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Subgroups can also be created by dragging more column headers into the grey grouping
area. The example below shows grouping by Coverage, Pattern number and % Friction
factor.

Figure 10.33: Grouping by multiple columns

10.5.2 Un-grouping columns

To ungroup any of the columns that have been previously grouped, left click the column
heading in the grey grouping bar, and drag it anywhere off the grouping bar before
releasing the button.

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Figure 10.34: Un-grouping columns

10.5.3 Sorting the results

The resulting patterns can be sorted (in either ascending or descending order) according to
any of the result columns, by clicking the arrow ( ), next to the header (text) at the top of
the column. If no arrow is visible, click the header itself.

For example, to sort the patterns by coverage, in ascending order, click on the “Coverage”
header. Click again to sort in descending order.

Control click the column header to undo the sorting of the results.

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Figure 10.35: Sorting the results

10.5.4 Filtering the patterns

The filter feature can be used to include or exclude patterns in the results table, according
to a particular result parameter. To do this, click the filter icon ( ). For example, if the user
wanted to see only results with a pattern number of 5, 6 or 9, then she could filter out the
other results as shown below:

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Figure 10.36: Filtering the results

10.5.5 Cycles

This value shows how many cycles the pattern has.

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One cycle is defined as one lap around the mandrel, back to the starting frame.

Figure 10.37: One cycle only

See also Section 10.3.16.

10.5.6 Coverage

This value shows the Coverage at the start frame. The Coverage parameter tells
CADWIND how close to wind adjacent bands. With 100% coverage, adjacent bands are
laid side-by-side so that they just touch. Coverage of <100% leaves gaps in between the
bands and coverage of >100% has overlaps. See also Section 10.3.16.

Figure 10.38: Tube winding example with 50% coverage

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10.5.7 Pattern Number

The pattern number characterises the winding pattern. It represents the number of cycles
wound around the mandrel before a band is laid down next to the first band. It is easiest to
understand the pattern number by considering a low-angle winding over a vessel with
closed-ends.

Figure 10.39: Winding sequence of a “3” pattern number

The figure above shows that three cycles are completed before a band is laid down next to
the first band on the fourth cycle. Hence, this is a “3” pattern, sometimes referred to in the
winding industry as a “3-star” pattern because of the 3 points on the dome that resemble
points of a star shape.

For comparison, a similar graphic showing the winding of a “5” pattern is shown below. In
that case, the 6th cycle is laid adjacent to the first.

Figure 10.40: Winding sequence of a “5” pattern

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10.5.8 Skip

The pattern number also has a skip value associated with it, and located in the next
column.

Using the star-points analogy for the pattern number (see Section 10.5.7), more winding
pattern possibilities exist if it is possible to skip points of the star. For example, if Cycle 1
winds the first star-point, it is then possible for Cycle 2 to wind either the 2nd, 3rd, 4th or 5th
star point. If Cycle 2 winds the 2nd star point, there has been a shift of 1 star-point per
cycle, hence the skip index is 1. If Cycle 2 winds the 3rd star point, then there has been an
increase of 2 star-points per cycle, so the skip index would be 2.

Figure 10.41: Comparison of skip effect

10.5.9 +/-

It is possible for a pattern number to be either positive or negative. For example, “Pattern =
+5, Skip = 1” and “Pattern = -5, Skip = 1”. It is easiest to describe the difference by
example. In this case, a +5 pattern will be considered.

If the bands in a +5 pattern were separated circumferentially by exactly 1/5th of the mandrel
(ie. 72°), the 6th band would fall exactly on top of the 1st band. The 7th band would fall
exactly on top of the 2nd band, etc. The mandrel would never be completely covered like
this, no matter how many cycles were wound. Clearly, this is not a good result in most
situations.

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Figure 10.42: Positive and negative winding patterns

So, each successive band must be separated by slightly more or slightly less than 1/5th of
the mandrel in order to achieve correct coverage. If the bands are separated by slightly
more than 1/5th of the mandrel (ie. 72° + bandwidth ÷ 5 ), then the 6th band would lie
ahead of the 1st band, the 7th band would lie ahead of the 2nd band, etc. This is a positive
pattern number.

If the bands are separated by slightly less than 1/5th the mandrel circumference (ie. 72° -
bandwidth ÷ 5), then the 6th band would lie behind the 1st band and the pattern number
would be negative.

Good understanding of skip index and the difference between positive and negative winding
patterns is not very important for using CADWIND, as CADWIND will suggest appropriate
patterns.

10.5.10 % of friction limit

Figure 10.43: Percent of friction limit

iWind display results which fall within a range of friction factors, from zero up to the limit set
by the user in the “Friction factor” field.

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The result column labelled “% of friction limit” is simply the percentage of the limit set by the
user. See Section 10.3.10 for details of the meaning of Friction factor.

10.5.11 Winding length

The front winding length is the distance, along the Y direction, from the end of the winding
(ie. the pole opening) to the end of the front turning zone. Similarly, the back winding length
is the distance from the back end of the winding, to the start of the back turning zone.

Figure 10.44: iWind parameters for winding length example

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Figure 10.45: Winding length example

10.5.12 Path length

Figure 10.46: Path length

The path length is the distance travelled by the fibre around the mandrel, either during the
1st cycle only, or the total length (ie. all cycles). It can be expressed in metres or feet.

For axisymmetric parts it is:

𝑇𝑜𝑡𝑎𝑙_𝑝𝑎𝑡ℎ_𝑙𝑒𝑛𝑔𝑡ℎ = 1𝑠𝑡_𝑐𝑦𝑐𝑙𝑒_𝑝𝑎𝑡ℎ_𝑙𝑒𝑛𝑔𝑡ℎ × 𝐶𝑦𝑐𝑙𝑒𝑠

For non-axisymmetric parts it is:

𝑇𝑜𝑡𝑎𝑙_𝑝𝑎𝑡ℎ_𝑙𝑒𝑛𝑔𝑡ℎ ≈ 1𝑠𝑡_𝑐𝑦𝑐𝑙𝑒_𝑝𝑎𝑡ℎ_𝑙𝑒𝑛𝑔𝑡ℎ × 𝐶𝑦𝑐𝑙𝑒𝑠

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10.5.13 Weight

Figure 10.47: Weight

The weight is the weight of the individual layer (not all layers), including turn-around areas.
It is expressed in kilograms (kg) or pounds (lb).

10.5.14 Thickness

Figure 10.48: Thickness

It takes some time to calculate thicknesses. So, only the thickness for the one pattern
displayed is given. To see the thickness values of other patterns, simply click on them in the
table.

Thicknesses range on the mandrel, so iWind gives the minimum and maximum values for
thickness, anywhere on the mandrel.

10.6 Save laminate data (for the export to FEA software)

The calculated laminate data can be saved in a file. These laminate data files are
necessary for using the Create FEA data feature (under the “File” menu) (see Section 14.).
So, if the user wishes to export from CADWIND to finite element analysis (FEA) software,
for structural or thermal analysis, the laminate data must be saved for each individual layer
in the laminate.

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There are two laminate data formats: the .LAM file format and the .iLAM file format.

After clicking on the “Save laminate data” or “Save iLAM data” button, browse to the desired
folder and type a file name for the laminate data file.

Figure 10.49: Save laminate data

10.6.1 Save laminate data as .LAM file

The .LAM files are necessary for the use in the Create FEA data feature (under the “File”
menu) (see Section 14.) if you do not choose “HDF5 Composite Data” as output format.
Furthermore .LAM files are text files that can be then opened by other software (eg. a text
editor or spreadsheet) for further analysis.

The laminate data file has the following structure:

Example line syntax Explanation

CADWIND LAMINATE DATA FILE Identification of the data file type
MM The data is in millimetres (MM) or inches
(IN)
300.000 99.897 22.000 0.301 Data record for the 1st roving element
300.994 99.840 21.991 0.301 Data record for the 2nd roving element
304.130 99.657 22.594 0.303 Data record for the 3rd roving element
305.008 99.506 22.893 0.304 Data record for the 4th roving element
…
281.580 99.897 22.000 0.301 Data record for the last roving element
Roving Mandrel Winding Layer The meaning of each column (information
element diameter angle thickness only - this line is not in the actual file)
Y
location

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As shown in the bottom row of the above table, each data record contains the Y mandrel
coordinate for the record, the mandrel’s average diameter at that coordinate, the winding
angle of the filament and the thickness of the layer.

10.6.2 Save laminate data as .iLAM file

If you want to export the laminate structure in the “HDF5 Composite Data” format in the
Create FEA data feature (under the “File” menu) (see Section 14.) you need to save the
laminate data in the .iLAM file format.

10.7 Load/Save iWind parameters

Figure 10.50: Load/Save iWind parameters

The iWind parameters can be loaded and saved in a text file, with a .iWind file extension.
This way, you can save iWind parameters for every layer of a winding project, and easily
return to any layer to see what was done or make changes.

Just click on the “Save parameter” button, browse to the desired folder and give the file a
name, with a .iWind extension. To load, click on the “Load parameter” button, browse to
and select the saved file.

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10.8 iWind compared with CADWIND’s classical non-
geodesic winding
Mathematically (ie. in the background), iWind works in a similar way to the classical non-
geodesic winding feature as described in Section 11.5.2. Like the classical non-geodesic
winding, it does friction calculations to avoid slipping. However, there are many
improvements made in the way that iWind is used and the way in which it presents
information, compared with the classical non-geodesic winding feature.

For example, iWind gives instant results on the screen as parameters are changed,
allowing for fast and easy experimentation. iWind also gives a complete list of verified
successful winding patterns, updated instantly, in the same window. Non-geodesic winding
gives a list in a separate window, only after the user clicks “Start winding”

iWind makes it easy and fast to finding successful winding patterns. iWind searches deeper
and finds more possible solutions than non-geodesic winding. It only lists winding patterns
which are successfully verified, the patterns listed work every time.

iWind also considers the full range of friction factors, up to and including the value set, in
order to find more winding pattern options.

Quick Comparison of Classical Non-geodesic Winding and iWind

Parameter Non-geodesic iWind
Friction calculations Yes Yes
Visual simulation of results Yes Yes
“Live” simulation as parameters
No Yes
change
Suggestion of possible patterns Yes Yes
Verification of suggested patterns to
No Yes
make sure they work
Processing power 1 CPU core only All CPU cores
Parameters changed by keyboard Yes Yes
Parameters changed by slider bar
No Yes
(mouse)
Filtering, sorting and grouping of
No Yes
suggested patterns
Start frame parameter Yes Yes
Start position parameter No Yes
Start winding direction option No Yes
Turning zones Yes Yes
Winding angle constant or variable Yes Yes
Considers windings only Considers the range of
at the set value. friction factors up to
Friction factor (FF) parameter the set value.

µ = FF 0 ≤ µ ≤ FF

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 No – Bandwidth is set in
Bandwidth as a variable parameter Yes
a different window
Dwell parameters Yes No
Considered as minimum A range is considered
Degree of coverage (DoC)
Minimum ≤ DoC ≤
DoC ≥ Minimum Maximum
Considered as minimum A range is considered
Number of cycles (NoC)
Minimum ≤ NoC ≤
NoC ≥ Minimum Maximum
Pattern search strength No Yes
First cycle only option No Yes

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10.9 Update mandrel / Reset / Save update
10.9.1 The Update mandrel feature

The Update mandrel and associated features are not available with CADWIND
ESSENTIAL.

Some windings contain many layers. With each layer, the mandrel increases in size and
changes its shape slightly. For thick walled parts, with many layers, it is necessary to
update the mandrel shape, otherwise there may be undesirable results, like fibre slipping,
inaccurate pole openings or inaccurate fibre winding angles. To prevent problems, it is
recommended that the mandrel be updated with every layer for thick-walled parts with
complex geometry (it is not as necessary for tubes and pipes, but still good practice).

Figure 10.51: Effect of the Update mandrel feature

It is also recommended that the real mandrel dimensions should be physically measured
after every few layers and a check made that the real shape matches the CADWIND model.
Sometimes it is good practice to make a new CADWIND mandrel (ie. not use the update
feature) once every few layers, to smooth out the bumps in order to get smoother and faster
machine movements.

10.9.2 How to use the Update mandrel feature

The Update mandrel feature allows the user to ‘grow’ the size and shape of the CADWIND
mandrel to simulate the way that the real mandrel would grow. To access this feature,
select:

“iWind” menu ► Update mandrel

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10.9.3 Updating non-axisymmetric mandrels

This feature only works with axisymmetric mandrels. Do not use with non-axisymmetric
mandrels.

This feature is primarily intended for vessels and pipes, although it can be used with all
axisymmetric mandrels.

10.9.4 Limitations of the Update mandrel feature

The thickness build-up is an estimate only and relies on accurate material parameters
(roving width, fiber volume content, etc). Mandrels can be updated again and again to
simulate the thickness of each new layer, however small inaccuracies can compound
(analogous to the degradation in quality that occurs when photocopying a photocopy of a
photocopy). It is not recommended to use the mandrel update feature more than 3-4 times
consecutively. After 3-4 updates, it is recommended that the user measure the dimensions
of the real-world mandrel and make a brand-new CADWIND mandrel using the measured
dimensions.

10.9.5 Circumferential winding over an updated mandrel

The updated mandrel will have a slightly larger diameter than the original mandrel.
However, cylindrical surfaces may become very slightly non-cylindrical when updated.

CADWIND will not wind circumferential layers over any surface that is not perfectly
cylindrical. Therefore, it may be necessary to open the mandrel file and manually adjust the
diameters of some frames on the cylindrical surface so that they are all exactly the same
(ie. making the surface exactly cylindrical again).

Refer to Section 8.4.3 for details on the mandrel contour file format and Section 16 for
details on the text editor which can be used for this purpose.

10.9.6 Reset

An updated mandrel can be reset to its original dimensions (ie. as it was before the update)
by selecting:

“iWind” menu ► Reset

Note that this will restore the mandrel to the dimensions it had when it was first loaded. So,
if more than one update was made without saving the updated mandrel, then all updates
will be lost.

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10.9.7 Save update...

The shape of an updated mandrel can be saved for future work by selecting:

“iWind” menu ► Save update...

A window will appear where the user can browse to the folder where the updated mandrel
is to be saved, and give the updated mandrel a file-name.

It is recommended that each updated mandrel (there may be several on thick windings) be
given a different (and systematic) filename from the original mandrel as it may be
necessary to refer back to the original mandrel to make adjustments to layers wound earlier
in the process.

Updated mandrels can be loaded in the normal way, by selecting:

“File” menu ► Load mandrel...

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11 Winding over the mandrel with the classical
algorithms

After a suitable mandrel model is loaded, and showing in the display window, it can be
wound over by using the options under the “Winding” menu.

11.1 The material parameters

The first step is to define the material parameters for the winding. To do this, select:
“Winding” menu ► Material...

The following window should appear:

Figure 11.1: The material parameters window

The material parameters

Parameter Description
Number of rovings Number of rovings or tow to be wound in the same
band.
Roving width The width of one roving only (not the entire bandwidth).

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Parameter Description
Fiber volume content Proportion of fibers in the composite, measured by
volume or mass. Typical values for volume content vary
or from 35-60%, with wetter laminates having a lower
value. If unsure, it is possible to measure a length of
Fiber mass content roving dry and the same length wet. Divide the dry
weight by the wet weight to get the Fiber mass content.

example:
10m dry glass roving weighs 24g,
10m wet roving (from fiber wet-out apparatus) weighs
34g.
24
𝐹𝑖𝑏𝑒𝑟 𝑚𝑎𝑠𝑠 𝑐𝑜𝑛𝑡𝑒𝑛𝑡 = ∙ 100% = 70.6%
34

TEX value The linear weight of one (dry) roving or tow in

(or ‘yield’ if imperial units grams/km, or yield in yards/lb. The manufacturer should
are used) supply this information in a datasheet, or you can
weight a roving with known length.

Fiber density The density of the fiber material alone. The fiber
manufacturer should supply this information. Typical
values are:

glass = 2.6 g/cm3 (1.50 oz/in3)

carbon = 1.8 g/cm3 (1.04 oz/in3)

Resin density The density of the resin alone. The resin manufacturer
should supply this information. A typical value is 1.2
g/cm3 (0.69 oz/in3).

The use of the material parameters

Parameter Use
Number of rovings Used to calculate the bandwidth for the winding pattern,
and also the laminate thickness
Roving width
𝐵𝑎𝑛𝑑𝑤𝑖𝑑𝑡ℎ = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑜𝑣𝑖𝑛𝑔𝑠 ∙ 𝑟𝑜𝑣𝑖𝑛𝑔 𝑤𝑖𝑑𝑡ℎ

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 Parameter Use
TEX value or yield Used only to calculate laminate thickness and the
laminate weight.
Fiber volume content /
fiber mass content These parameters have no effect on the winding
pattern generated.
Fiber density

Resin density

11.2 The division of the mandrel into zones

For all winding except circumferential (hoop) winding, it is necessary to turn the fibers at the
mandrel ends, so that they return to the centre and continue the winding. CADWIND uses
allocated turning-zones on the mandrel to control the positioning of the turns.

Hence, the mandrel is divided into the following winding zones.

• Front turning zone
• Centre winding zone
• Back turning zone

In the centre turning zone, it is not the intention to turn the fiber, so the fibers follow the
geodesic path (see Section 11.5.1) in this area.

Figure 11.2: Winding zones and winding angle deviation

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It is important to note that the allocation of centre winding zone and turning zones is
arbitrary and is the decision of the designer/engineer. It is not dependant on the mandrel
shape. Closed-end pressure vessels often have turning zones which lie on the domes while
the centre winding zone lies on the cylindrical section, however this is not a necessity from
the winding view-point.

11.3 Circumferential (hoop) winding

Circumferential winding is commonly known in the industry as ‘hoop’ winding. It is the most
simple form of winding and covers a cylindrical mandrel with a winding angle of close to
90°.

It is useful for giving hoop and crush strength to pressure pipes and pressure vessels. As all
the fibers are at a high angle, hoop winding does not provide much longitudinal
(tension/compression) strength or bending strength.

In this form of winding, the spindle spins quickly while the carriage moves slowly along the
mandrel. CADWIND uses a different algorithm for circumferential winding than for the other
winding methods.

CADWIND does not show circumferential winding in the display window as for the other
forms of winding, however it does calculate the part program just the same.

Note that circumferential winding can only be done on a part of the mandrel which is
perfectly cylindrical, and an error message will be shown if circumferential winding is
attempted on any non-cylindrical part of a mandrel. To use circumferential winding on non-
cylindrical mandrels use non-geodesic winding (see Section 11.5) with a high winding
angle.

Figure 11.3: Circumferential winding: Position 0.0 to 900.0, with 100% coverage

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To enter the parameters for circumferential winding, select:

“Winding” menu ► Circumferential...

The following window should appear:

Figure 11.4: Circumferential winding parameters window

The circumferential winding parameters are entered in the style of a table or spreadsheet.
Rows can be added, inserted and deleted just like in a spreadsheet. The meaning of the
parameters is given below.

11.3.1 Position

The “position” parameters tell CADWIND where to start and finish winding the fiber. It is the
defined as the distance from the mandrel coordinate system origin to the winding point and
is in millimetres or inches (depending on the preference for units chosen in the General
options menu).

The example in Figure 11.4 tells CADWIND to wind a circumferential layer from position 0
to position 900. The result of this winding is shown in Figure 11.3

If another layer was required, more rows could be added to instruct CADWIND to return to
the start, or to return to another point on the mandrel. For example:

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Figure 11.5: Circumferential winding parameters window

These parameters would create a winding program that starts at position 0, moves to
position 900, then reverses the machine and returns to position 360. The area between
positions 360 and 900 would get 2 layers applied, while the area from position 0 to 360
would get only 1 layer, as shown.

Figure 11.6: Circumferential winding example with extra row

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By adding more rows, more complicated winding patterns can be produced. In this way,
multiple layers, thickened ribs, stepped thickness build-ups and many other features can be
programmed.

11.3.2 Degree of coverage

The degree of coverage parameter tells CADWIND how close to wind adjacent bands. With
100% coverage, adjacent bands are laid side-by-side so that they just touch. Coverage of
<100% leaves gaps in between the bands and coverage of >100% has overlaps.

Figure 11.7: Circumferential winding parameters window

The above circumferential winding parameters would lead to the winding shown below:

Figure 11.8: Circumferential winding example with 50% coverage

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In the above example, the advance is 80mm, while the bandwidth is 40mm, leading to a
degree of coverage of 50%. As the coverage is <100%, gaps are visible in the winding.

𝑏𝑎𝑛𝑑𝑤𝑖𝑡ℎ
𝐷𝑒𝑔𝑟𝑒𝑒 𝑜𝑓 𝑐𝑜𝑣𝑒𝑟𝑎𝑔𝑒 = ∙ 100%
𝑎𝑑𝑣𝑎𝑛𝑐𝑒

11.3.3 Dwell

By entering a dwell value, the mandrel will rotate at the end of a carriage movement by the
amount specified, but there will be no carriage movement. This has the effect of building up
fiber in one place on the mandrel only.

Figure 11.9: The effect of dwell

Without any dwell, in the above example, the carriage will move from position 0 to position
900 and as soon as it reaches position 900 it will immediately start moving to the next
position (ie. 360), which is a reverse movement in this case. In doing this, it may not wind
enough fiber at the end of the movement (position 900), leaving the laminate at position 900
thinner than intended. The use of dwell is a simple method to build up fiber at the end of a
movement to correct this.

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11.4 Helical winding
Helical winding can be used to lay fiber at lower winding angles than circumferential
winding, onto axisymmetric cylinders and vessels with equal pole openings.

The winding path is calculated from the Clairaut condition:

𝑟1 ∙ sin ∝1 = 𝑟2 ∙ sin ∝2 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡

Where:
r = radius of mandrel at any given point (eg point 1, 2, etc)
α = winding angle, measured relative to the axis of rotation

Figure 11.10: The Clairaut condition

Helical winding follows the geodesic path, with no consideration of fiber friction or slippage
limits. Therefore, there is no guarantee that the fiber will not slip, with this form of winding.
This allows a greater range of pattern numbers, but with the risk that some of them may
cause fiber slippage.

To wind helically over an axisymmetric mandrel with equal sized poles, select:

“Winding” menu ► Helical...

The winding parameters window should appear, as shown:

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Figure 11.11: Helical winding parameters window

11.4.1 Pole openings on vessel mandrels

Pressure vessels are usually designed so that there is a small area at the extreme ends,
called the pole, which is not wound over. There are several reasons for this:

Figure 11.12: The pole opening

• It is necessary to support the mandrel in the winding machine at one or both poles,
so there needs to be a structural attachment of some kind at the poles which should
not be covered with fiber.

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 • It is possible to attach the mandrel at one pole only and completely cover the other
pole, however, this leads to a very thick buildup of fiber at the covered pole. This is
because every band in the winding covers the pole in the same place. So, typically
20- 40 bands are required to cover the cylinder of a vessel, and if the designer
decides to cover the back pole, then the laminate at the back pole will be 20-40
times as thick as at the cylinder. This makes winding difficult, adds unnecessary
material and is unaesthetic.
• Because of the relationship between fiber angle and mandrel radius (ie. the Clairaut
condition - explained earlier), it is difficult to find a winding path that leaves one pole
open with the other pole closed. CADWIND has features which make this possible
using non-geodesic winding, but it is not possible with helical winding. For this
reason, helical winding must be done on vessels with equal pole openings only.

11.4.2 Starting angle

This is the desired winding angle (ie. the angle between the fibre direction and mandrel
rotation axis) at the starting frame. Usually on a vessel, pipe or tube, this is the nominal
winding angle on the cylindrical section, and the starting frame is located somewhere on the
starting frame. For example, see α1 on Figure 11.10.

11.4.3 Starting frame

This is the frame number on the mandrel where the winding will start and finish. See
Section 8.2 for an explanation of frames if unsure. The best place for the starting position
on a vessel is often where the cylindrical section meets the dome, at the front end. For a
pipe or tube, the best place is the front edge of the central winding zone (see Section 11.2).

To determine the frame number from the graphical view of the mandrel, simply turn on
Frame numbering (click FN in the toolbar). If all frame numbers don’t appear, zoom in on
the starting position until the frame number does appear.

11.4.4 Degree of covering / Number of cycles

This is the degree of coverage (see Section 11.3.2) desired on the mandrel, at the starting
frame. Note that the degree of covering will change in areas where the mandrel diameter
differs from that of the starting frame. For example, where the diameter of the mandrel is
lower at the domes of a pressure vessel, the degree of covering will increase (ie. the bands
will overlap to a greater extent). As a reminder, 100% covering will cover the mandrel
without gaps or overlaps.

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Alternatively, it is possible to specify the number of cycles desired instead of the degree of
covering. For example, a filter-housing may require specific sized gaps in-between the
bands (for the filtered fluid to flow through). The designer would calculate the number of
cycles required to achieve the required gap-width, and enter that instead of the degree of
coverage. To enter the number of cycles instead of degree of covering, click on the drop-
down box marked “Deg. of covering [%]” and choose “Number of cycles” instead. Then
enter the desired number of cycles in the adjacent box.

11.4.5 Pattern number and skip index

Pattern Number

The pattern number characterises the winding pattern. It represents the number of cycles
wound around the mandrel before a band is laid down immediately next to the first band. It
is easiest to understand the pattern number by considering a helical winding over a vessel
with closed-ends.

Figure 11.13: Winding sequence of a “3” pattern number. End views and isometric view

The figure above shows that three cycles are completed before a band is laid down next to
the first band on the fourth cycle. Hence, this is a “3” pattern, sometimes referred to in the
winding industry as a “3-star” pattern because of the 3 points on the dome that resemble
points of a star shape.

For comparison, a similar graphic showing the winding of a “5” pattern is shown in Figure
11.14. In that case, the 6th cycle is laid adjacent to the first.

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Figure 11.14: Winding sequence of a “5” pattern number. End views and isometric view

Skip Index

The pattern number also contains a skip index value after it and separated by a slash. For
example, a “3” pattern with a “1” skip index is referred to as “3/1".

Using the star-points analogy for the pattern number more winding pattern possibilities exist
if it is possible to skip points of the star. For example if Cycle 1 winds the first star-point, it is
then possible for Cycle 2 to winding either the 2nd, 3rd, 4th or 5th star point. If cycle 2
winds the 2nd star point, there has been a shift of 1 star-point per cycle, hence the skip
index is 1. If cycle 2 winds the 3rd star point, then there has been an increase of 2 star-
points per cycle, so the skip index would be 2.

Figure 11.15: Comparison of Skip Index effect on “5/1” and “5/2” patterns

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Negative and positive pattern numbers

It is possible for a pattern number to be either positive or negative. For example “+5/1” (the
“+” is usually ignored, and so it would be written “5/1” ) and -5/1. It is easiest to describe the
difference by example. In this case, a +5/1 pattern will be considered.

If the bands in a 5/1 pattern were separated circumferentially by exactly 1/5th of the
mandrel (ie. 72°), the 6th band would fall exactly on top of the 1st band. The 7th band
would fall exactly on top of the 2nd band, etc. The mandrel would never be completely
covered like this, no matter how many cycles were wound.

Figure 11.16: Positive and negative winding pattern

So, each successive band must be separated by slightly more or slightly less than 1/5th of
the mandrel in order to achieve correct coverage. If the bands are separated by slightly
more than 1/5th of the mandrel (ie. 72° + bandwidth ÷ 5 ), then the 6th band would lie
ahead of the 1st band, the 7th band would lie ahead of the 2nd band, etc. This is a positive
pattern number.

If the bands are separated by slightly less than 1/5th the mandrel circumference (ie. 72° -
bandwidth ÷ 5), then the 6th band would lie behind the 1st band and the pattern number
would be negative.

Good understanding of skip index and the difference between positive and negative winding
patterns is not very important for using CADWIND, as CADWIND will suggest appropriate
patterns.

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11.4.6 Closing of winding pattern options

As explained in the previous section, a cycle must finish at a precise location on the
mandrel, ready to start the next cycle. If the winding path is not precisely controlled like this
a full layer would not cover the mandrel evenly - some areas would receive thicker laminate
coverage than other areas and some areas may not be covered at all. Even coverage of the
mandrel is essential, so this must be avoided. Hence, the winding path must be adjusted in
order to finish each cycle in the correct position for the chosen winding pattern. This
adjustment is called “closing the winding pattern”.

For a helical winding, CADWIND has options for the locations on the mandrel where the
winding path adjustment will be made in order to close the pattern. In other words,
depending on the geometry of the mandrel, the geodesic winding path across the mandrel
surface may not necessarily close the pattern automatically, so CADWIND asks if it is
allowed to make adjustments to the geodesic path, and if so, where it should make those
adjustments.

The options for closing the winding pattern are in the top-right corner of the Helical winding
parameters window (see Figure 11.11). The choices are:

• don’t change path = follow the geodesic path, making no adjustments.

• change entire path = make small adjustments to the geodesic path everywhere, as
required to close the winding pattern
• in turning zones only = make larger adjustments, but only in the turning zones. The
geodesic path will be followed in the centre winding zone (between the turning
zones).

The option selected may have an effect on the success or otherwise of the pattern number
entered. If “don’t change path” is selected, then the geodesic path will be followed, so there
is no chance of fiber slipping (assuming all machine configuration options are correct and
the mandrel model is accurate, of course). However it may not be possible to close the
winding path with the desired pattern number if this option is selected. If this occurs,
CADWIND offers suggested alternative patterns (see following section for details).

On the other hand, if “change entire path” or “in turning zones only” are selected, it will
always be possible to close any pattern number. However, there is no accounting for friction
in the calculations and when you wind the pattern on the machine, there is no guarantee
that the fibers won’t slip. To overcome these problems, “non-geodesic” winding was
developed (see Section 11.5).

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11.4.7 Pattern recommendations

If helical winding is used with the “don’t change path” option, or non-geodesic winding is
used and CADWIND calculates that it is impossible to close the pattern with the given
pattern number, then a table with recommended alternative pattern numbers appears (see
Figure 11.17).

Figure 11.17: Pattern recommendations

This table gives alternative pattern numbers which are as close as possible to the desired
degree of covering.

It is not guaranteed that the patterns listed will close the winding pattern successfully.
Occasionally, none of the recommended patterns work and it is simply not possible to close
the winding pattern with the parameters given. In this situation, it is necessary to return to
the winding parameters and make an adjustment to one or more of:
• winding angle
• friction factor (if non-geodesic winding)

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 • close winding pattern (if helical winding)
• turning zones
• dwell

The bandwidth can also be adjusted to give different pattern options, if necessary. Smaller
bandwidths give a wider range of potentially successful patterns.

The pattern recommendations are given in order of the most likely to succeed through to
the least likely to succeed. Usually, only the first few recommendations are likely to
succeed. So, if the selected pattern does not work, try selecting a different pattern, higher
up in the table.

To select a winding pattern, simply click on it in the table (with the left mouse button) to
move the blue highlight over it. When the pattern you wish to wind is highlighted (ie. blue
background), click OK .

CADWIND will then attempt the winding path calculation (which may take a few seconds),
and if it fails (ie. the selected winding pattern can not be closed), it will simply return to the
table of recommendations and wait for another option to be selected. If the calculation takes
more than a few seconds, click Cancel and change one or more of the winding
parameters before retrying.

Suggestions for choosing the best winding pattern

When choosing the best winding pattern from the recommendations, first consider what is
most important for your particular winding. For example, it is often very important to get
even coverage of the mandrel with minimal gaps or overlaps and minimal winding time /
minimal material use. In this case, you would want to choose a pattern that gives as close
to 100% coverage as possible (less than 100% is often unacceptable as it leaves gaps).

If aesthetics are important for the winding, you may wish to choose a low pattern number
such as 3/1 or 5/1, which will give a distinctive and aesthetically pleasing pattern (see
Figure 11.18).

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Figure 11.18: The aesthetic effect of pattern number

If it is important to avoid the ‘birds-nest’ effect around the pole openings, which can lead to
a lot of fiber-overlapping and bridging, you may wish to choose a very low pattern number
such as 1/1. If you wish to have higher impact strength, more fiber overlapping may be
desirable, so a higher pattern number might be better.

11.4.8 Dwell in helical winding

Just like dwell in circumferential winding (see Section 11.3.3), dwell in helical winding
means that the spindle will rotate while the carriage and other axes stay still. This
movement is done at the front and/or back poles. The amount that the spindle rotates is
controlled by the “dwell front” and “dwell back” value entered in the winding parameters
(entered in degrees, see Figure 11.11).

Figure 11.19: The effect of dwell

This works well for helical winding over cylindrical mandrels or with a high winding angle on
closed-end vessels.

However, when helical winding with a low winding angle over a closed-end vessel, the use
of dwell will cause the fibers to slip across the surface and/or bunch-up against the pole or

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shaft (ie. become more like a rope than a flat ribbon). CADWIND does not model this effect,
so what you wind on the machine will look different from what is shown in the display
window. If the “bunching” effect occurs, it will also reduce the bandwidth at the poles. For
these reasons, using dwell with low-angle helical winding on a vessel is not normally
recommended. It can be used as a last-resort to close a very small pole opening without
crashing the head of the winding machine into the supporting shaft, in rare situations.

11.4.9 Number of layers

This option (refer to Figure 11.11) is the number of times the layer (as defined in the Helical
winding parameters window) will be repeated during the actual winding on the machine.

Note that only one layer is shown in the display window and all the layer thickness
calculations are for one layer only, regardless of the number of layers entered here.
However, the machine movement simulation and part program will wind all the layers in it
(ie. the same layer repeated as specified).

11.5 Non-geodesic winding

11.5.1 Geodesic versus non-geodesic winding

As previously mentioned, helical winding is geodesic winding (with some necessary

adjustment to close the winding pattern, as explained in Section 11.4.6), but CADWIND
also offers the ability to wind non-geodesically. This section explains the difference between
the two.

Figure 11.20: Geodesic path from Paris to New York

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The word “geodesic” comes from “geodesy”, the science of measuring the size and shape
of the earth.

Under the original meaning, the geodesic path was the shortest route between any two
places on the surface of the earth. It is simple to demonstrate this by stretching a slippery
string tightly across two points on a globe.

In the modern, mathematical meaning, a geodesic winding path is the shortest path across
the surface of a mandrel between two points.

The geodesic path is the only path that a filament stretched tightly between two points on a
mandrel can take without relying on friction to prevent slipping.

Figure 11.21: Example of geodesic & non-geodesic paths across a dome

So, non-geodesic winding is a method of calculating a winding path that uses friction
between the filament and the mandrel to move away from the geodesic path.

The amount to which the filament can move away from the geodesic path depends on the
amount of friction between the filament and the mandrel. Very sticky filaments (eg. warm
tow-preg) on high-friction mandrels (eg. rubber) can take a path that is greatly different from
the geodesic path. However, very slippery filaments (eg. fiber lubricated with a low viscosity
liquid resin) on very smooth mandrels (eg. polished stainless steel) must follow a path that
is very similar to the geodesic path, or they will slip.

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11.5.2 Non-geodesic winding

Non-geodesic winding opens up a wide range of winding possibilities to the designer, with
the security of knowing that the filament will not slip if the correct friction factor, machine
parameters and accurate mandrel geometry are used. However, the iWind feature, new to
version 10 is an improvement on the Non-geodesic winding feature, as it finds more
possible patterns and offers more winding options. However, Non-geodesic winding has
been kept in CADWIND version 10, for backwards compatibility and for the convenience of
experienced users who are familiar with it.

Non-geodesic winding can be used on all mandrel geometries except T-shaped mandrels.

By intelligent use of turning zones, varying friction factors and varying winding angles, a
great variety of winding paths are possible on any given mandrel geometry.

To wind non-geodesically, select “Winding” menu ► Non-geodesic...

Figure 11.22: Non-geodesic parameters window

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11.5.3 Winding angle

If the winding angle is constant (ie. the variable winding angle feature is not being used),
then the winding angle has the same meaning as “Starting angle” in the helical winding
parameters (see Section 11.4.2). If variable winding angle is used, refer to Section 11.5.5

11.5.4 Friction factor

This factor is actually the coefficient of friction between the filament and the mandrel
surface. As explained previously, this friction allows a deviation from the geodesic path,
which allows windings to be achieved that would not be possible geodesically. Non-
geodesic winding can also be used to achieve a geodesic winding simply by entering a
friction factor of zero.

The table below gives an approximate indication of typical friction factors for various
combinations of filament and mandrel materials. It may be used as a guide, but tests should
be conducted with any new mandrel / fiber / resin combination, to determine the real friction
factor.

Mandrel Surface Dry fiber Wet fiber Prepreg fiber

Smooth metal 0.18 0.15 0.35
Smooth plastic 0.20 0.17 0.32
Dry laminate 0.22 - -
Impregnated - 0.14 -
laminate
Prepreg laminate - - 0.37

If it is critical that the fiber does not slip, then a friction factor below those listed (above)
should be used to give some margin of safety.

11.5.5 Variable friction factor and variable winding angle

It is possible to assign different friction factors and/or different winding angles for different
parts of the mandrel by changing the “Var/Const” (ie. “Variable / Constant”) toggle button(s)
to “Var”. This opens a table of winding angles and/or friction factors that can be altered for
different mandrel areas.

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Figure 11.23: Variable winding angle and friction parameters

The numbers in the first row of each table are the frames on the mandrel. So, in the above
example:

• the winding angle between frames 10-11 would be 40°,

• when the filament passes frame 11, CADWIND will start to turn the fiber using a
friction factor of 0.4 (not visible in the diagram), until it reaches an angle of 75°.
• CADWIND will continue with a 75° fiber angle until it passes frame 14,
• After frame 14, it will start turning the fiber again in the other direction with a friction
factor of 0.4 until it passes frame 15
• At frame 15, the friction factor is reduced to only 0.1. The fiber angle will continue to
reduce towards 40°, but the rate of change will be much more gradual than it was
with the higher friction factor.
• If the filament is still changing its angle (ie. not yet at 40°) after it passes frame 17,
the friction factor will change again to 0.2. With the higher friction factor, the rate of
change of winding angle will be greater.

The diagram below is the result of this winding. Note the much higher winding angles in
between frames 11-14, and the gradual changing winding angle. This gradual changing of
winding angle means that the angle you entered in the winding parameters table is not
necessarily the actual winding angle on the mandrel - it is just the target winding angle, and

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the limits of friction will be respected in getting to the target winding angle so that slippage
will not occur.

Figure 11.24: Variable winding angle and friction parameters

11.5.6 Set range

With “var” (variable) winding angle or friction factor selected, new buttons appear giving the
option to “Set range”. This is a faster way of entering the same friction factor or winding
angle across many frames, rather than entering the same number for each frame
individually. To use this feature, click "Set range". Enter the desired value for friction or
winding angle, the starting frame and the ending frame for this particular value in the
window that appears, then click "OK". CADWIND will return to the “Non-geodesic
parameters” window and the relevant cells in the table will be automatically filled-in.

Figure 11.25: Variable winding angle and friction parameters

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11.5.7 Constant thickness

Another winding possibility created by the ability to vary the winding angle is that a constant
thickness layer can be achieved on mandrels which vary their diameter. Normally if a
mandrel diameter increases, the thickness of the layer wound on it will be reduced.
However, by precise control of the winding angle, this effect can be avoided as shown in
Figure 11.26.

Figure 11.26: Constant laminate thickness winding example

Figure 11.27: Constant laminate thickness window

This feature works in a similar way to the “Set range” feature. From the Non-geodesic
parameters window, first make sure the "Var/Const" button is set to “variable” winding
angle, then click on the "Const thick" button.

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Decide the winding angle needed and at what frame that angle should be and fill this
information into the window that appears. When “Ok” is clicked, the winding angle at all
other frames (except the chosen frame) will be adjusted to give a laminate with a constant
thickness. The winding angles will be visible in the variable winding angle table (in the non-
geodesic parameters window).

11.5.8 Pattern number

The pattern number has the same meaning as for helical winding. Refer to Section 11.4.5.

11.5.9 Degree of covering / Number of cycles

This has the same meaning as for helical winding. Refer to Section 11.4.4.

11.5.10 Dwell Front and Dwell Back

This has the same meaning as for helical winding. Refer to Section 11.4.8.

11.5.11 Number of layers

This has the same meaning as for helical winding. Refer to Section 11.4.9.

11.5.12 Turning zone front and Turning zone back

This is the number of the frame that divides the Front turning zone from the Centre winding
zone, or the Back turning zone from the Centre winding zone. Refer to section 11.2 for
details.

11.5.13 Starting frame

This is the number of the frame where the winding program will start and finish. It is also the
frame number used for the winding angle calculation.

11.5.14 Starting position

This is the rotation angle of the mandrel / spindle at the start of the winding program. If you
use combination winding programs to link one program to the next, it might be important to
use the correct starting position (particularly for non-axisymmetric winding). However, for
most winding, a starting angle of 0° is recommended.

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11.6 Polar winding
11.6.1 Application and limitations of Polar winding

Polar winding is used only for short vessels with the total length (ie. length from pole
opening to pole opening) of:

𝐿 ≤2∙𝐷

Figure 11.28: Polar winding

It is for covering the vessel completely up to the poles, without the need to manually
calculate the required winding angle. However, the same winding can also be achieved
using Helical or Non-geodesic winding, both of which give more options.

This winding method takes no account of friction limitations (there is no guarantee that the
filament won’t slip), and winds the filament in a direct line between the pole openings.

11.6.2 How to use Polar winding

To use Polar winding, click: “Winding” menu ► Polar...

The following window should appear.

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Figure 11.29: Polar winding

There is no need to specify an angle for polar winding, as CADWIND automatically

calculates the angle required to wind the entire vessel up to the poles. The winding angle
will be:

(∅𝐹𝑟𝑜𝑛𝑡 𝑝𝑜𝑙𝑒 + ∅𝐵𝑎𝑐𝑘 𝑝𝑜𝑙𝑒 )

∝ = arctan [ ]
2∙𝐿

11.6.3 Band centring on poles

Note that the centre of the bandwidth (not the edge) will align with the edge of the pole on
the mandrel. So, if the edge of the band must touch the pole, then the pole opening
diameter on the mandrel must be increased by the size of one bandwidth (ie. the radius
increased by ½ bandwidth).

11.6.4 Polar winding options

There are very few options to choose from. The only possible pattern numbers are +1/1 or -
1/1 (refer to Section 11.4.5 for details).

The degree of covering, number of layers and starting frame have their usual meanings.
Refer to Section 11.4 for details.

11.7 Combination (transitional) winding

Combination winding is not offered with CADWIND ESSENTIAL.

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To wind two different layers on the mandrel (eg. a helical layer, then a circumferential layer)
without stopping the machine and cutting the filament, a combination program can be used.

A combination winding is a program created separately from the other programs. It moves
the machine from the end of the preceding program to the start of the next program in such
a way that the fiber does not need to be cut and will not slip. A combination program is not
intended to wind a lot of fiber onto the mandrel. It is not a layer in the laminate. A good
combination program should wind only the minimum fiber that is necessary for the
transition, which is much less than the fiber required for a full layer.

Program 1 (eg. 22° helical winding)

Combination (transition) program

Program 2 (eg 88° circumferential winding)

11.7.1 How to use Combination winding

To use Combination winding, click “Winding” menu ► Combination...

The following window should appear.

Figure 11.30: Combination parameters

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11.7.2 Starting angle

This is the winding angle at which the combination winding will start. It must be the same as
the angle of the previous winding (ie. Program 1 in the example 22°) in order to correctly
link to the previous program.

11.7.3 Starting frame

This is the number of the mandrel frame at which the combination winding will start. Note
that this is not the position or frame number of the machine, but the frame number where
the filament contacts the mandrel.

The starting frame must be the same as the ending frame of the previous winding
(remember that ending frame = starting frame of a normal non-combination winding) -
Program1 in the example. This is necessary in order to correctly transition from the
previous winding.

11.7.4 Starting position

This is the mandrel rotation angle (α in Figure 11.31) at which the combination winding will
start, on the starting frame.

Figure 11.31: Starting point and angle on starting frame

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This must be the mandrel rotation angle at the end of the previous program. If the part
program is in relative coordinates (ie. not absolute coordinates - see Section 13.2.8) and
the mandrel is axisymmetric, then the starting position is unimportant and 0° will work.
Otherwise, take note of the spindle rotation angle at the end of the previous program (turn
on the Numerical data ND display during the machine simulation).

11.7.5 Ending angle

This is the winding angle at the end of the combination.

The ending angle entered must be the same as the starting angle for the next winding
(Program 2 in the example 88°) in order for the machine to transition correctly to the next
winding.

11.7.6 Ending frame

This is the number of the mandrel frame at which the combination winding will end. Note
that it is not the position or frame number of the machine pay-out head, but the frame
number where the filament last makes contact with the mandrel.

The ending frame entered must be the same as the starting frame for the next winding
(Program 2 in the example 88°) in order for the machine to transition correctly to the next
winding.

11.7.7 Friction factor

This is the coefficient of friction that the combination winding will use when turning the fiber
angle from the starting angle towards the ending angle. The friction factor is the user’s only
control of the rate of change of fiber angle and the only real choice that the user must make
(given that all other parameters are already determined by the programs beforehand and
afterwards).

A higher friction factor will turn the fiber more quickly towards the new winding angle. The
fiber will reach the new angle sooner with a higher friction factor. But, if the friction factor
you use exceeds the maximum physical friction between fiber and mandrel, the fiber will
slip, so take care to respect the physical friction limits.

11.7.8 How the Combination winding algorithm works

The combination winding algorithm must achieve two objectives:

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 1. Change the winding angle of the filament from the starting angle to the ending angle
2. Move the filament from the starting frame to the ending frame

The algorithm works on these objectives in the order given above. For example, if it is given
a 22° starting angle and an 88° ending angle, with starting frame 20 and ending frame 20, it
will follow the following sequence:
1. Start at frame 20 with a 22° winding angle (ie. the starting angle)
2. Slowly increase the winding angle by turning the fiber. The rate of turn is controlled
by the friction factor.
3. When the ending angle of 88° is reached, it will stop turning the fiber and check the
frame number at the point where 88° was reached.
4. If the frame number where the ending angle was reached is not the ending frame
(20), then it continues to wind the filament at the ending angle of 88° until it reaches
the ending frame of 20.
5. When the ending frame is reached with the fiber at the ending angle, the algorithm
and the winding are finished.

Understanding of this algorithm is important for optimising combination windings.

11.7.9 Optimising the combination winding by adjusting the friction factor

It is very easy to create a combination winding program that winds more fiber onto the
mandrel and takes more time than is necessary - particularly when making a transition to a
hoop program. If the combination reaches a high ending angle (for a circumferential winding
afterwards) long before the ending frame, it will hoop-wind until it reaches the ending frame,
which may add a lot of unnecessary fiber to the mandrel and take up time (which might be
undesirable in a mass-production situation).

To avoid this, adjust the friction factor (some trial and error may be necessary) until the
combination program reaches the ending angle at the same time that it reaches the ending
frame, as shown in the following table.

Sequence Inoptimum winding program Optimum winding program

of events (friction factor too high) (optimum friction factor)

1.

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 2.

3.

Figure 11.32: Optimization of combination winding by varying the friction factor

11.8 T-winding
A T-shaped parts is generally used for joining the branch of a pipe/tube with the main
pipe/tube. It is possible to filament-wind these parts with a normal winding machine, but
they present some unique challenges. There are also custom-built machines in existence
purely for filament winding T-parts.

Figure 11.33: T-shaped mandrel

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11.8.1 Possible T-winding patterns

For ‘T' parts, there are a limited range of useful winding patterns. The possible winding
patterns are shown in the following table:

hoop1 hoop2
Winds hoop fibers over the first Winds hoop fibers over the second
branch (nearest the headstock) branch

hoop3 trian
Winds hoop fibers over the third Winds over the triangular section
branch (nearest the tailstock) between the branches.
Figure 11.34: Possible T-Winding patterns

11.8.2 Creating the T winding sequence

Before T-winding can be defined, a T-shaped mandrel must be loaded in the display
window. Refer to Section 8.1.6 for details on creating a T-shaped mandrel.

To tell CADWIND the types of winding required, and their sequence, a ‘CADWIND T
Sequence File' must be written. Different winding types can be combined in any sequence
and with any degree of coverage or number of cycles.

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To write the T Sequence file, select:

“Winding” menu ► T...

A window should appear, with the contents of the CADWIND.TSQ file showing inside it (see
following diagram). If there are no contents, or an error message, this is because there is
no CADWIND.TSQ file yet written.

The contents of the window can be altered as required to any combination or sequence of
the available winding patterns, with any degree of coverage for each pattern.

Figure 11.35: Example of a T-Sequence file

11.8.3 Syntax for the T Sequence file

The syntax of the T sequence is as follows:

Line 1:
This line is for identification and must always say:

CADWIND T SEQUENCE FILE

Line 2:
The second line must be an integer number (eg. 1, 2, 3, etc.). This is the
number of layers to wind.

Line 3 onwards:

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 Each winding pattern is represented by a line in the T sequence file. Starting
at line 3, you must tell CADWIND what winding types you want and how many
circuits OR how much coverage you want each time.

The format is:

Winding Type Number of Circuits Coverage in percent (%)

hoop1 eg, 50, 100, 200
0
hoop2 or
or
hoop3 0
1, 2, 3, 4, etc.
trian

Important note:
Either the number of circuits for each winding or the percent coverage must be entered for
each line in the winding sequence section, but not both. If the number of circuits (ie. number
of times to wrap around the mandrel) is specified, then ‘0' must be entered for the coverage.
If the percent coverage is entered, then ‘0' must be entered for the number of circuits.

Correct Examples:

hoop1 0 200 : A ‘hoop1' winding pattern with 200% mandrel coverage

hoop1 5 0 : A ‘hoop1' winding pattern with 5 circuits (wraps the fiber 5 times
around the mandrel)

Incorrect Example:

hoop1 5 200 : This will create an error because both the number of circuits and
the mandrel coverage are entered.

11.9 Update mandrel / Reset / Save update

11.9.1 The Update mandrel feature

The Update mandrel and associated features are not available with CADWIND
ESSENTIAL.

During the filament-winding of a thick-walled part, the mandrel changes its size and shape
as the winding progresses. In other words, as fiber is wound onto a mandrel, it grows in
size.

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If the mandrel size and shape are not updated in CADWIND, this mandrel growth can lead
to problems with the actual winding during later layers - the fibers can slip and in some
cases there may even be collisions with the head of the machine into the mandrel surface
because the real surface of the mandrel is not the same as the CADWIND mandrel surface.

Figure 11.36: Update mandrel example showing thickness build-up at the pole

11.9.2 How to use the Update mandrel feature

The Update mandrel feature allows the user to ‘grow’ the size and shape of the CADWIND
mandrel to simulate the way that the real mandrel would grow. To access this feature,
select:

“Winding” menu ► Update mandrel

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11.9.3 Updating non-axisymmetric mandrels

This feature only works with axisymmetric mandrels. Do not use with non-axisymmetric
mandrels.

This feature is primarily intended for vessels and pipes, although it can be used with all
axisymmetric mandrels.

11.9.4 Limitations of the Update mandrel feature

The thickness build-up is an estimate only and relies on accurate material parameters
(roving width, fiber volume content, etc). Mandrels can be updated again and again to
simulate the thickness of each new layer, however small inaccuracies can compound
(analogous to the degradation in quality that occurs when photocopying a photocopy of a
photocopy). It is not recommended to use the mandrel update feature more than 3-4 times
consecutively. After 3-4 updates, it is recommended that the user measure the dimensions
of the real-world mandrel and make a brand-new CADWIND mandrel using the measured
dimensions.

11.9.5 Circumferential winding over an updated mandrel

The updated mandrel will have a slightly larger diameter than the original mandrel.
However, cylindrical surfaces may become very slightly non-cylindrical when updated.

CADWIND will not wind circumferential layers over any surface that is not perfectly
cylindrical. Therefore, it may be necessary to open the mandrel file and manually adjust the
diameters of some frames on the cylindrical surface so that they are all exactly the same
(ie. making the surface exactly cylindrical again).

Refer to Section 8.4.3 for details on the mandrel contour file format and Section 16 for
details on the text editor which can be used for this purpose.

11.9.6 Reset

An updated mandrel can be reset to its original dimensions (ie. as it was before the update)
by selecting:

“Winding” menu ► Reset

Note that this will restore the mandrel to the dimensions it had when it was first loaded. So,
if more than one update was made without saving the updated mandrel, then all updates
will be lost.

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11.9.7 Save update...

The shape of an updated mandrel can be saved for future work by selecting:

“Winding” menu ► Save update...

A window will appear where the user can browse to the folder where the updated mandrel
is to be saved, and give the updated mandrel a file-name.

It is recommended that each updated mandrel (there may be several on thick windings) be
given a different (and systematic) filename from the original mandrel as it may be
necessary to refer back to the original mandrel to make adjustments to layers wound earlier
in the process.

Updated mandrels can be loaded in the normal way, by selecting:

“File” menu ► Load mandrel...

11.10 Winding options

There are several options related to the winding calculations, which can be changed by
selecting:

“Winding” menu ► Options...

The following window will appear:

Figure 11.37: Winding options window

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The three options presented are discussed below.

11.10.1 Pattern display on axisymmetric geometries

If the pattern display on axisymmetric geometries is selected (ie checked on), then the
entire wound pattern will be displayed on an axisymmetric mandrel.

If it is not selected (ie. off), then only one cycle will be displayed on an axisymmetric
mandrel instead of the entire pattern (see Figure 11.38).

Figure 11.38: Effect of Pattern display for axisymmetric parts

By default the pattern display for axisymmetric parts is on. However, it can be helpful to turn
it off to avoid display annoyances with a high number of winding cycles (eg. slow dynamic
rotation, long winding calculation time, etc).

Note that the degree of coverage and laminate thickness calculations can not be performed
with the pattern display for axisymmetric parts turned off.

11.10.2 Save laminate data

If this option is turned on, CADWIND will save the laminate data for the winding (when
“Start winding” is selected) in a text file that can be then opened by other software (eg. a
text editor or spreadsheet) for further analysis.

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Select Browse to select a filename and folder for the laminate data. It will be stored in an
ASCII standard text file, with a .LAM file extension. The laminate data file has the following
structure:

Example line syntax Explanation

CADWIND LAMINATE DATA FILE Identification of the data file type
MM The data is in millimetres (MM) or inches
(IN)
300.000 99.897 22.000 0.301 Data record for the 1st roving element
300.994 99.840 21.991 0.301 Data record for the 2nd roving element
304.130 99.657 22.594 0.303 Data record for the 3rd roving element
305.008 99.506 22.893 0.304 Data record for the 4th roving element
…
281.580 99.897 22.000 0.301 Data record for the last roving element
Roving Mandrel Winding Layer The meaning of each column (information
element diameter angle thickness only - this line is not in the actual file)
Y
location

As shown in the bottom row of the above table, each data record contains the Y mandrel
coordinate for the record, the mandrel’s average diameter at that coordinate, the winding
angle of the filament and the thickness of the layer.

11.10.3 Save winding path

The Save winding path feature is only available with CADWIND EXPERT or HIGH-END.

If this option is turned on (checked), CADWIND will save the winding path data for the
winding when “Start winding” is selected. It is saved in a text file that can be then opened by
other software (eg. a text editor or spreadsheet) for further analysis. This gives advanced
CADWIND users the option to make manual adjustments to the winding path outside of
CADWIND.

A saved (and possibly adjusted) winding path can be opened by the post-processor and a
part program created from it. This enables part programs to be created to wind specific
paths that CADWIND can not generate automatically. This opens up manufacturing
possibilities that would not otherwise be possible. Eg. winding around a boss in an unusual
location on the mandrel, etc.

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Select Browse to choose a filename and folder for the winding path data. It will be stored
in an ASCII standard text file, with a .PTH file extension. The winding path file has the
following structure:

Example line syntax Explanation

CADWIND WINDING PATH FILE Identification of the data file type
MM Data is in millimetres (MM) or
inches (IN)
AXISYM: YES Is the mandrel axisymmetric?
YES or NO
PINS FRONT: NO Are winding pins used at the
front? YES or NO
PINS BACK: NO Are winding pins used at the
back? YES or NO
VECTORS: YES Does the winding path contain
vectors? YES or NO
50.0000 Largest mandrel radius (measured
from the mandrel rotation axis)
-50.0000 Minimum Y (longitudinal)
coordinate
350.0000 Maximum Y (longitudinal)
coordinate
LAYER UNIT Identification: beginning of the
path data
1 Number of layers
27 Number of cycles
19 Winding pattern skip index
49.6922 3.9109 0 0.9969 0.0785 0.0 Record for 1st winding path point
49.3844 7.8217 9.7097 0.9969 0.0785 0.0 Record for 2nd winding path point
47.5528 15.4508 29.129 0.9724 0.2334 0.0 Record for 3rd winding path point
…
-11.598 -48.355 -4.1300 -0.2326 -0.969 -0.08 Record for last winding path point
X Y Z X Y Z The meaning of each column (this
line is information only and not in
the actual winding path file).
Winding path coordinates Normal Vector Coord’s

The normal vectors are only needed for calculation of the vertical axis and the yaw axis
machine movements (ie. the 5th and 6th machine axes). If manual changes to the winding
path file, and calculation of the yaw and vertical axes are not required (eg. if a two, three of

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four axis machine is being used that does not have a yaw or vertical axis), then the vectors
can be left out for simplification. To do this, in line 6, enter: "VECTORS: NO"

11.11 Load / Save winding parameters

All parameters entered under the “Winding” menu, including the Material parameters and
Winding options can be saved using:

“Winding” menu ► Save...

Browse to the folder location where the winding parameters will be saved and enter a
filename with the keyboard. Winding parameters must have a .WIP file extension.

Winding parameters should only be reloaded if the original mandrel is open in the display
window. If a different mandrel is in the display window, an error message may appear (in
which case the correct mandrel should then be loaded first). To reload saved winding
parameters select:

“Winding” menu ► Load...

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12 Postprocessing

Posprocessing is the third step in the CADWIND process (the first step being to create the
mandrel geometry and the second step being to create a winding path across the mandrel).

The postprocessor takes the winding path (ie. the path that the fiber takes across the
mandrel’s surface) and calculates the movements of the machine necessary to wind that
path.

Usually the winding path used for these calculations is the winding path showing in the
display window, however a previously saved winding path can also be used with CADWIND
EXPERT and HIGH-END (this feature is called “open post-processing”), which gives
advanced users the opportunity to make manual adjustments.

In calculating the machine movements, machine parameters such as the maximum speeds
and accelerations allowed for each axis is taken into consideration. The parameters entered
in the Postprocessing parameters window are also taken into consideration.

12.1 Calculation of the control data for the part program

The normal procedure after the winding path is finished is to define the postprocessing
parameters and then make a part program for the machine controller. To define the
postprocessing parameters, select:

“Postprocessing” menu ► Parameters...

The following window should appear:

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Figure 12.1: Postprocessing parameters window

The postprocessing parameters available under the “General” tab are defined in the
following paragraphs.

12.1.1 Calculation mode

There are four different calculation modes to choose from. Each calculation mode will move
the machine in a different way in order to achieve the same winding. There are advantages
and disadvantages of each calculation mode, depending on the type of winding. The four
calculation modes are discussed individually below:

Constant free fiber length

Calculates the machine motion required to keep a constant free fiber length. Free fiber
length is defined as the distance between the fiber/mandrel contact point and the pay-out
eye, as shown below.

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Figure 12.2: Definition of Free-fiber length

This calculation mode is recommended for use with:

• Elbow winding
• T winding
• Other non-axisymmetric winding

It can be used (but is not recommended) for:

• Axisymmetric winding

Open enveloping cylinder

The Open enveloping cylinder postprocessing option calculates machine motions which are
constrained to lie on the shape of an open ended cylinder which envelops the mandrel, a
certain distance from its surface (at the largest diameter). The cylinder shape is relative to
the mandrel’s view reference - imagine an ant’s viewpoint who sits stationary on the
rotating mandrel, watching the machine motion. The machine pay-out would appear to
rotate around the mandrel rather than the mandrel itself rotating. The pay-out from the ant’s
view-point would lie on an invisible cylindrical surface

For details see Figure 12.3 (a = “minimal distance”).

This calculation mode does not allow any cross-carriage movement.

This calculation mode is recommended for use with:

• 2-axis axisymmetric winding

• 2-axis non-axisymmetric winding

It can be used (but is not recommended) for:

• All axisymmetric winding

• All non-axisymmetric winding

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This calculation mode can not be used for:
• T winding

Figure 12.3: Machine motion from Open-enveloping cylinder mode

Closed enveloping cylinder

This mode calculates machine motions which are constrained to lie on a cylindrical shape
with closed ends that envelopes the mandrel at a certain distance from it surface (at the
largest diameter). The cylinder shape is relative to the mandrel as explained for the “Open
enveloping cylinder” above.

Figure 12.4: Machine motion from Closed-enveloping cylinder mode

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In other words, this allows cross-carriage movement to wind over the domes of a vessel,
with no carriage movement. It also allows carriage movement to wind on the cylinder, with
no cross-carriage movement.

In Figure 12.4:

Payout eye width

𝑏=𝑎+
2
with a = “minimal distance”

See Section 13.1.2 for the definition of the Pay-out eye width. This calculation mode is
recommended for use with:
• Any 4 axis machine which has a controller than can only process a maximum of 3
simultaneous axis movements
• 4-axis axisymmetric winding
• 4-axis non-axisymmetric winding

It can be used (but is not recommended) for:

• All non-axisymmetric winding

• Elbows
• 2 and 3 axis winding

This calculation mode can not be used for:

• T winding

Enveloping contour

This versatile mode calculates machine motions which are constrained to lie on a contoured
surface which envelopes the mandrel a certain distance from the mandrel surface.

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Figure 12.5: Machine motion from Enveloping contour mode

In other words, this requires simultaneous movement of the carriage and cross-carriage
axes in order to trace a smooth shape around the mandrel profile.

In Figure 12.5:

Payout eye width

𝑏=𝑎+
2
with a = “minimal distance”

See Section 13.1.2 for the definition of the Pay-out eye width. This calculation mode is
recommended for use with:

• All axisymmetric winding

• All 4, 5 and 6 axis winding
• Most non-axisymmetric winding except T winding

It can be used for:

• Elbows

This calculation mode can not be used for:

• T winding

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12.1.2 Velocity calculation

The Calculation mode options explained above determine the shape of the movements that
the machine will take, whereas the Velocity calculation options determine the speed of
those movements.

The time that the part program will take to complete can be changed by speeding up and
slowing down the movements in various parts of the program. The Velocity calculation
affects this speed variation.

There are three different Velocity calculation options, each described below:

Minimum production time

This is the most commonly used option for winding with 3 or more axes of motion. The
machine motions will be calculated to be as fast as possible without exceeding the
maximum velocities, maximum accelerations or the minimum processing time as entered in
the Machine parameters (refer to Section 13 for details on machine parameters). In other
words: at each program step, the slowest axis will be moving at its fastest permissible
velocity. The fastest permissible velocity takes into account both the axis’ maximum velocity
and maximum acceleration (along with the preceding velocity) - refer to Section 13 for more
details.

This option usually gives the fastest machine movements and the shortest possible time to
complete a part program. Note that the choice of calculation modes will also affect the
winding time, along with the filter value, minimal distance and especially the machine
parameters. For production, where winding time is important, it may be worth experimenting
with different calculation modes and filter values to find the optimum winding time. Caution
should be taken however as machine accelerations or velocities which are too high may
damage the machine or create a safety risk.

Constant pay-out speed

The Constant pay-out speed option controls the machine motion such that a constant rate
of fiber lay-down is achieved. This is useful for machines which spray liquid resin onto the
fiber as it moves through the wet-out system. In this situation, a constant fiber speed may
be required in order to avoid spraying too much or too little resin onto the moving fibers.

The Constant pay-out speed option gives good results for hoop winding and moderate to
high-angle helical winding. It is well suited for for 2-axis machines winding pipe or tube with
a fiber angle of 40 degrees or higher. However it will result in very slow running programs
for low-angle helical winding of 30 degrees or lower. This is because the slow pay-out
speed which occurs at the turn-around becomes the speed for the entire program in order
to make the pay-out speed constant.

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Constant mandrel speed

This adjusts the movements so the mandrel is rotating at a constant speed throughout the
program.

It creates a very smooth, fast running program for hoop-windings, and is acceptable for
high-angle helical winding. However, for low-angle helical winding, it can be very slow as it
finds the slowest mandrel rotation speed (usually during the turn-arounds) and keeps the
mandrel rotating at that speed for the duration of the program.

This option can be useful for very large, heavy mandrels that should not change speed
during the winding for mechanical or safety reasons.

12.1.3 Minimal distance

This is the minimum distance from the mandrel surface to the pay-out eye of the machine.
See ‘a’ in Figure 12.3, Figure 12.4 and Figure 12.5.

12.1.4 Pay-out speed

This option is only available if “Constant pay-out speed” Velocity calculation option is
chosen. It is the linear rate that the filament is wound onto the mandrel, in metres per
second (metric) or inches per second (English units). Refer to Section 12.1.2 for details.

12.1.5 Filter value

The filter value is the maximum distance that the pay-out eye will move when the machine
controller runs one line (sometimes called a ‘block’ - it represents one movement of the
machine) of the part program. This value can be altered to increase or decrease the
number of lines in the part program. As an approximate guide, it should between 10% -
25% of the mandrel diameter for best results.

This control filters out any machine movements that are smaller than the “filter value”
setting.

Smaller filter values usually give smoother programs, but they are longer in size (ie. more
lines). If your controller has a restriction on the number of lines in the part program, then the
filter value may need to be set higher than optimum to reduce the number of lines in it.
Sometimes very small machine movements are calculated which create ‘bumps’ in the
motion. In this case, the filter value should be increased to eliminate these small
movements for a smoother running program.

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 Low filter value = more (smaller) machine High filter value = fewer (larger) machine
movements movements
Figure 12.6: The effect of filter value on programmed motion

Note that large filter values will also produce a poor visual representation of the winding, as
the fiber representation will short-cut from one point in the winding to the next point. If the
filter value is too high, it may short-cut through the mandrel surface (see Figure 12.7).

Filter Value set to 10% mandrel diameter Filter Value set to 50% mandrel diameter
Figure 12.7: The visual effect of filter value

12.1.6 Positioning Length

This tells CADWIND where the mandrel is positioned in the winding machine (measured
along the winding machine’s carriage axis, or the CADWIND mandrel ‘Y’ axis).

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It is the distance from the machine reference feature (often the chuck face, but is chosen
the machine parameters are entered. See Section 13.1.1 for the mandrel coordinate
system. For an elbow or ‘T’ shaped mandrel, this is the centre (or point where the branch
axes intersect for a ‘T’). See Figure 12.8. For CADWIND generated cylindrical mandrel, it is
the point where cylinder meets dome (see Figure 13.2). For mandrels created outside of
CADWIND, it is the user’s choice. The user must be aware of the location of the mandrel
coordinate system before measuring the positioning length.

Figure 12.8: Positioning length for a CADWIND generated elbow mandrel

12.1.7 Axes to Calculate

These are the axes for which CADWIND will calculate machine movements. Select only
axes that exist on the machine and are also selected in the “Machine” menu ► Parameters
► Axes tab. If it is desired that an axis should not move for a particular a part-program,
unselect it here.

12.1.8 Yaw mode

For machines with a yaw axis, there is the option to orient the yaw axis either to be in-line
with the fiber, or perpendicular to the mandrel surface. See Figure 12.9 for a comparison
between the two.

If winding a low-angle helical over a pressure vessel with closed ends and flat domes, the
“inline with fiber” option should be chosen. If the “perpendicular to surface” option is
chosen, then the yaw angle will become 90° at the polar openings, and could cause
incorrect machine movements.

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 Yaw axis in-line with fiber Yaw axis perpendicular to surface
Figure 12.9: The yaw-axis alignment options

12.1.9 Save as

Usually in the “Save as” area, “Part Program” will be selected, then “Browse” will be clicked
in order to type in a part program file name and folder location. This will create a part
program, using the format defined in the Machine Parameters.

Alternatively, a part program can be created using CADWIND’s native part-program format
“CCDF” = “CADWIND Control Data Format”. The CCDF format, which is usually saved as a
.DAT file, will not be compatible (ie. not work) with your machine’s controller. However, you
must make a part program in CCDF format if you want to use CADWIND’s ‘Postprocessing
-> Display’ function to analyse the machine’s movements.

The CCDF format is also a convenient way to send part program files to other CADWIND
users for error checking, or to others who require a different part program format for which
you do not have a definition file.

When the ‘Postprocessing parameters’ are all entered, click on one of the following three
options:

Control data
Clicking Control data will exit the Postprocessing parameters window, save the input
parameters, then create the part program file and start the simulation of the machine’s
movements.

Ok

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Clicking OK will save the parameters input in the Postprocessing parameters window.
The window disappears, but the part program is not created and the simulation is not
started.

Cancel
Clicking Cancel will exit the Postprocessing parameters window without saving the input
parameters.

12.2 Postprocessing parameters: Part program tab

The Part program tab gives the user the option to enter additional data into the part
program. The definition file (which determines the format of the part program) can be set up
to output any of the data entered under the Part program tab. See Section 13.2 for details.

The data can be used in the part program for any purpose. Using this data is optional (it
depends on the particular definition file used). Typical uses for the data are given below.

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Figure 12.10: Part program tab

12.2.1 Program number

Some controllers (eg. Siemens) identify programs according to a label rather than the
filename. The Program number often acts as the label. In that situation, the Program
number should be changed to a unique number each time a new program is created.

The program number must be an integer. No letters, decimal points or punctuation is

permitted.

12.2.2 Gear & Spindle

If the part program is generated in the TCS84 format for a Baer winding machine, these
values specify the gear number and spindle number used. They can be used in other
formats for any purpose (see Section 13.2 for details).

An integer number must be used for both Gear and Spindle. No letters, decimal points or
punctuation can be used.

12.2.3 Heating, Tension, Compaction

These fields are sometimes used for providing extra information to the controller. For
example, if digital filament tension control is used, the controller may have the ability to set
the level of tension in the filaments or a computer controlled heater may be able to set the
temperature in the resin bath. If the definition file is set-up to provide this information (see
Section 13.2), then the user can enter the filament tension desired or the resin temperature
directly into CADWIND. Whatever is entered into these fields will appear in the part
program exactly as it was written, and could possibly be read by the controller.

All letters, numbers and punctuation are accepted in these fields.

12.2.4 Mandrel ID, Fiber ID, Resin ID

These fields are sometimes entered into the part program for the information of someone
reading the program. Some controllers can be also be programmed to display this
information on the screen for the operator to read during the winding. Typically this will help
the operator to identify which mandrel, fiber and resin should be used for this particular
winding.

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Organisations which use several different mandrels, fiber and resin types are encouraged
to create a system for identifying them and to provide this information in the part program
(by using these fields) to help avoid mistakes like using the wrong mandrel or resin system.

All letters, numbers and punctuation are accepted in these fields.

12.3 Postprocessing parameters: Source tab

The Source tab is only available to CADWIND EXPERT and HIGH-END users.

The Source tab gives the user the option to generate the part program using either the
winding path currently loaded into CADWIND and visible on the screen (ie. Actual winding
path), or to use a winding path that was created previously and saved on the hard-disk (ie.
Saved winding path).

Figure 12.11: Source tab

A saved winding path may have had changes made manually or by software (or a
spreadsheet) outside of CADWIND. By giving the option to use this saved winding path, a
part program can be created for a winding path that would not be possible to create inside
CADWIND. See Section 11.10.3 for details. A saved winding path is loaded in the normal
way by clicking Browse and selecting a folder and file name with a .PTH extension.

12.4 Postprocessing parameters: Tumbler tab

The Tumbler tab gives the option to create a part program for a normal winding machine or
a tumble machine.

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Figure 12.12: Tumbler tab

Rather than pivoting a yaw axis as is more common, tumble machines rotate the mandrel
instead around an axis perpendicular to the spindle axis. See the diagram below.

Figure 12.13: Normal vs Tumble winding

Tumble machines were originally developed as a way to wind low angle helical layers onto
a short, or spherical pressure vessel, before computer control technology was available.
CADWIND still gives the option to create a part program with this type of (CNC) machine.

Unless a tumble machine is being used, the Calculation mode choice should always be
“Normal”.

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If a tumble machine is being used, it should be noted that CADWIND assumes that the
mandrel pivots around the mandrel coordinate origin (see Figure 12.13). Therefore, the
mandrel coordinate system origin must lie at the location of the mandrel pivot for a tumble
winder. This may require changes to the mandrel (.MDR) file to be made.

12.5 Postprocessing parameters: Begin tab

Under the Begin tab, there is the option to begin the winding either at the starting frame (as
defined in the Winding parameters - see Section 11.4.3) or at the front end of the mandrel,
nearest the head-stock.

Figure 12.14: Begin tab

If this option is selected the part program is resorted at the very last stage of the
postprocessing calculation so that the winding starts at the front end of the mandrel.

Please note that this is not displayed in the animation of the machine movement in the main
display window. To see the difference you can create two CCDF files: one with "Begin
winding at starting frame" and one with "Begin winding at front end". You can then compare
both files with a text editor (see Section 16) or by visualizing them by selecting
“Postprocessing” menu ► Display... (see Section 12.9).

12.6 Postprocessing parameters: Mandrel rotation tab

Negative mandrel rotations can occur on non-axisymmetric mandrels with important
eccentricities. If the machine and/or the machine's controller can not handle negative
mandrel rotations or if they are very small and lead to a part program which does not run
smoothly you can try and filter them out. There are three options:

Allow negative mandrel rotation

This is the normal setting. Nothing is filtered.

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Set negative mandrel rotation to zero
The machine positions with the negative mandrel rotation will be kept in the part program
but the negative mandrel rotation will be set to zero.

Filter positions with negative mandrel rotation

The machine positions with the negative mandrel rotation will be removed from the part
program.

Figure 12.15: Mandrel rotation tab

Important note:
Setting negative mandrel rotations to zero or removing them can result in unpredictable
machine movements. Make sure to analyse the part programs in detail before using them.

The setting of this parameter does not have any influence on the calculation on
axisymmetric mandrels.

12.7 CCDF-> Part program...

A CADWIND Control Data Format (CCDF) part program is a part program in CADWIND’s
own non-machine-specific format, as explained in more detail under Section 12.1.9. A
CCDF part program can be transformed into a machine-specific part program using this
feature. Select:

“Postprocessing” menu ► CCDF -> Part program…

This feature can be useful for organisations with more than one CADWIND license and/or
more than one winding machine, or by different organisations collaborating on a project. For
example, a program developed by one organisation can be saved in CCDF format and sent
to the other organisation. The second organisation can simply convert the program to their
own machine-specific format using their own definition file and start winding.

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To use this feature, simply select the CCDF file to be converted from the first window that
appears, then choose a folder and filename for the part program in the second window that
appears. Make sure that all the desired post-processing parameters for the part program
are set before the CCDF-> Part program transformation is done, as these values will be
used for the conversion.

If converting a CCDF to a part program, the animated machine simulation will not run.

12.8 Translate Baer TCS-84...

This feature is to be used for creating part programs for the Baer TCS-84 machine only.
The Baer TCS-84 has a different part-program format that can not be created using the
standard post-processing options and definition file. Baer TCS-84 users who require
assistance with their part programs should contact MATERIAL SA directly.

12.9 Display...
The display feature opens an X-Y style graph showing the machine movements contained
within a part program. To use this feature, select:

“Postprocessing” menu ► Display...

In the window that appears, you must browse to and select a CCDF (CADWIND Control
Data Format) part program file, previously created by the post-processor. Usually files of
this kind have a .DAT file extension (although this is not strictly necessary). Note that the
display feature will only open part programs in the CCDF format. Machine specific part
programs created using a definition file can not be opened.

The Display feature is a good way to check part programs for problems - rapid movements,
jerky motion caused by rapid accelerations, etc. The graphs can help identify exactly where
in the program a problem is occurring and discover the source of the problem (for example
an acceleration parameter set too high).

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Figure 12.16:“Display” graph showing position vs time for a 4-axis pressure vessel part
program

12.9.1 What can be graphed on the Y-axis

By selecting the drop-down box at the top left (see above diagram), there are three options
for the Y-axis of the graph:
• Position
• Velocity
• Acceleration

Note that “Acceleration” in this case is not the physical acceleration of each machine axis. It
is the change in velocity from one programmed movement to the next movement.

The axes to be displayed on the graph can be checked (selected for viewing) or unchecked
(unselected). In this way, any number of axes from zero up to six can be displayed on the
same graph. The axes are color coded for position and velocity graphs (ie. the color of the
axis label on the left corresponds to the color of the line for that axis in the graph).

12.9.2 The scale of the Y axis

In the second drop-down box, the scale of the Y axis can be changed to either of:
• 100%=maximum program value
• 100%=maximum machine value

The “100%=max program value” option sets the scale of the Y axis from 0 to the highest
value for each axis, anywhere in the program. This will show immediately the location in the

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program of the maximum movements, fastest motions or greatest acceleration (= change in
velocity between programmed movements) for each axis.

The “100%=max machine value” option sets the scale of the Y axis from 0 to the highest
value listed in the machine parameters (see Section 13.1). This option is good for
identifying which axis is responsible for overly slow movements in the program. For
example, a pay-out eye or cross carriage maximum velocity or acceleration value that is too
slow in the machine parameters may cause a slow turn-around even if the carriage and
mandrel values are ok and the display feature with “100%=max machine value” will quickly
show this. Similarly, jerky movements caused by rapid accelerations can also be identified
using this feature.

12.9.3 What can be graphed on the X axis

In the drop-down box in the bottom left of the “Display” window, the value of the X
(horizontal) axis to be graphed can be chosen. The options are:

• Time
• Block
• Position : mandrel, carriage, etc.

Time
Time is the most common choice.

Block
“Block” is the line number in the program. By choosing “Block” for the X-axis, it makes it
easier to identify exactly where in the program a particular movement is occurring and verify
it against the numerical data.

Caution: Block numbering in CCDF format part programs increase by an increment of 1

(see Figure 12.17), but block numbers in a machine-specific format may increase by any
increment programmed into the definition file. So, the block number shown on the graph,
which was produced from the CCDF data may not be the same as the block number in the
machine-specific part program.

Position : mandrel, carriage, etc.

Graphing the positions, velocities and accelerations (ie. change in velocity) of each axis
relative to another axis is also possible. This gives an envelope of machine motions in
space, and can be used to check for collisions and relative motion of two axes, among
other things.

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Figure 12.17: Block numbers in a CCDF part program

12.9.4 Zooming and panning the graph

The mouse can be used to zoom in on any part of the graph. Click with the left button, hold
the button down and move the mouse right and upwards or downwards to draw a box.
When the left button is released, the graph will zoom into the box that was drawn. Similarly,
to zoom back out, click the left button as before but drag it to the left.

Figure 12.18: Zooming in on a graph

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Figure 12.19: Zooming out on a graph

To pan (ie. move the graph sideways, up or down), use the right mouse button. Click, hold
the button down and drag the graph in the desired direction .

12.10 Load... and Save...

The postprocessing parameters entered can be loaded and saved by selecting:

“Postprocessing” menu ► Load...

“Postprocessing” menu ► Save...
The postprocessing parameter file has a .PPP extension, which is an abbreviation for Post
Processing Parameters. The “Open” and “Save” windows that appear function in the same
way as for other CADWIND features.

12.11 Notes on part programs which contain sub-

programs
If the part program is calculated in a user defined (ie. machine specific) format, the
definition file may specify a sub-program. Some controllers support sub-programs (eg.
Siemens Sinumerik) and some do not. Do not use sub-programs if the controller does not
support them.

If unsure whether a definition file uses a sub-program, check by opening the definition file
using “Tools” menu ► Editor... and look for {SUBPROG} ... {ENDSUBPROG}.

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Sub-programs are created in a separate file with a separate filename. The filename
specified in the post-processing parameters is the main program, and the main program
calls the subprogram when it is run.

The filename of the subprogram is specified in the line immediately underneath the
{SUBPROG} statement in the definition file.

For axisymmetric winding, the sub-program contains the movements for one cycle only.
The subprogram is repeated a specific number of times in a continuing loop, until the layer
is complete.

Subprograms are a way of dividing the program in order to make:

• the main program easier to read

• it possible to program several sub-programs into the same main-program for winding
multiple layers automatically one after the other

See Section 13.2 for more details on writing the definition file to include a sub-program.

If the part programs are calculated in the TCS84-format for Baer winding machines, only
the header file will be stored under the preset filename. The “stamm” and “prog” files are
stored under the filenames STAMM and PROG respectively, with the added program
number which should be entered in “Postprocessing” menu ► Translate Baer TCS84...

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13 Machine

13.1 Parameters...
The “Machine” menu ► Parameters... window contains the parameters for the winding
machine. Each winding machine is different, so the first time CADWIND is installed or
configured for a new machine, these parameters will need to be entered. However, after the
machine parameters are correct, there should be no need to change them again.

13.1.1 Reference tab

To calculate the part program, CADWIND’s mandrel coordinate system must be

transformed into the coordinate system of the winding machine. In other words, CADWIND
needs to know exactly where the mandrel will be, relative to the machine’s coordinate
system (ie. the ‘zero point’) so that it can make allowances for this in the part program.

Therefore, CADWIND needs to know where the ‘zero point’ of the machine is exactly. In the
longitudinal direction (Y direction in the diagram over the page), this reference point is
usually measured from a convenient feature on the machine, such as the chuck face. The
same reference feature can then be used to measure the “positioning length” (ie. distance
from the reference feature to the mandrel coordinate system).

Figure 13.1: Reference tab

In order to determine the Reference parameters (Figure 13.1), the machine should be
moved to the zero location (ie. where all axes read “0.000" on the controller) and the
following distances measured:

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 Machine axis distance to be measured
Mandrel Angle of spindle to the vertical when at zero. Usually 0.0.
Carriage YREF in Figure 13.2 = longitudinal distance from chuck face or
similar reference feature to the zero point.
Cross-carriage XREF in Figure 13.2 = radial distance from spindle axis to zero
point + Yaw radius (if the machine has a 5th yaw axis).
Pay-out rotation Angle between the pay-out eye and the vertical, when pay-out eye
is at the zero point. Usually this is 0.0.
Vertical axis Z distance from pay-out eye rotation axis to spindle rotation axis.
Usually this is 0.0.
Yaw axis Angle between yaw axis and a radial from the spindle axis when
the yaw axis is at its zero angle. Usually this is 0.0.

Figure 13.2: Top View showing the Zero point and Positioning length of a typical mandrel

XM, YM = Mandrel coordinate system

XREF = Cross-carriage reference (a machine with a yaw access must
have the yaw radius added to this). Should be > 0.
YREF = Carriage reference (shown here > 0)
Positioning length = Longitudinal distance from chuck face (or other chosen
reference feature) to the mandrel coordinate system. Always > 0.

All these parameters except the positioning length are constant on a specific machine and
need be measured and entered only once. However, in the direction of the carriage,
different clamping mechanisms and different mandrels mean that the position of the

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mandrel relative to the chuck face can change with each winding. To facilitate this, the
“Positioning length” is used, which is the distance from the mandrel coordinate system to a
convenient reference feature which must be selected for each machine. This is often the
chuck face. The Positioning length must be entered in the Post-processing parameters (see
Section 12.1.6) before each part program is created.

13.1.2 Dimensions tab

Figure 13.3:Dimensions tab

This tab stores information on the dimensions of the machine. Specifically:

• The range of movement of each axis, from minimum to maximum, in the machine’s
coordinate system
• The pay-out eye width
• The eccentricity of the pay-out eye
• The yaw axis radius
• The spindle rotation axis height above the floor

These parameters are explained in detail in the following paragraphs.

Minimum and Maximum: Range of movement

The minimum and maximums define the possible range of movement for each axis.
CADWIND uses this information to determine if any of the axes will move outside of the
range of movement during the winding and trip a limit switch. If CADWIND determines that
this will happen, a warning message will appear after the part program has been created
(ie. after “Control Data” is clicked).

Pay-out eye width

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This parameter has the following effects:

• Increases the offset distance from the mandrel surface to the machine pay-out eye at
the mandrel ends only (See Section 12.1.1).
• Determines how big to draw the pay-out eye on the machine movements simulation.
This helps the user to see whether a collision is going to occur between pay-out eye
and mandrel, as it will be visible during the simulation.

Figure 13.4:Pay-out eye width

Pay-out eccentricity
The pay-out eccentricity is the distance from the axis of the pay-out rotation to the roving
contact point on the pay-out, as illustrated below for two different styles of pay-out system.

Figure 13.5:Pay-out eccentricity on roller and D-ring style pay-out systems

Note that many machines have zero pay-out eccentricity, so this value is often 0.0.

In order to calculate the effect of pay-out eccentricity on the movement of the carriage, the
pay-out eye axis must be activated in the “Postprocessing” menu ► Parameters... window
(see Section 12.1) and also in the “Machine” menu ► Parameters ► Axes tab (Section
13.1.7). However, for a 2 axis machine with a passive pay-out eye (ie. free-rotating rather

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than controlled) the pay-out eye positions need to be eliminated in the part program. This
can be achieved by setting the resolution of the pay-out axis to 0 (ie. zero INC/360̊) in the
“Machine” menu ► Parameters ► Resolutions tab (see Section 13.1.6).

Yaw radius
For machines with a yaw axis (5th axis), the yaw radius must be entered. This is the radial
distance from the yaw pivot axis to the fiber contact point on the pay-out eye.

Figure 13.6:Yaw radius

Rotation axis height

If a rotation axis height is entered, and the display option is selected, CADWIND will draw
the floor of the workshop. The size of the floor is determined by the carriage and cross-
carriage minimum and maximum dimensions. In other words, the floor is a projection of the
area accessible by the pay-out eye.

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Figure 13.7: Rotation axis height

13.1.3 Velocities tab

The maximum velocities of all the axes are entered under this tab. Low values will tend to
slow down the machine motion (via the part program) and a high values tend to speed it up.
Most winding machines will come with recommended maximum velocities (consult the
machine manual).

Slow-running programs
Note that the maximum velocities of all axes are considered during the calculation of the
part program. If increasing the speed of one axis alone fails to increase the program speed,
then it is possible that one of the other axes is moving at its maximum velocity and limiting
the overall speed of all axes. The axes must move in unison, so one axis with a slow
maximum velocity will affect the motion of all axes. Furthermore, winding speed can be
limited by other factors:
• the maximum accelerations (see the section below) which affect the number of
blocks (steps) needed to reach the maximum velocities of the axes.
• the filter value (see the “Accelerations and Filter Value” section, below)
• the minimum processing time (see Section 13.1.5).
• the pay-out speed, if “Constant pay-out speed” is selected in the post-processing
parameters (see Section 12.1.2).

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 • the choice of velocity calculation (see Section 12.1.2).

The rotating axes (ie. Mandrel, Pay-out rotation and Yaw) maximum velocities are entered
in revolutions per minute (rpm or rev/min), as indicated by the label “360°/min”.

13.1.4 Accelerations tab

Caution must be taken when entering the accelerations as they are not the physical
accelerations of the machine. The parameters entered here are the maximum changes in
velocity allowable between one programmed machine motion (ie. one line or block of the
part program) and the next.

Smoother running programs can sometimes be achieved by reducing the accelerations so

that smaller changes in velocity occur between machine movements (ie. less tendency to
jerk). However, reducing the acceleration values may increase the winding time for the
program, so there must be a compromise made.

Accelerations and Filter Value

Because the CADWIND acceleration parameters are actually maximum changes in velocity
between machine movements, physical slowing and speeding of the machine will be
affected by the distance covered by each movement.

For example, if the machine must slow the carriage to a stop from a speed of 1 m/s, with a
carriage acceleration parameter of 0.1 m/s, then it will take 10 machine movements to do
this. If the filter value is set at 20mm, then the distance to stop would be 10 movements x
20mm = 200mm. However, if the filter value is set at 50mm, the distance to stop would be
10 movements x 50mm = 500mm. With a higher filter value, the physical slowing of the
machine is more gradual even with the same acceleration value, which results in slower
running programs.

Typical acceleration values

Some experimentation is often required to find appropriate acceleration values for a new
machine. The table below may be used as a guide to get started.

Suggested accelerations as a percent of a typical mandrel diameter,

with Filter value = 10% mandrel diameter
Axis Acceleration for smooth Acceleration for fast running
running
Mandrel (360°/min) 3 6
Carriage 15% of diameter per second 30% of diameter per second
Cross-carriage 20% of diameter per second 40% of diameter per second
Pay-out rotation (360°/min) 5 10

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 Vertical 20% of diameter per second 40% of diameter per second
Yaw (360°/min) 5 10

13.1.5 Processing time tab

The Min. processing time (the only option under the “Processing time” tab) represents the
minimum time that the controller requires to process each line of the part program.

The parameter exists in order to avoid feeding instructions to the controller faster than they
can be computed. For a winder with a modern controller or computer, low minimum
processing times of 0.002 - 0.05 may be used. Higher minimum processing times should be
used for older controllers or if intentional slowing of the program is desired without altering
the machine velocities or accelerations.

Notes:
• If the minimum processing time value is too high, it may slow the speed of the
winding program, even if the maximum velocities and accelerations have not been
reached.
• The consideration of the minimum processing time can slightly disturb the dynamics
of the machine movement.
• To avoid the above try setting the minimum processing time value to 0 and test how
the controller and the machine reacts.

13.1.6 Resolutions tab

The parameters under this tab give the incremental resolutions of each axis of motion. In
other words, CADWIND multiplies by the values here to get the programmed machine
positions. For example, if the cross-carriage Resolution was -1 increment/mm, and the
cross-carriage were required to move 5mm (using relative motion), the value in the part
program would be:
5mm x -1 = -5mm.

The values for the linear motion axes (ie. carriage, cross carriage and vertical axis) are
increments per millimetre or increments per inch (depending on the system of units
selected). These values will usually be 1 or -1 (but may have other values).

The rotational axes (ie. mandrel, pay-out rotation and yaw axis) are in increments per
revolution (labelled as “inc/360°”). For controllers which accept rotational values in degrees,
these values will be either 360 or -360.

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Figure 13.8: Resolutions tab

If an axis of the machine moves in the wrong direction, it can be fixed by changing the
resolution from positive to negative (or vice-versa).

Positive directions of axes

The positive direction of the axes are defined as follows:

Axis Positive direction

Mandrel rotation so that fiber winds over the top of the mandrel (see Figure 13.10)
Carriage from the chuck (headstock) to the tailstock (see Figure 13.9)
Cross-carriage towards the mandrel (see Figure 13.9)
Pay-out rotation such that the side of the pay-out eye closest the head-stock moves
down (see Figure 13.10)
Vertical axis upwards
Yaw-axis pointing away from the headstock, towards the tailstock (see Figure
13.11).

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Figure 13.9: Top-view; CADWIND assumed positive direction for carriage & cross-carriage

Figure 13.10: CADWIND assumed positive direction for mandrel and pay-out axes

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Figure 13.11: CADWIND assumed positive direction for yaw axis

13.1.7 Axes tab

The machine’s axes of motion which are to be computer controlled must be selected here.
Any axes that the machine does not have should not be selected. So, for a two-axis
machine, all boxes should be unselected (mandrel and carriage are not present as these
axes are always controlled). For a four axis machine, select only cross-carriage and pay-out
rotation. For a six axis machine, select all axes.

13.1.8 Format tab

CADWIND has two options for generating part programs - either in a user defined format or
the specific format for the Baer-TCS84 machine controller. The choice is made in the drop-
down box in the upper left corner of the Format tab.

If the Baer-TCS84 machine format is selected, then no further information is required here
and the “Postprocessing” menu ► Translate BaerTCS84 option should be used for
postprocessing.

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If the user defined format is used (as for most machines), then the appropriate definition file
(.DEF) must be selected in the format tab. The definition file defines the structure of the part
program. In other words, it is a template for the part program, and CADWIND simply fills in
the numbers in the template for each program. A little effort is required to set-up the
definition file for a new machine, but the advantage is that the definition file system is
extremely versatile and enables CADWIND to output part programs for almost any winding
machine no matter how it is configured. See the next section for more details on
programming definition files.

13.2 Definition Files

CADWIND comes with many definition files for most common winding machine controllers,
but even so, it may be necessary to make changes to the definition file as controllers are
often configured differently. Changes to the definition file can either be made in a text editor
(eg. the CADWIND editor under “Tools” menu ► Editor or Notepad which comes with
Microsoft Windows), or changes can be made directly in the Format tab.

13.2.1 Defining different sections of the part program

The following labels are for the definition of the different program sections:

{BLOCKINC}
Individual blocks (lines) in a part program often require a block number. The next two digits
after the {BLOCKINC} label represent the increment from one block number to the next. For
example, {BLOCKINC}10 would give a program with block numbers 10, 20, 30, etc. It is
common to use a value greater than 1 so that blocks can be inserted into the part program
afterwards without the need to change the block number of every block afterwards.

{BLOCK=}
This sets the value of the current block number. The 4 digits immediately afterwards
represent the new block number. For example {BLOCK=}1025 would set a block number of
1025.

{SUBPROG}, {ENDSUBPROG}
These mark the start and end of a subprogram. Everything between these two labels is
included in the subprogram. It is not necessary to use a subprogram, but if your controller
can support it, it is a good way to keep your main program simple and easy to read. The
line immediately after the {SUBPROG} term will be the filename for the subprogram. The
subprogram definition must come before the main program definition. For an example, see
SINUM.DEF in the "DEF examples" folder and refer to Section 12.11 for more details.

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{LUCO}, {ENDLUCO}
These labels mark the start and end of the layer information. All movements of the machine
that wind the layer (not including moving to the starting position before the layer winding
starts or any movement made after the layer is finished) must lie between these two labels.
For an example, refer to any of the .DEF files in the "DEF examples" folder (for example,
SINUM.DEF).

{POS}, {ENDPOS}
These label the start and end of the position block (line). This position block will be
repeated for each machine movement, so will usually create most of the part program.
These labels must lie between the {LUCO} and {ENDLUCO} labels.

{ENDPOS NEXT}
This label can be used instead of {ENDPOS} when another position block label will be
used. For example, if the controller requires each axis movement to be given one-by-one
(eg. all mandrel movements in the program, followed by all carriage movements, followed
by all cross-carriage movements, etc) the {ENDPOS NEXT} label would need to be used to
separate the data for each axis. The program flow for a 3-axis program would be as below.
See CTS.DEF in the "DEF examples" folder for a complete example.

{LUCO}

{POS}
Time {tabs[s]} , Mandrel position {maabs}
{ENDPOS NEXT}

{POS}
Time {tabs[s]} , Carriage position {caabs}
{ENDPOS NEXT}

{POS}
Time {tabs[s]} , Cross-carriage position {ccabs}
{ENDPOS}

{ENDLUCO}

{FB}, {ENDFB}
Any statements which are between the {FB} (=”First Block”) and {ENDFB} labels will only
be written in the first position block and not written in the other position blocks. See
SINUM.DEF for example. The {FB} and {ENDFB} labels must both lie between the {POS}
and {ENDPOS} labels.

{LB}, {ENDLB}

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“Last Block” and “END Last Block”, are similar to {FB}, {ENDFB}. Anything contained
between these labels is written in the last position block only.

13.2.2 Variables for Loops, Sub-programs and block numbers

The following variables are available for the definition of loops, subprograms and block
numbers, etc. The variable in the definition file (which is written by the user) will be replaced
with a number or text in the part program which is generated by CADWIND. An example of
the definition file input and resulting part program for a layer with 48 cycles is given below:

Example line in definition file:

N{blo} CYCLES = {cyc}

Resulting block in the part program:

N010 CYCLES = 48

Variable as Meaning Where the variable value Value type

written in the is defined
definition file
{prg} Program number Postprocessing parameters integer
number
{sub} Subprogram number Postprocessing parameters integer
number
{name} File name of part Postprocessing parameters text string
program
{date} Date and time stamp Computer’s clock text string

{blo} Block number Calculated automatically integer

using {BLOCKINC} and number
{BLOCK=} statements
{cyc} Number of cycles Winding parameters for integer
axisymmetric windings or number
= 1 for non-axisymmetric
{cyc-1} Number of cycles - 1 As above integer
number
{lbl} Label number Assigend automatically integer
based on the position of number
the {lbl} marker in the
program

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 Variable as Meaning Where the variable value Value type
written in the is defined
definition file
{bgn} Number of the block Determined automatically integer
which is marked with based on the position of number
{*B*} the {*B*} marker in the
program
{end} Number of the block Determined automatically integer
which is marked with based on the position of number
{*E*} the {*E*} marker in the
program
{dma} mandrel rotation offset in Calculated automatically real number
degrees after one cycle based on the winding
(0-360°) parameters
{nblo} Number of position Calculated automatically integer
blocks in the layer number

13.2.3 Markers

There are two markers that can be used in the program as references to block numbers.
These are not replaced with numbers like a variable, but instead the value of the marker
block number is stored internally by CADWIND for future use in the program. The stored
value is determined by the position of the marker in the program. These markers can be
useful with GOTO and LOOP style statements that redirect the controller to different parts
of the program.

Marker as Meaning Definition Value type

written in the
definition file
{*B*} Loop begin marker, see = the block number integer
{bgn} variable wherever it is located in the number
part program
{*E*} Loop end marker, see = the block number integer
{end} variable wherever it is located in the number
part program

13.2.4 Machine Position Variables

The most important information in a part program is the positioning of the machine. The
following variables will be replaced by numbers in the part program. The numbers represent

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the position of a machine axis. At least some of these variables must be used in every
definition file.

Variable Axis Description

{mapsp} Mandrel
{capsp} Carriage
{ccpsp} Cross-Carriage
Relative pattern start position (PSP)
{popsp} Pay-out rotation
{vepsp} Vertical
{ywpsp} Yaw

Variable Axis Description

{+/-mapsp} Mandrel
{+/-capsp} Carriage
{+/-ccpsp} Cross-Carriage Relative pattern start position (PSP) with
{+/-popsp} Pay-out rotation “+” or “-“ sign
{+/-vepsp} Vertical
{+/-ywpsp} Yaw

Variable Axis Description

{mapspabs} Mandrel
{capspabs} Carriage
{ccpspabs} Cross-Carriage
Absolute pattern start position (PSP)
{popspabs} Pay-out rotation
{vepspabs} Vertical
{ywpspabs} Yaw

Variable Axis Description

{+/-mapspabs} Mandrel
{+/-capspabs} Carriage Absolute pattern start position (PSP)
{+/-ccpspabs} Cross-Carriage with “+” or “-“ sign
{+/-popspabs} Pay-out rotation

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Variable Axis Description
{+/-vepspabs} Vertical
{+/-ywpspabs} Yaw

Variable Axis Description

{ma} Mandrel
{ca} Carriage
{cc} Cross-Carriage
Relative position
{po} Pay-out rotation
{ve} Vertical
{yw} Yaw

Variable Axis Description

{+/-ma} Mandrel
{+/-ca} Carriage
{+/-cc} Cross-Carriage
Relative position with “+” or “-“ sign
{+/-po} Pay-out rotation
{+/-ve} Vertical
{+/-yw} Yaw

Variable Axis Description

{/ma/} Mandrel
{/ca/} Carriage
Absolute value of the relative position ie.
{/cc/} Cross-Carriage
{/po/} Pay-out rotation −𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑝𝑜𝑠 𝑓𝑜𝑟 𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑝𝑜𝑠 < 0
={
𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑝𝑜𝑠 𝑓𝑜𝑟 𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒𝑝𝑜𝑠 ≥ 0
{/ve/} Vertical
{/yw/} Yaw

Variable Axis Description

{maabs} Mandrel
{caabs} Carriage
Absolute position
{ccabs} Cross-Carriage
{poabs} Pay-out rotation

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 Variable Axis Description
{veabs} Vertical
{ywabs} Yaw

Variable Axis Description

{+/-maabs} Mandrel
{+/-caabs} Carriage
{+/-ccabs} Cross-Carriage
Absolute position with “+” or “-“ sign
{+/-poabs} Pay-out rotation
{+/-veabs} Vertical
{+/-ywabs} Yaw

13.2.5 Time and feed-rate variables

Time or feed-rate is usually used in a part program to define the speed of the machine
movement.

Variable as Meaning Units Value type

written in the
definition file
{t[s]} Relative time seconds real number
{t[ms]} Relative time milliseconds real number
{t[1/min]} Reciprocal relative time 1 / minutes real number
(ie. 1 / relative time) (ie. per minute)
{tabs[s]} Absolute time seconds real number
{tabs[ms]} absolute time milliseconds real number
{feed[inc/min]} feed-rate increments per minute real number

13.2.6 Calculation of feedrate (in increments per minute)

If the {feed[inc/min]} command is used for feed-rate of a block, the value written into the
part program is calculated as follows:

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 𝐴
𝐹 = 60
𝑡

where,
F = feed-rate in increments / minute
t = time taken for the movement in seconds
A = vector addition of the distance moved by all axes

𝐴 = √{𝑚𝑎}2 + {𝑐𝑎}2 +{𝑐𝑐}2 + {𝑝𝑜}2 +{𝑦𝑤}2 + {𝑣𝑒}2

If {feed[inc/min]} is used in the definition file, be careful that the machine controller
interprets this feedrate in the same way that CADWIND calculates it. Some controllers
accept feedrate commands, but interpret them differently (eg. not taking account of the
rotational distances of the mandrel and payout eye as CADWIND does). This can lead to
programs that have sudden (and sometimes violent) jerking motions. It is safer to use a
time based variable than a feedrate if possible, to avoid misinterpretations.

13.2.7 Number of digits after the decimal point (of a variable)

The number of digits after the decimal point used for any variable can be defined after a
colon. For example:

{+/-ma}:6

The default number of digits after the decimal point is 4, if not specified.

13.2.8 Absolute versus relative programming

An “absolute” position for a machine axis means the position of that axis relative to an
absolute, unchanging reference. The absolute position is independent of the previous
machine position and the next machine position.

However, a “relative” machine movement is the change in position from the previous
instruction.

For example if the machine carriage is 95mm from the reference, and is instructed to move
to absolute position 100mm, then it will move 5mm (ie. from 95 to 100). However, if the
machine is 95mm from the reference and is instructed to move 100mm relatively, then it will
move until it is 195mm from the reference (ie. 95 + 100 = 195).

There are advantages and disadvantages to programming with both systems. For example,
absolute programming creates code that is easy to read as the position data given in the
program will be the same as the position data visible on the controller screen. However,

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there can be a safety issue with some machines. If it is possible to stop the program mid-
way through (eg. by pressing the ‘E-stop’ button), manually move the machine axes before
restarting the program from where it was interrupted, then the machine will detect that it is
in the wrong position and may try to correct itself with a large and rapid movement. If a
person is in the path of the machine, it could cause injury or damage the machine. Relative
programming won’t do this but it may be possible for small rounding errors to accumulate
over the course of a long program, particularly if there is no periodic correction in absolute
coordinates at the end of a cycle or at the end of a layer. However, relative programming
can be easier to make smooth running combination windings in some cases. It is up to the
programmer to consider the nature of their own machine and requirements before making
the decision to use relative or absolute coordinates.

13.2.9 Special characters

Special ASCII text characters can be used in the part program by entering #/ and the ASCII
code into the definition file. This is generally used for characters that do not appear on the
keyboard.

For example: for the symbol “@” to appear in the part program, enter the code #/064 into
the definition file. Refer to any ASCII character table for the available characters 1 through
255.

13.3 Load... and Save...

All parameters under the “Machine” menu can be saved and loaded by selecting:

“Machine” menu ► Load...

“Machine” menu ► Save...

The machine parameters files should have a .MAC filename extension.

The same installation of CADWIND can be used to make part programs for multiple
machines by loading the appropriate machine parameters before the part program is
created.

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14 Export for Finite Element Analysis (FEA)

Note: The DESIGN PACK extension is necessary for the export to FEA functionality. If you
do not have the DESIGN PACK extension please contact MATERIAL for details.

14.1 Overview
With “File” menu ► “Create FEA data...” you can you can combine the mandrel model
together with the laminate data of several winding layers into one file. Then this file can be
read and analysed by finite element analysis (FEA) software.

First you have to save the laminate data for each individual layer in the laminate. Please
see Section 10.6 for details.

With “File” menu ► “Create FEA data...” you can open the create FEA data dialog:

Figure 14.1: Create FEA data dialog

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Via this dialog you can combine the data and generate the file which can be used by FEA
software.

1. Select the output format.

2. Select the unit in which the data should be exported (not necessary for “HDF5
Composite Data” format)

3. Select the mandrel model file (.MDR file) (not necessary for “HDF5 Composite Data”
format)

4. In "List of laminate data files" or "List of iLAM data files" add each layer's laminate
data file (.LAM file or .iLAM file) to build the laminate’s stacking sequence. You can
use the “Add...” button or edit the list directly. You can also generate the list within
CADWIND's text editor (“Tools” menu ► Editor...) or by any other text editor and
copy/paste the list into the list field.

5. Choose the output file name.

6. Click OK to start the calculation.

14.2 Output formats

14.2.1 The HDF5 Composite Data format

There are several FEA software systems which support and recommend HDF5 Composite
Data format (e.g. ANSYS, Siemens/Vistagy/FiberSIM). This is the preferred format if your
FEA software supports it.

If the “HDF5 Composite Data” format is used the laminate data files must be in the .iLAM
format (see Section 10.6). It is not necessary to select a mandrel model since the .iLAM
files contain already the mandrel model data.

The output files use the HDF5 container format. For more details about this container
format please see https://www.hdfgroup.org. It is a binary file format. You can view its
content with the free “HDF View” software which can be downloaded on
https://www.hdfgroup.org.

The format selection “HDF5 Composite Data + mandrel model ANSYS CDB” creates two
files simultaneously:

1. a HDF5 Composite Data file

2. an ANSYS CDB containing only the mandrel model

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The ANSYS CDB file is saved under the same file name as the HDF5 Composite Data file,
but with the extension CDB.

ANSYS users can use the CDB file to import the mandrel model first before importing the
laminate data with the HDF5 Composite Data file.

14.2.2 Other formats

If other output formats are selected the output will be in the proprietary format of the
corresponding FEA software.

These are text files. You can have a look at it by using CADWIND's text editor (“Tools”
menu ► Editor...) or by any other text editor.

It is necessary to select a mandrel model file and the laminate data files must be in the
.LAM format (see Section 10.6).

14.2.3 Format summary

mandrel model laminate data file output file

file

HDF5 Composite Data not needed .iLAM format HDF5 file

format

other formats needed .LAM format text file

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15 Printing from CADWIND

15.1 Printing graphics

The recommended method for printing of CADWIND graphics is to take a screen-shot and
paste it into software designed for printing such as MS Paint, Word or Excel. There are
many free and payable software programs available for taking screenshots (eg. the
Snipping Tool in Windows 7). You can also use Windows Print Screen function to copy a
screen shot of the complete desktop into the clipboard.

15.2 Printing reports

Notes on the winding, including all the parameters used for the winding, summarised in the
form of a report (see Section 17.1) can be printed by selecting:

“Help” menu ► Print report...

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16 The text editor (Tools menu)

CADWIND comes with a build-in text editing feature. It can be accessed by selecting:

“Tools” menu ► Editor...

Browse to the text file to be edited from the window that appears, and the text file should
then appear in the editor window.

Any ASCII standard text file can be manually edited here, including mandrel files, control
data files, part programs, winding parameters and every other CADWIND file. The
functioning of the text editor is very similar to Notepad (which comes free with MS
Windows) and generally conforms to MS Windows standards for operation and interface.
Some short-cut key combinations are listed below:

Key Combination Command

CTRL + F Find text
CTRL + R Replace text
CTRL + L Repeat find text
CTRL + I Tab (Indent)
CTRL + C Copy selection to clipboard
CTRL + V Paste clipboard selection at insertion point
CTRL + Z Undo

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17 Help menu

17.1 Help reports

CADWIND can generate a report automatically which contains all the information related to
the winding being done. If assistance is required, this is an effective way of saving all the
information in one place so that an engineer from MATERIAL SA can replicate your winding
problem on their computer so they can offer you the best advice. To print or save a report,
select:

Help menu ► Print report...

Help menu ► Save report...

The report contains

• A message written by the user. The user is prompted to enter a message (usually a
description of the problem they are having) after clicking on Print report... or Save
report...
• The options selected in the Options menu.
• Winding parameters
• Winding options
• Postprocessing parameters
• Machine parameters
• The winding results
• The definition file
• The mandrel file

17.2 About...
The “About” window gives information on the version and build number of the CADWIND
installation. Select:

Help menu ► About...

A window with information about the version and package should appear. To remove the
About window, left-click on it.

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18 Function summary

18.1 File
Function Description
Load mandrel Loads an existing mandrel file.
Create Create a new mandrel file of a common winding shape.
DXF->contour Converts an Autocad .DXF file to a CADWIND axisymmetric
contour mandrel.
DXF->surface Converts an Autocad .DXF file to a non-axisymmetric surface
mandrel.
Create FEA data Creates a finite element analysis (FEA) model from the current
winding.
Load project Loads a .CWP CADWIND project file.
Save project Saves a project file with winding, machine, postprocessing
parameters, etc. in a .CWP file.
Exit Exits (terminates and closes) the program.

18.2 View
Function Description
New mandrel view Opens a new display window. Used to show multiple mandrel
views.
Results Opens a window showing the winding calculation results
Clear winding patterns Clears all winding patterns off the mandrel
Show only last pattern If checked, old winding patterns will be erased, and only the
last shown

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18.3 iWind
Function Description
iWind Opens a window for iWind winding simulations.
Update mandrel Updates the mandrel size to include the thickness of the current
layer.
Reset Returns the mandrel to its original dimensions before updates
were applied.
Save update Saves the updated mandrel into a new mandrel file.

18.4 Winding
Function Description
Start winding Calculates the winding pattern over the loaded mandrel using
the winding and material parameters.
Non-geodesic Opens a window for entering the parameters for non-geodesic
winding.
Circumferential Opens a window for entering the parameters for circumferential
winding.
Helical Opens a window for entering the parameters for helical
winding.
Polar Opens a window for entering the parameters for polar winding.
Combination Opens a window for entering the parameters for the combining
(transition) between two layers.
T Opens a window for entering the parameters for T winding.
Material Opens a window for entering the material parameters.
Update mandrel Updates the mandrel size to include the thickness of the
current layer.
Reset Returns the mandrel to its original dimensions before updates
were applied.
Save update Saves the updated mandrel into a new mandrel file.
Options Opens a window for the selection of the different winding
options.
Load Loads the winding and material parameters from a .WIP file.
Save Saves the winding and material parameters into a .WIP file.

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18.5 Postprocessing
Function Description
Control data Calculates the control data of the last generated winding path
according to the postprocessing and machine parameters and
makes a part program.
Parameters Opens a window for entering the postprocessing parameters.
CCDF -> part program Converts a CADWIND Control Data Format CCDF program into
a machine specific part program (generated using a definition
file).
Translate Baer TCS-84 Calculates a part program for a Baer TCS-84 winding machine.
Display Displays the machine motion of a CCDF program in X-Y
diagrams.
Load Load a saved set of post-processing parameters from a .PPP
file.
Save Saves the postprocessing parameters into a .PPP file.

18.6 Machine
Function Description
Parameters Opens a window for entering or changing the machine
parameters, below:
Dimensions Tab for entering the range of machine movement, pay-out eye
width, eccentricity of the fiber guide, yaw axis radius and
rotation axis height.
Velocities Tab for entering the maximum velocities of each axis.
Accelerations Tab for entering the maximum changes of velocity between any
two blocks.
Processing time Tab for entering the time the controller needs to process one
block.

Resolutions Tab for entering the incremental resolutions of the axes.

Axes Tab for entering the existing machine axes.

Format Tab for the selection and modification of the definition file.

Load Loads the machine parameters from a .MAC file.

Save Saves the machine parameters in a .MAC file

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18.7 Tools
Function Description
Editor Opens a text editor for making manual changes to any ASCII
text file (including all CADWIND files).

18.8 Window
Function Description
Tile Arranges the display windows so they are all visible on the
screen, tiled vertically one underneath the next.
Cascade Arranges the display windows so they are overlaid in a cascade
with the edges all visible.

18.9 Options
Function Description
General options Dialogue window for selecting the language and units.

18.10 Help
Function Description
About Opens a window which shows the software version, date and
build-number.
Print report Prints a help report containing all parameters and a note from
the user.
Save report Saves a help report containing all parameters and a note from
the user.

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19 CADWIND file types and their extensions

The file types that CADWIND can write and can read are summarised below. Note that all
these file types are text files and their content can be displayed with any text editor.

File Description Where to Load / Save / Edit /

Extension Use
.CWGen Mandrel generation parameters. This files stores • File ► Create mandrel
the parameters entered by the user to create a ► Any option except “T”
mandrel, whereas a mandrel file stores the frame ► Load parameter…
data (frame diameters, Y positions, etc). • File ► Create mandrel
► Any option except “T”
► Save parameter…
.CWP CADWIND project file. Saves information on the • File ► Load project
entire project including the mandrel filename, • File ► Save project
winding parameters and material parameters.
.DAT CCDF (CADWIND Control Data Format) file. This • Postprocessing
is CADWIND’s non-machine specific format for ► Parameters
saving machine movements (part programs). • Postprocessing
► CCDF -> Part Program
.DEF Definition file for defining the format of the part • Machine ► Parameters
program (ie. the file sent to the winding machine). ► Format
.iWind iWind parameter file. Stores the winding • iWind ► iWind
parameters and material parameters entered into ►Load parameter
iWind. • iWind ► iWind
►Save parameter
.LAM Laminate data file. Stores information on the • Winding ► Options
laminate created by the winding. • File ► Create FEA data
.MAC Machine parameters. These define the physical • Machine ► Load
dimensions and limitations of the winding machine • Machine ► Save
(velocity, acceleration, etc) • Machine ► Parameters
.MDR Mandrel file. Contains the data which defines the • File ► Load mandrel
shape of a mandrel. • File ► Create mandrel
.PPP Postprocessing parameter file. A record of a set of • Postprocessing ► Load
postprocessing parameters. • Postprocessing ► Save
• Postprocessing
► Parameters
.PPR Part program file. This is the default extension for a • Postprocessing
machine-specific part program, however many ► Parameters
controllers require different file extensions (eg.
.MPF, .SPF, .MCL, .MCC, etc).
.PTH Winding path file. This is the calculated path of a • Winding ► Options
filament across the surface of the mandrel • Postprocessing
► Parameters ► Source
.WIP Winding parameter file. Stores the winding • Winding ► Load
parameters and material parameters. • Winding ► Save

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Elements
select and use insert bookmark, then reference it with insert cross-reference

OK

Cancel

Yes

No

Open

Save

Browse

Start winding

Control data

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