The ultimate
software for
filament winding

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Filament winding

Process

Filament winding combines accurate fiber lay-up with a high degree of automation. The tensioned fibers are impregnated in-line prior of being wound on a rotating mandrel. Using the materials in their basic forms allows to produce composites efficiently at low-cost. In recent years, the use of pre-impregnated fibers (thermoset or thermoplastic) have been introduced to enhance quality control and increase productivity.

Equipment

Today, multi-axis computer controlled machines are used to guide the fibers at precise angles around the mandrel. Besides the traditional lathe type designs, robotic systems find their ways to the production floor. To produce high quality parts, the fiber tensioning and impregnation devices are of vital importance.

Software

ComposicaD is the key to successful design and efficient production of filament wound parts. The software allows to model the entire lamination sequence and prepare the numerical data for FEA in order to verify different load conditions.

Once optimized, the code to control the filament winding machines is calculated resulting in a smooth and precise motion. Interfaces for all machines have been developed in cooperation with all major equipment suppliers. ComposicaD is the industry standard since 2010.

Composite
Pressure Vessels

Markets

CPV’s are an excellent example for efficient use of filament winding technology. The fibers can be aligned to create a laminate which responds best to the stresses in the different directions. To use these an-isotropic properties is key to design optimization, resulting in a weight reduction of up to 80 % compared to steel cylinders.

Also, the high level of automation allows a high-volume production to meet industrial market requirements. Typical applications are water purification, LPG, SCBA, CNG & H2 for automotive, rocket motor cases …

Approach

ComposicaD designs the vessel geometry based on a parametric model. When changing the initial dimensions (e.g. diameter or length), all calculations will be updated instantly.

This feature is of vital importance to qualify variant designs of certified CPV’s.

Lamination

ComposicaD is the only software which can model up to 100 layers (hoop, helical or transitions) automatically and anticipate the thickness build-up of the laminate.

The material data base allows to compare different fibers and evaluate their properties on the laminate design.

FEA Interface

Numerical modelling of the liner, laminate and boss parts is essential for strength and fatigue prediction of the CPV. A seamless interface to state-of-the-art FEA software (ESAcomp, ABAQUS, ANSYS, NASTRAN, …) allows a fast and accurate evaluation.

The laminate information is described by a detailed mesh of shell or solid elements. Numerical modelling is the basis for understanding the behavior under load and optimizing the structure accordingly.

Machine motion

ComposicaD generates the motion program for the multi-axis production equipment.

A smooth and fast winding operation is calculated according to the given specification of the machine. Speed and acceleration control of the fiber ensures control of impregnation and fiber tensioning at all times.

Markets

CPV’s are an excellent example for efficient use of filament winding technology. The fibers can be aligned to create a laminate which responds best to the stresses in the different directions. To use these an-isotropic properties is key to design optimization, resulting in a weight reduction of up to 80 % compared to steel cylinders.

Also, the high level of automation allows a high-volume production to meet industrial market requirements. Typical applications are water purification, LPG, SCBA, CNG & H2 for automotive, rocket motor cases …

Other typical
applications

  • Tubes and rods
  • Figures of revolution
  • Elbows and T’s

Other typical
applications

  • Tubes and rods
  • Figures of revolution
  • Elbows and T’s

Software
specification

Bronze
Silver
Gold
Iron
Application
tubes and rods
vessel and tanks
 
 
figures of revolution
 
 
 
elbows and t's
 
 
 
Calculation
parametric mandrel description
material data base
modelling of complete laminat
FEA interface
optionalopt.
optionalopt.
optionalopt.
 
Postprocessor
2-4 axis machine motion
yaw motion (5th axis)
 
optionalopt.
optionalopt.
optionalopt.
perpendicular carriage (6th axis)
 
 
 
optionalopt.
robot interface
optionalopt.
optionalopt.
optionalopt.
optionalopt.
Contact us

Our background

ComposicaD has been developed since 2010 by Michael “Mike” Skinner and Axel Seifert to meet the increasingly demanding requirements of the filament winding industry. As former president of ENTEC Composites Machines (USA), Mike has a wealth of experience designing state-of-the-art equipment. At MATERIAL SA (Belgium), Axel co-developed the CADWIND software which until then was leading the market.

With Mike’s retirement in 2019, Axel formed a new team to continue the development and support of ComposicaD. Young and dynamic engineers will ensure the continuity for the decades to come!

Contact us

info@composicad.com